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How to use this manual
A Few Words About Safety
How to use this manual
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. 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.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda CGX125SH 2011

  • Page 1 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 2 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 3 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). 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.
  • Page 4 dummyhead dummyhead CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE IGNITION SYSTEM FUEL SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR CRANKSHAFT/TRANSMISSION/KICKSTARTER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/BRAKE/SUSPENSION/STEERING REAR WHEEL/BRAKE/SUSPENSION BATTERY/CHARGING SYSTEM LIGHTS/METER/SWITCHES WIRING DIAGRAMS INDEX...
  • Page 5 dummyhead dummyhead MEMO...
  • Page 6 dummytext 1. GENERAL INFORMATION SERVICE RULES ··········································1-2 TORQUE VALUES ········································ 1-8 MODEL IDENTIFICATION ····························1-2 CABLE & HARNESS ROUTING················· 1-12 SPECIFICATIONS ·········································1-3 EMISSION CONTROL SYSTEMS ·············· 1-19...
  • Page 7 SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don’t 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 8 dummyhead dummyhead GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N.) [1] is stamped on The registered number plate [1] is riveted on the left side of the right side of the steering head. the steering head. The engine serial number [1] is stamped on the lower left side The color label [1] is attached as shown.
  • Page 9 dummyhead dummyhead GENERAL INFORMATION ITEM SPECIFICATION FRAME Frame type Diamond type Front suspension Telescopic fork Front wheel travel 116 mm (4.6 in) Rear suspension Swingarm Rear wheel travel 92 mm (3.6 in) Front tire size 80/100-18M/C 47P Rear tire size 90/90-18M/C 51P Front tire brand C-116 (CHENG SHIN)
  • Page 10 – After disassembly 1.0 liters (1.1 US qt, 0.9 Imp qt) – Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent API classification: SG or higher (except oils labeled as energy conserving – on the circular API service label)
  • Page 11 dummyhead dummyhead GENERAL INFORMATION CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder I.D. 52.400 – 52.410 (2.0630 – 2.0634) 52.50 (2.067) Out-of-round – 0.10 (0.004) Taper – 0.10 (0.004) Warpage – 0.10 (0.004) Piston, Piston O.D. at 8 mm (0.3 in) 52.375 –...
  • Page 12 dummyhead dummyhead GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Transmission Gear I.D. M2, M3 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671) 18.000 – 18.018 (0.7087 – 0.7094) 18.04 (0.710) 20.000 – 20.018 (0.7874 – 0.7881) 20.04 (0.789) Bushing O.D. 17.966 – 17.984 (0.7073 – 0.7080) 17.94 (0.706) Bushing I.D.
  • Page 13 dummyhead dummyhead GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type CB3L-A Capacity 12 V – 3 Ah Current leakage 0.1 mA max. Specific gravity Fully charged 1.270 – 1.290 (20°C/68°F) Needs Below 1.230 charging Voltage Fully charged 12.7 – 12.9 V (20°C/68°F) Needs Below 12.3 V...
  • Page 14 dummyhead dummyhead GENERAL INFORMATION ENGINE & FRAME TORQUE VALUES FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Side cover mounting screw 5 (0.5, 3.7) Shock absorber upper mounting nut 24 (2.4, 18) Rear cowl mounting screw A 1 (0.1, 0.7) (Except NR/DK) Rear side reflector mounting nut...
  • Page 15 dummyhead dummyhead GENERAL INFORMATION LUBRICATION SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Oil pump cover screw 3 (0.3, 2.2) Oil pump mounting bolt 12 (1.2, 9) CYLINDER HEAD/VALVES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Camshaft stopper bolt 12 (1.2, 9) Rocker arm shaft bolt...
  • Page 16 dummyhead dummyhead GENERAL INFORMATION FRONT WHEEL/BRAKE/SUSPENSION/STEERING THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Front axle nut 59 (6.0, 44) U-nut Front spoke (Spoke wheel type) BC3.2 3.7 (0.4, 2.7) Front brake arm nut 10 (1.0, 7) Handlebar holder bolt 11.8 (1.2, 9) Rearview mirror lock nut 34 (3.5, 25)
  • Page 17 dummyhead dummyhead GENERAL INFORMATION CABLE & HARNESS ROUTING II NR/III NR/III DK: IGNITION SWITCH 2P CONNECTOR FRONT BRAKE LIGHT SWITCH WIRE INSIDE BOOT CONNECTORS: SPEEDOMETER CABLE – SPEEDOMETER 3P (Black) – SPEEDOMETER 4P HEADLIGHT 3P CONNECTOR INSIDE BOOT CONNECTORS: – LEFT HANDLEBAR SWITCH 2P MAIN WIRE HARNESS –...
  • Page 18 dummyhead dummyhead GENERAL INFORMATION EXCEPT II NR/III NR/III DK: FRONT BRAKE LIGHT SWITCH WIRE CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE SPEEDOMETER CABLE FRONT BRAKE CABLE SPEEDOMETER WIRE LEFT FRONT TURN SIGNAL LIGHT WIRE RIGHT FRONT TURN SIGNAL LIGHT WIRE MAIN WIRE HARNESS IGNITION SWITCH 2P CONNECTOR LEFT HANDLEBAR SWITCH 2P CONNECTOR...
  • Page 19 dummyhead dummyhead GENERAL INFORMATION II NR/III NR/III DK: MAIN WIRE HARNESS REGULATOR/RECTIFIER REAR BRAKE LIGHT SWITCH 3P CONNECTOR REAR BRAKE LIGHT SWITCH WIRE HORN WIRE SPARK PLUG WIRE IGNITION COIL CLUTCH CABLE THROTTLE CABLE SPEEDOMETER CABLE FUEL HOSE FRONT BRAKE CABLE 1-14...
  • Page 20 dummyhead dummyhead GENERAL INFORMATION EXCEPT II NR/III NR/III DK: MAIN WIRE HARNESS REGULATOR/RECTIFIER REAR BRAKE LIGHT SWITCH 3P CONNECTOR REAR BRAKE LIGHT SWITCH WIRE HORN WIRE SPARK PLUG WIRE IGNITION COIL CLUTCH CABLE THROTTLE CABLE SPEEDOMETER CABLE FUEL HOSE FRONT BRAKE CABLE 1-15...
  • Page 21 dummyhead dummyhead GENERAL INFORMATION ALL TYPES – MAIN FUSE 20 A – SUB FUSE 15 A CARBURETOR AIR VENT HOSE GROUND TERMINAL INTAKE HOSE BATTERY NEGATIVE (-) CABLE TURN SIGNAL SPARK PLUG WIRE RELAY BATTERY POSITIVE (+) IGNITION CABLE COIL WIRE TURN SIGNAL RELAY (GRAY) WIRE...
  • Page 22 dummyhead dummyhead GENERAL INFORMATION THROTTLE CABLE CLUTCH CABLE CRANKCASE BREATHER HOSE INTAKE HOSE CARBURETOR AIR VENT HOSE FUEL HOSE ALTERNATOR/ NEUTRAL SWITCH WIRE NEUTRAL SWITCH WIRE CARBURETOR DRAIN HOSE BATTERY BREATHER HOSE AG/CL TYPES: MAIN WIRE HARNESS CARBURETOR HEATER WIRE 1-17...
  • Page 23 dummyhead dummyhead GENERAL INFORMATION EXCEPT NR/DK BRAKE/TAILLIGHT LEFT REAR TURN BRAKE/TAILLIGHT WIRE WIRE LEFT REAR TURN SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE RIGHT REAR TURN SIGNAL LIGHT WIRE INSIDE BOOT CONNECTORS: – BRAKE/TAILLIGHT 3P BRAKE/TAILLIGHT WIRE – REAR TURN SIGNAL LIGHT WIRE RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN...
  • Page 24 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.
  • Page 25 dummyhead dummyhead MEMO...
  • Page 26 dummytext 2. FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER ·················································2-2 REAR COWL (Except NR/DK) ····················· 2-6 SEAT······························································2-2 PILLION STEP BOARD (NR/DK only) ········· 2-6 FRONT VISOR (II NR/III NR/III DK only) ······2-3 REAR FENDER (Except NR/DK) ················· 2-7 HEADLIGHT REAR COVER REAR FENDER (NR/DK) ······························ 2-9 (II NR/III NR/III DK only)································2-3 EXHAUST PIPE/MUFFLER ························...
  • Page 27 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION Remove the screw [1]. Remove the side cover [2] by releasing its bosses [3] Be careful not to from the grommets [4]. damage the side cover bosses. Installation is in the reverse order of removal. TORQUE: Side cover mounting screw: 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
  • Page 28 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT VISOR (II NR/III NR/III DK only) REMOVAL/INSTALLATION Remove the cap [1], screws [2] and front visor [3] by Be careful not to releasing its tabs [4]. damage the tabs. Disconnect the headlight 3P connector [5] and position light wire connectors [6].
  • Page 29 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Remove the following: – Bolts [1] – Washers [2] – Headlight rear cover [3] – Collars [4] Installation is in the reverse order of removal. FUEL TANK REMOVAL/INSTALLATION Remove the seat (page 2-2) Turn the fuel valve [1] OFF and disconnect the fuel Wipe off spilled hose [2] from the fuel valve body.
  • Page 30 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Release the cable holder [1] from the front fender. Remove the following: – Bolts [2] – Washers [3] – Front side reflectors [4] (NR/DK/CL/II CL only) [4] (NR/DK/ – Collars [5] CL/II CL only) –...
  • Page 31 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR COWL (Except NR/DK) REMOVAL/INSTALLATION Remove the grab rail (page 2-5). Remove the rear cowl mounting screws A [1] and mounting screws B [2]. Remove the rear cowl [3] by releasing its tabs [4] from the rear fender grooves [5].
  • Page 32 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER (Except NR/DK) REMOVAL/INSTALLATION Remove the rear cowl (page 2-6). Disconnect the brake/taillight 3P connector [1] and rear turn signal light wire connectors [2]. Remove the bolts [3], collars [4] and rear fender [5] by releasing its hooks [6] from the frame.
  • Page 33 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY It is not necessary to separate the rear fender for rear turn signal light brake/taillight assembly replacement. [11] Release the wires [1] from the wire guides [2]. Remove the wire band [3] and release the wires from the wire band.
  • Page 34 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER (NR/DK) REMOVAL/INSTALLATION Remove the seat (page 2-2). Disconnect the brake/taillight wire connectors [1] and rear turn signal light wire connectors [2]. Remove the special bolts [3] and rear fender [4] by releasing its grooves [5] and hooks [6] from the frame. Install the rear fender by aligning its right side hook with the slot.
  • Page 35 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY TAILLIGHT UNIT REMOVAL/INSTALLATION Release the wires [1] from the wire guides [2]. Remove the wire band [3] and release the wires from the wire band. Remove the nuts [4], bolts [5], collars [6], mounting rubbers [7] and brake/taillight assembly [8].
  • Page 36 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER REMOVAL Remove the exhaust pipe joint nuts [1] and rear engine hanger nut [2]. Remove the mounting nut [3], collar [4], bolt [5], washer [6] and exhaust pipe/muffler [7]. Remove the exhaust pipe gasket [8] from the exhaust port. Remove the screws [9] and muffler protector [10].
  • Page 37 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM STUD BOLT REPLACEMENT After installing the stud bolts [1], check that the length 19.5 – 21.5 mm from the bolt head to the cylinder head surface is within (0.77 – 0.85 in) specification. TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft) DRIVE CHAIN CASE (NR/DK types) REMOVAL/INSTALLATION Remove the four bolts [1], lower drive chain case [2]...
  • Page 38 dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 DRIVE CHAIN ··············································· 3-9 FUEL STRAINER SCREEN ··························3-3 BATTERY ···················································· 3-11 THROTTLE OPERATION······························3-3 BRAKE SHOES WEAR ······························ 3-12 AIR CLEANER (NR/DK types) ·····················3-4 BRAKE SYSTEM ········································ 3-13 AIR CLEANER (Except NR/DK types)·········3-4 BRAKE LIGHT SWITCH ····························· 3-13 CRANKCASE BREATHER ···························3-5 HEADLIGHT AIM ········································...
  • Page 39 * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test the motorcycle after each periodic maintenance is carried out. NOTES: 1.
  • Page 40 dummyhead dummyhead MAINTENANCE FUEL STRAINER SCREEN Turn the fuel valve OFF. Remove the fuel strainer cup [1] and drain the contents Wipe off spilled of the cup into a suitable container. gasoline. Remove the O-ring [2] and strainer screen [3]. Wash the strainer screen and cup in clean non- flammable or high flash point solvent.
  • Page 41 Saturate the air cleaner element with recommended engine oil, then squeeze out the excess oil as shown. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent Squeeze out API classification: SG or higher Dry thoroughly the excess oil...
  • Page 42 dummyhead dummyhead MAINTENANCE CRANKCASE BREATHER • Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposits level can be seen in the transparent section of the breather drain hose. Remove the left side cover (page 2-2).
  • Page 43 dummyhead dummyhead MAINTENANCE VALVE CLEARANCE INSPECTION Remove the cylinder head cover (page 7-4). Inspect and adjust the valve clearance Remove the timing hole cap and crankshaft hole cap. while the engine is Rotate the crankshaft counterclockwise and align the cold (below 35°C/ “T”...
  • Page 44 If the level is below or near the lower mark [1] on the dipstick, fill the crankcase with recommended oil to the upper level [2]. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent API classification: SG or higher (except oils labeled as energy conserving on the circular API service label)
  • Page 45 dummyhead dummyhead MAINTENANCE ENGINE OIL STRAINER SCREEN Remove the right crankcase cover (page 9-4). Remove the oil strainer screen [1]. Clean the oil strainer screen and clean it in non- flammable or high flash point solvent. Check oil strainer screen for damage, replace it if necessary. Install the oil strainer screen with the thin edge facing toward the crankcase and flange side facing up as shown.
  • Page 46 dummyhead dummyhead MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Excessive chain slack, 50 mm (2.0 in) or more, may damage the frame. Remove the drive chain inspection hole cap [1]. NR/DK types only: Support the motorcycle on its centerstand. Turn off the ignition switch OFF and shift the Never inspect and transmission into neutral.
  • Page 47 dummyhead dummyhead MAINTENANCE REMOVAL/INSTALLATION Remove the drive chain case (page 2-12). NR/DK types only: Remove the drive sprocket cover (page 12-3). Carefully remove the retaining clip [1] with pliers. Remove the master link and drive chain. Install the drive chain onto the sprockets. Install the master link [1] and link plate [2].
  • Page 48 dummyhead dummyhead MAINTENANCE SPROCKETS Installing a new chain on badly worn sprockets will cause a new chain to wear quickly. Remove the drive chain case (page 2-12). NR/DK types only: Remove the drive sprocket cover (page 12-3). Inspect the drive and driven sprocket teeth for wear or damage, replace them if necessary.
  • Page 49 dummyhead dummyhead MAINTENANCE SPECIFIC GRAVITY The battery electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. The specific gravity must be checked with a hydro meter [1]. Test each cell by drawing electrolyte into the hydrometer. SPECIFIC GRAVITY: Fully charged: 1.270 –...
  • Page 50 dummyhead dummyhead MAINTENANCE REAR BRAKE SHOES Check the wear indicator position when the brake pedal is applied. If the arrow [1] on the brake arm aligns with the mark " " [2] on the brake panel, inspect the brake drum (page 14-7).
  • Page 51 dummyhead dummyhead MAINTENANCE HEADLIGHT AIM Except II NR/III NR/III DK Place the motorcycle on a level surface. Adjust the headlight beam vertically by loosening the Adjust the headlight headlight case mounting bolts [1]. beam as specified by local laws and After adjustment, tighten the headlight case mounting regulations.
  • Page 52 dummyhead dummyhead MAINTENANCE Major adjustments are made with the lower adjusting nut at the engine. Loosen the lock nut [1] and turn the adjusting nut [2] to obtain the freeplay. After adjustment is complete, tighten the lock nut securely while holding the adjusting nut. Check the clutch operation.
  • Page 53 dummyhead dummyhead MAINTENANCE WHEELS/TIRES Support the motorcycle on its centerstand and raise the front wheel off the ground. Hold the front fork leg and move the front wheel sideways with force to see if the wheel bearings are worn. For front wheel service (page 13-7). Support the motorcycle on its centerstand and make sure the rear wheel off the ground.
  • Page 54 dummytext 4. IGNITION SYSTEM SYSTEM LOCATION·····································4-2 IGNITION SYSTEM INSPECTION ················ 4-4 SYSTEM DIAGRAM ······································4-2 IGNITION TIMING ········································· 4-5 SERVICE INFORMATION ·····························4-3 IGNITION COIL ············································· 4-6 TROUBLESHOOTING···································4-3 ICM ································································ 4-6...
  • Page 55 dummyhead dummyhead IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM IGNITION SWITCH IGNITION COIL BATTERY SPARK PLUG IGNITION PULSE GENERATOR MAIN FUSE (20 A) SYSTEM DIAGRAM IGNITION SWITCH MAIN FUSE (20 A) Bl/Y IGNITION Bu/Y Bu/Y R/Bl COIL Bl/Y IGNITION PULSE GENERATOR SPARK BATTERY PLUG...
  • Page 56 dummyhead dummyhead IGNITION SYSTEM SERVICE INFORMATION GENERAL • The Ignition Control Module (ICM) may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the ICM. Always turn the ignition switch OFF before servicing. •...
  • Page 57 dummyhead dummyhead 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 commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. •...
  • Page 58 dummyhead dummyhead IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK VOLTAGE • Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Remove the ICM (page 4-6). Connect the Imrie diagnostic tester or adaptor probes to the wire harness side ICM 4P connector [1] terminals.
  • Page 59 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Disconnect the spark plug cap from the spark plug. Remove and release the wire band [1] and disconnect the ignition coil primary wire connector [2]. Remove the bolts [3], ground wire terminal [4] and ignition coil [5].
  • Page 60 dummytext 5. FUEL SYSTEM COMPONENT LOCATION ····························5-2 INSULATOR ·················································· 5-9 SERVICE INFORMATION ·····························5-2 INTAKE MANIFOLD A ·································· 5-9 TROUBLESHOOTING···································5-3 FUEL STRAINER ·········································· 5-9 AIR CLEANER HOUSING·····························5-4 AIR SCREW ADJUSTMENT······················· 5-10 CARBURETOR··············································5-5...
  • Page 61 dummyhead dummyhead FUEL SYSTEM COMPONENT LOCATION FUEL SYSTEM AG/CL types: SERVICE INFORMATION GENERAL • Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.
  • Page 62 dummyhead dummyhead FUEL SYSTEM TROUBLESHOOTING Engine won’t start • No fuel in tank • No fuel to carburetor – Fuel strainer clogged – Fuel line clogged – Fuel valve stuck – Float level misadjusted – Fuel tank breather clogged • Too much fuel getting to the engine –...
  • Page 63 dummyhead dummyhead FUEL SYSTEM AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the following: RIGHT SIDE: LEFT SIDE: – Side covers (page 2-2) – Battery (page 15-5) Remove the screw [1]. Disconnect the crankcase breather hose [2]. Loosen the connecting hose band screw [3]. Remove the bolt [4] and air cleaner housing from left side.
  • Page 64 dummyhead dummyhead FUEL SYSTEM CARBURETOR REMOVAL Place a suitable container under the carburetor drain hose and drain the fuel from the carburetor by loosing the drain screw [1]. Tighten the drain screw to the specified torque. TORQUE: 1.47 N·m (0.1 kgf·m, 1.1 lbf·ft) Disconnect the carburetor air vent hose [2].
  • Page 65 dummyhead dummyhead FUEL SYSTEM DISASSEMBLY/ASSEMBLY THROTTLE VALVE Remove the throttle cable [1] from the throttle valve [2] while compressing the throttle valve spring [3]. Remove the retainer [1], spring [2] and jet needle [3] while pushing the retainer with a screwdriver slightly and turning it counterclockwise.
  • Page 66 dummyhead dummyhead FUEL SYSTEM Disassemble and assemble the carburetor as following illustration. CARBURETOR HEATER RETAINER (AG/CL types only) SPRING 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) JET NEEDLE THROTTLE VALVE SPRING WASHER O-RINGS AIR SCREW FLOAT VALVE INTAKE MANIFOLD B O-RING THROTTLE STOP SCREW CHOKE LEVER 3.4 N·m...
  • Page 67 dummyhead dummyhead FUEL SYSTEM INSTALLATION Connect the carburetor to the insulator by aligning the Align tab of the carburetor and groove of the insulator. 0.5 – 2.0 mm Make sure the insulator band hole align with the (0.02 – 0.08 in) insulator tab and tighten the insulator band screw [1] to the specified range.
  • Page 68 dummyhead dummyhead FUEL SYSTEM INSULATOR REMOVAL/INSTALLATION Remove the carburetor (page 5-5). Loosen the insulator band screw [1] and remove the 0.5 – 2.0 mm insulator [2] from the intake manifold A. (0.02 – 0.08 in) Install the insulator by aligning its tab with the intake manifold A groove.
  • Page 69 dummyhead dummyhead FUEL SYSTEM AIR SCREW ADJUSTMENT BEST IDLE PROCEDURE (NR/DK types) • The air screw is factory pre-set and no adjustment is necessary unless the carburetor is overhauled or the air screw is replaced. • The engine must be warm for accurate adjustment. 10 minutes of stop-and-go riding is sufficient.
  • Page 70 dummyhead dummyhead FUEL SYSTEM IDLE DROP PROCEDURE (Except NR/ DK types) • The air screw is factory pre-set and no adjustment is necessary unless the carburetor is overhauled or the air screw is replaced. • The engine must be warm for accurate adjustment. 10 minutes of stop-and-go riding is sufficient.
  • Page 71 dummyhead dummyhead MEMO...
  • Page 72 dummytext 6. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ············6-2 TROUBLESHOOTING ·································· 6-3 SERVICE INFORMATION ·····························6-3 OIL PUMP ····················································· 6-3...
  • Page 73 dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM ROCKER ARM CAMSHAFT CRANKSHAFT OIL FILTER ROTOR MAINSHAFT OIL PUMP COUNTERSHAFT OIL STRAINER SCREEN...
  • Page 74 dummyhead dummyhead LUBRICATION SYSTEM SERVICE INFORMATION GENERAL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.
  • Page 75 dummyhead dummyhead LUBRICATION SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the oil pump as following illustration. LOCK PIN OIL PUMP SHAFT OUTER ROTOR OIL PUMP COVER OIL PUMP DRIVE GEAR WASHER OIL PUMP BODY CLIP INNER ROTOR OIL PUMP COVER SCREW 3 N·m (0.3 kgf·m, 2.2 lbf·ft) INSPECTION Disassemble the oil pump (page 6-4).
  • Page 76 dummytext 7. CYLINDER HEAD/VALVES COMPONENT LOCATION ····························7-2 CYLINDER HEAD COVER ··························· 7-4 SERVICE INFORMATION ·····························7-2 CAMSHAFT··················································· 7-4 TROUBLESHOOTING···································7-3 CYLINDER HEAD ········································· 7-8 CYLINDER COMPRESSION·························7-3...
  • Page 77 dummyhead dummyhead CYLINDER HEAD/VALVES COMPONENT LOCATION CYLINDER HEAD/VALVES 18 N·m (1.8 kgf·m, 13 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves, rocker arms and camshaft. •...
  • Page 78 dummyhead dummyhead CYLINDER HEAD/VALVES TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noises to the top-end with a sounding rod or stethoscope. • If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for seized piston ring.
  • Page 79 dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL/INSTALLATION Remove the spark plug cap (page 3-5). Remove the bolts [1] and cylinder head cover [2]. Remove the dowel pin [1] and packing [2] from the cylinder head cover [3]. Clean the oil passages of the cylinder head cover using compressed air.
  • Page 80 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the crankcase sealing bolt [1] and sealing washer [2]. [1]/[2] Loosen the cam sprocket bolt [1] while holding the [1]/[3] sprocket with the special tool as shown. TOOL: [2] Universal holder 07725-0030000 Remove the bolt, washer [3] and cam sprocket [4]. Attach a piece of wire to the cam chain to prevent it from falling into crankcase.
  • Page 81 dummyhead dummyhead CYLINDER HEAD/VALVES INSPECTION Turn the outer race of each camshaft bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the camshaft. Replace the camshaft assembly if the bearing does not turn smoothly, quietly, or if they fit loosely on the camshaft.
  • Page 82 dummyhead dummyhead CYLINDER HEAD/VALVES Rotate the crankshaft counterclockwise until the "T" Be careful not to mark [1] on the flywheel is aligned with the index notch jam the cam chain. [2] on the left crankcase cover. Apply engine oil to the cam chain [1] whole surface. Align Install the cam chain on the cam sprocket [2] so that the index lines of the cam sprocket are aligned with the...
  • Page 83 dummyhead dummyhead CYLINDER HEAD/VALVES Pour 1.0 – 2.0 cc of engine oil into the cam chain tensioner push rod as shown. Install a new sealing washer [1] and bolt [2], then tighten it. Adjust the valve clearance (page 3-6). Install the following: –...
  • Page 84 dummyhead dummyhead CYLINDER HEAD/VALVES Apply clean engine oil to the threads and seating [1]/[2] surfaces of the cylinder head nuts [1]. Install the washers [2] and the cylinder head nuts. Tighten the cylinder head nuts to the specified torque in a crisscross pattern in several steps.
  • Page 85 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the following: Mark all disassembled parts – Spring retainer [1] to ensure correct – Valve spring [2] reassembly. – Stem seal [3] – Spring seat [4] – Valve [5] Remove the carbon deposits from the combustion chamber.
  • Page 86 dummyhead dummyhead CYLINDER HEAD/VALVES Install the valve spring with the tightly wound coils facing the combustion chamber. Install the spring retainer. Compress the valve spring and install the valve cotters Grease the cotters [1]. to ease installation. To prevent loss of TOOL: tension, do not [2] Valve spring compressor...
  • Page 87 dummyhead dummyhead CYLINDER HEAD/VALVES INSPECTION VALVE GUIDE Ream the valve guide to remove the carbon build-up Always rotate the before measuring the valve guide I.D. reamer clockwise, never TOOL: counterclockwise [1] Valve guide reamer 07984-MA60001 when installing, removing and reaming. Measure and record each valve guide I.D.
  • Page 88 dummyhead dummyhead CYLINDER HEAD/VALVES While the cylinder head is still heated, remove the new valve guides from the freezer and install new clips [1] to new valve guides [2]. Drive new valve guides in the cylinder head from the camshaft side until the clip is fully seated using the special tool.
  • Page 89 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the valve and inspect the width of each valve seat face. The valve seat contact should be within the specified width and even all around the circumference. STANDARD: 0.9 – 1.1 mm (0.035 – 0.043 in) SERVICE LIMIT: 1.5 mm (0.06 in) If the valve seat width is not within specification, reface the valve seat (page 7-14).
  • Page 90 dummytext 8. CYLINDER/PISTON COMPONENT LOCATION ····························8-2 CYLINDER ···················································· 8-4 SERVICE INFORMATION ·····························8-3 PISTON ························································· 8-5 TROUBLESHOOTING···································8-3...
  • Page 91 dummyhead dummyhead CYLINDER/PISTON COMPONENT LOCATION CYLINDER/PISTON 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 92 dummyhead dummyhead CYLINDER/PISTON SERVICE INFORMATION GENERAL • The engine must be removed from the frame to service the cylinder and piston. • Take care not to damage the cylinder wall and piston. • Be careful not to damage the mating surfaces when removing the cylinder. Do not tap the cylinder too hard during removal. •...
  • Page 93 dummyhead dummyhead CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder head (page 7-8). Remove the cam chain guide roller pin bolt [1], sealing washer [2] and cam chain guide roller [3]. Lift the cylinder [4] and remove it, being careful not to Do not tap the damage the piston.
  • Page 94 dummyhead dummyhead CYLINDER/PISTON STUD BOLT REPLACEMENT Remove the cylinder (page 8-4). 183.0 – 185.0 mm (7.20 – 7.28 in) Thread two nuts onto the stud and tighten them together, and use wrench on them to turn the stud bolt [1] out. Install new stud bolts into the crankcase to the specified torque.
  • Page 95 dummyhead dummyhead CYLINDER/PISTON When cleaning the cylinder mating surface [1], place a clean shop towel in the crankcase opening to prevent the gasket material or piston pin clip from falling into the crankcase. Clean off any gasket material from the cylinder mating Be careful not to surface of the crankcase.
  • Page 96 dummytext 9. CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION ····························9-2 CLUTCH ························································ 9-6 SERVICE INFORMATION ·····························9-3 GEARSHIFT LINKAGE ································· 9-9 TROUBLESHOOTING···································9-3 PRIMARY DRIVE GEAR ····························· 9-12 RIGHT CRANKCASE COVER ······················9-4...
  • Page 97 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION CLUTCH/GEARSHIFT LINKAGE 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 98 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL • This section covers service of the clutch and gearshift linkage. All services can be done with the engine installed in the frame. • Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or motorcycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
  • Page 99 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-7). Remove the bolt [1] and kickstarter pedal [2]. When removing the kickstarter pedal, mark the pedal position to ensure correct reassembly in its original location. Loosen the right crankcase cover bolts [1] in a crisscross pattern in 2 or 3 steps.
  • Page 100 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Install the kickstarter pedal [1] on its original position as marked during removal. Install and tighten the bolt [2]. Inspect the clutch lever freeplay (page 3-14). Fill the crankcase with the recommended engine oil (page 3-7). CLEANING Remove the right crankcase cover (page 9-4).
  • Page 101 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE CLUTCH REMOVAL Remove the following: – Right crankcase cover (page 9-4) – Oil filter rotor cover (page 3-8) Install the gear holder [1] between the primary drive and driven gears as shown, and loosen the oil filter rotor lock nut [2].
  • Page 102 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Remove the washer [1] and clutch outer [2]. Remove the clutch outer guide [1]. INSTALLATION Apply molybdenum oil solution to the clutch outer guide outer surface and install it onto the mainshaft. Apply clean engine oil to the primary driven gear teeth [1].
  • Page 103 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Install the clutch center assembly [1] into the clutch outer [2]. Apply clean engine oil to the clutch center lock nut [3] threads and seating surface. Install the washer [4] and clutch center lock nut. Attach the clutch center holder [1] to the pressure plate using clutch lifter plate bolts to hold the clutch center, and then tighten the lock nut [2].
  • Page 104 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL/INSPECTION Remove the clutch (page 9-6). Remove the bolt [1] and gearshift pedal [2]. When removing gearshift pedal, Clean the left side gearshift spindle end. mark the pedal position to ensure correct reassembly in its original position.
  • Page 105 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Check the gearshift spindle oil seal [1] for deterioration or damage, replace it if necessary. • When replacing the gearshift spindle oil seal, 0.5 – 1.0 mm remove the drive sprocket cover (page 12-3). (0.02 – 0.04 in) •...
  • Page 106 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Apply a locking agent to the gearshift cam bolt threads (page 1-9). Tighten the gearshift cam bolt [1] to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) If the gearshift spindle return spring pin [2] is removed, apply locking agent to the threads (page 1-9) and tighten it to the specified torque.
  • Page 107 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE PRIMARY DRIVE GEAR REMOVAL/INSTALLATION Remove the clutch (page 9-6). Remove the primary drive gear [1]. Remove the spacer [2] and woodruff key [3]. Be careful not to damage the key Install the woodruff key onto the crankshaft. groove.
  • Page 108 dummytext 10. ALTERNATOR COMPONENT LOCATION ··························10-2 FLYWHEEL ················································· 10-4 SERVICE INFORMATION ···························10-2 STATOR/IGNITION PULSE GENERATOR ·············································· 10-5 LEFT CRANKCASE COVER ······················10-3 CAM CHAIN TENSIONER ·························· 10-5 10-1...
  • Page 109 dummyhead dummyhead ALTERNATOR COMPONENT LOCATION ALTERNATOR 12 N·m (1.2 kgf·m, 9 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) SERVICE INFORMATION GENERAL • This section covers the removal and installation of the alternator stator, flywheel and cam chain tensioner. These services can be done with the engine installed in the frame.
  • Page 110 dummyhead dummyhead ALTERNATOR LEFT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-7). Remove the following: – Right side cover (page 2-2) – Drive sprocket cover (page 12-3) Release the boot [1] and disconnect the alternator 3P connector [2] and ignition pulse generator/neutral switch 3P connector [3].
  • Page 111 dummyhead dummyhead ALTERNATOR FLYWHEEL REMOVAL Remove the left crankcase cover (page 10-3). [2]/[3] Hold the flywheel with the flywheel holder [1] and remove the nut [2] and washer [3]. TOOL: Flywheel holder 07725-0040001 Remove the flywheel [1] using the flywheel puller [2]. TOOL: Flywheel puller 07KMC-HE00100...
  • Page 112 dummyhead dummyhead ALTERNATOR Apply clean engine oil to the flywheel nut threads and [1]/[2] seating surface. Install the washer [1] and flywheel nut [2]. Hold the flywheel with the flywheel holder [3] and tighten the nut to the specified torque. TOOL: Flywheel holder 07725-0040001...
  • Page 113 dummyhead dummyhead ALTERNATOR Remove the pivot bolt [1], washer [2], tensioner arm [3], [3]/[4] collar [4] and tensioner roller [5]. Remove the bolt [6], washer [7], collar [8] and cam chain guide roller [9]. [6]/[7]/[8] [1]/[2] INSTALLATION Install the cam chain guide roller [1], collar [2], washer [3] and bolt [4].
  • Page 114 dummytext 11. CRANKSHAFT/TRANSMISSION/KICKSTARTER COMPONENT LOCATION ··························11-2 TRANSMISSION ········································· 11-5 SERVICE INFORMATION ···························11-3 CRANKSHAFT ············································ 11-7 TROUBLESHOOTING·································11-3 TRANSMISSION BEARING REPLACEMENT ········································· 11-9 CRANKCASE SEPARATION/ ASSEMBLY ·················································11-4 KICKSTARTER ········································· 11-11 11-1...
  • Page 115 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER COMPONENT LOCATION CRANKSHAFT/TRANSMISSION/KICKSTARTER 11-2...
  • Page 116 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER SERVICE INFORMATION GENERAL • The following components must be removed before separating the crankcase: – Engine (page 12-3) – Flywheel (page 10-4) – Cam chain tensioner (page 10-5) – Cylinder head (page 7-8) – Cylinder (page 8-4) –...
  • Page 117 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER CRANKCASE SEPARATION/ASSEMBLY Refer to Service Information (page 11-3) for removal of necessary parts before disassembling the crankcase. Loosen the left crankcase bolts [1] in a crisscross pattern in 2 or 3 steps. Remove the left crankcase bolts and cam chain [2]. Place the crankcase assembly with the right side down.
  • Page 118 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER TRANSMISSION REMOVAL Separate the crankcase halves (page 11-4). Pull out the shift fork shaft [1]. Remove the shift forks [2] and shift drum [3]. Remove the mainshaft [1] and countershaft [2] as an assembly. Disassemble the mainshaft [1] and countershaft [2]. Do not expand the snap ring more than necessary for...
  • Page 119 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER INSTALLATION Clean all parts in solvent. Apply clean engine oil to the all gear teeth. Apply molybdenum oil solution to the bushing sliding surface and shift fork grooves to ensure initial lubrication. Assemble all parts into their original positions. •...
  • Page 120 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER COUNTERSHAFT COUNTERSHAFT SNAP RING SPLINE WASHER LOCK WASHER C4 GEAR (22T) C2 GEAR (29T) C1 GEAR BUSHING COLLAR C1 GEAR (35T) THRUST WASHER : Each gear teeth C3 GEAR (26T) : C1, C4 gear inner surface C1 gear bushing whole surface C3 gearshift fork shifter groove The shift forks have the following identification marks.
  • Page 121 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER If the right crankshaft bearing [1] remains on the crankshaft, remove it using a special tool. TOOL: [2] Universal bearing puller 07631-0010000 If the right crankshaft bearing [1] remains in the crankcase, drive it out from the outside. INSTALLATION Apply clean engine oil to a new right crankshaft bearing rolling surface.
  • Page 122 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER TRANSMISSION BEARING REPLACEMENT Remove the following: – Transmission (page 11-5) – Crankshaft (page 11-7) – Kickstarter (page 11-11) RIGHT CRANKCASE Remove the bolts [1] and mainshaft bearing setting [1]/[2] plates [2] from the right crankcase. Drive out the mainshaft bearing [3] and countershaft bearing [4] from the right crankcase.
  • Page 123 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER LEFT CRANKCASE Remove the countershaft oil seal [1] from the left crankcase. Drive out the countershaft bearing [1] from the left crankcase. Remove the mainshaft bearing [2] from the left crankcase using following tools. TOOLS: Remover head, 12 mm 07936-1660110 Remover shaft, 12 mm 07936-1660120...
  • Page 124 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER KICKSTARTER REMOVAL Separate the crankcase (page 11-4). Remove the snap ring [1] and retainer [2] from the kickstarter spindle. Remove the kickstarter spindle [1] from the right crankcase. INSTALLATION Apply engine oil to the kickstarter gear teeth. Install the kickstarter spindle while aligning its ratchet spring with the right crankcase groove and hole as shown.
  • Page 125 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER DISASSEMBLY/ASSEMBLY Disassemble and assemble the kickstarter as following illustration. KICKSTARTER SPINDLE COLLAR LOCK WASHER RETURN SPRING SNAP RINGS WASHER STARTER RATCHET GEAR STARTER PINION GEAR RATCHET SPRING Install the return spring [1] to the kickstarter spindle Align while aligning the spring end with the hole on the spindle.
  • Page 126 dummytext 12. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ··························12-2 ENGINE REMOVAL ···································· 12-3 SERVICE INFORMATION ···························12-2 ENGINE INSTALLATION···························· 12-4 12-1...
  • Page 127 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION 54 N·m (5.5 kgf·m, 40 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) SERVICE INFORMATION GENERAL • A floor jack or other adjustable support is required to support and maneuver the engine. • When removing/installing the engine, tape the frame around the engine beforehand for frame protection. •...
  • Page 128 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Support the motorcycle on its centerstand. Drain the engine oil (page 3-7). Remove the following: – Footpeg bar – Spark plug cap (page 3-5) – Carburetor (page 5-5) – Exhaust pipe/muffler (page 2-11) Release the boot [1] and disconnect the alternator 3P connector [2] and ignition pulse generator/neutral switch 3P connector [3].
  • Page 129 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal. Remove the following: – Front engine hanger nuts and bolts [1] – Front engine hanger plate [2] Remove the rear engine hanger nut [1] and bolts [2]. [1]/[2] Remove the engine from the frame.
  • Page 130 dummytext 13. FRONT WHEEL/BRAKE/SUSPENSION/STEERING COMPONENT LOCATION ··························13-2 FRONT WHEEL ·········································· 13-7 SERVICE INFORMATION ···························13-3 FRONT DRUM BRAKE ····························· 13-10 TROUBLESHOOTING·································13-3 FORK························································· 13-11 HANDLEBAR ··············································13-4 STEERING STEM ····································· 13-17 13-1...
  • Page 131 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING COMPONENT LOCATION FRONT WHEEL/BRAKE/SUSPENSION/STEERING 11.8 N·m (1.2 kgf·m, 9 lbf·ft) 37 N·m (3.8 kgf·m, 27 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) Except II NR/III NR/III DK: 59 N·m (6.0 kgf·m, 44 lbf·ft) 13-2...
  • Page 132 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING SERVICE INFORMATION GENERAL Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. •...
  • Page 133 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the following: The right rearview mirror lock nut has – Wire bands [1] left hand threads. – Rearview mirrors [2] Remove the bolts [1], holder [2] and brake lever bracket [3]. Remove the screws [1] and separate the throttle housing [2].
  • Page 134 TORQUE: 11.8 N·m (1.2 kgf·m, 9 lbf·ft) If the handlebar grips are removed, apply Honda Bond A or equivalent to the inner surface of the grip rubber and to the clean surface of the throttle pipe and left side of handlebar.
  • Page 135 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the clutch lever bracket [1] aligning its edge with the punch mark on the handlebar. Align Install the holder [2], bolts [3] and tighten the upper bolt Install the holder first, then the lower bolt. with the “UP”...
  • Page 136 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WHEEL REMOVAL Disconnect the speedometer cable [1] by pushing the [6]/[7] tab [2]. Disconnect the brake cable [3] by removing the adjusting nut [4], and remove the brake cable and joint pin [5]. Loosen the axle nut [6]. Raise the front wheel off the ground and support the motorcycle securely.
  • Page 137 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the remover head into the bearing. From the opposite side of the wheel, install the remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing.
  • Page 138 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING WHEEL ASSEMBLY Pack a new bearing cavities with grease. Drive in a new left side (brake drum side) bearing [1] squarely with the sealed side facing up until it is fully seated. Install the distance collar. Drive in a new right side bearing squarely with the sealed side facing up until it is fully seated to the distance collar.
  • Page 139 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the axle nut [1] and tighten it to the specified torque. TORQUE: 59 N·m (6.0 kgf·m, 44 lbf·ft) Install the brake cable [2] into the brake panel and connect it with the joint pin [3] and adjusting nut [4]. Adjust the brake lever freeplay and check the brake operation (page 3-13).
  • Page 140 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK REMOVAL Remove the following: – Front wheel (page 13-7) – Front fender (page 2-5) Remove the top bridge bolt [1] and washer [2]. Loosen the bottom bridge pinch bolts [1] while If the fork will be supporting the fork leg.
  • Page 141 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the dust seal [1] and stopper ring [2]. Be careful not to scratch the fork pipe. Hold the fork slider [1] in a vise with soft jaws or shop Do not over-tighten towel. the vise on the fork slider.
  • Page 142 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the oil seal using the special tool. TOOL: [1] Oil seal remover 07748-0010001 Remove the back-up ring [2]. INSPECTION FORK SPRING Check the fork spring for fatigue or damage. Measure the fork spring free length. STANDARD: 456.0 –...
  • Page 143 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY DUST SEAL FORK PIPE FORK CAP 22 N·m (2.2 kgf·m, 16 lbf·ft) STOPPER RING FORK PISTON RING OIL SEAL BACK-UP RING FORK O-RING PISTON FORK SLIDER FORK SPRING REBOUND SPRING SEALING WASHER OIL LOCK PIECE SOCKET BOLT 20 N·m (2.0 kgf·m, 15 lbf·ft) Before assembly, wash all parts with a high-flash or...
  • Page 144 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Hold the fork slider in a vise with soft jaws or shop Do not over-tighten towel. the vice. Hold the fork piston using the 14 mm socket wrench. Clean and apply a locking agent to the socket bolt threads.
  • Page 145 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Pour the specified amount of the fork fluid into the fork pipe. FLUID CAPACITY: 135 ± 2.5 cm (4.6 ± 0.08 US oz, 4.8 ± 0.09 Imp oz) Slowly pump the fork pipe several times to remove any 169.5 mm trapped air from the lower portion of the fork pipe.
  • Page 146 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING STEERING STEM REMOVAL Remove the headlight rear cover (page 2-3). II NR/III NR/III DK only: Remove the following: Except II NR/III NR/ III DK: – Headlight case (page 16-3) – Speedometer (page 16-7) Remove the following: All types: –...
  • Page 147 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING BEARING REPLACEMENT Remove the upper and lower outer races using the Always replace the special tool. bearings and races as a set. TOOL: [1] Ball race remover 07944-1150001 Install the stem nut [1] onto the steering stem to prevent the threads from being damaged when removing the inner race [2].
  • Page 148 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Drive in new upper and lower bearing outer races into the steering head pipe. TOOLS: Driver 07749-0010000 Attachment, 37 x 40 07746-0010200 INSTALLATION Grease with extreme pressure agent (recommended: STEM NUT 74 N·m (7.5 kgf·m, 55 lbf·ft) EXCELITE EP2 manufactured by KYODO YUSHI, Japan or Shell ALVANIA EP2 or equivalent) ADJUSTING NUT...
  • Page 149 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Tighten the adjusting nut [1] to the initial torque. TOOL: [2] Stem socket wrench 07916-3710101 TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft) Turn the steering stem left and right, lock-to-lock several times to seat the bearings. Completely loosen the adjustment nut [1].
  • Page 150 dummytext 14. REAR WHEEL/BRAKE/SUSPENSION COMPONENT LOCATION ··························14-2 REAR DRUM BRAKE ································· 14-7 SERVICE INFORMATION ···························14-3 BRAKE PEDAL/CENTERSTAND··············· 14-8 TROUBLESHOOTING·································14-3 SHOCK ABSORBER ·································· 14-9 REAR WHEEL ·············································14-4 SWINGARM ················································ 14-9 14-1...
  • Page 151 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION COMPONENT LOCATION REAR WHEEL/BRAKE/SUSPENSION 69 N·m (7.0 kgf·m, 51 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 88 N·m (8.9 kgf·m, 65 lbf·ft) 14-2...
  • Page 152 • A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent. • Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. • For drive chain information (page 3-9).
  • Page 153 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Remove the drive chain case (page 2-12). NR/DK types only: Place the motorcycle on its centerstand. Disconnect the brake rod [1] by removing the adjusting nut [2], spring [3], washer [4] and joint pin [5]. Remove the following: –...
  • Page 154 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY/ASSEMBLY Disassemble and assemble the rear wheel as following illustration. BEARING (6302U) BEARING (6302U) DAMPER RUBBER DRIVEN SPROCKET NUTS 64 N·m (6.5 kgf·m, 47 lbf·ft) DRIVEN SPROCKET DISTANCE COLLAR BEARING (6004UU) O-RING SLEEVE DRIVEN FLANGE DUST SEAL Install the bearing remover head [1] into the wheel bearing.
  • Page 155 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION WHEEL ASSEMBLY Pack new bearing cavities with grease. Drive in a new right side (brake drum side) bearing [1] squarely with the sealed side facing up until it is fully seated. Install the distance collar. Drive in a new left side bearing with the sealed side facing up until it is fully seated to the distance collar.
  • Page 156 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Connect the stopper arm [1] to the brake panel with the joint bolt [2]. Install the rubber seat [3], washer [4] and nut [5] and tighten the nut securely. Install a new cotter pin [6] into the joint bolt. Install the joint pin [1] into the brake arm.
  • Page 157 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Apply 0.2 - 0.3 g of grease to the anchor pin and brake cam sliding surfaces. Assemble the brake shoes [1] and springs [2] in the direction as shown. Install the shoe assembly onto the brake panel so the spring ends are facing up (wheel side).
  • Page 158 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Remove the following: – Cotter pin [1] and washer [2] – Brake rod [3] Installation is in the reverse order of removal. • Apply grease to the grooves in the pivot shaft. • Replace the cotter pins with new ones. •...
  • Page 159 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY/ASSEMBLY Disassemble and assemble the swingarm as following illustration. SWINGARM CHAIN SLIDER BRAKE PANEL STOPPER ARM COTTER PIN SPRING WASHER WASHER CHAIN ADJUSTER Install the chain slider [1] by setting the bosses [2] into the holes in the swingarm securely and aligning the slits with the swingarm tab [3].
  • Page 160 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Route the drive chain and install the swingarm into the frame. Apply thin coat of grease to the swingarm pivot sliding surface. Insert the pivot bolt [1] from left side and loosely tighten the pivot nut [2]. Install the brake pedal return spring [1].
  • Page 161 dummyhead dummyhead MEMO...
  • Page 162 dummytext 15. BATTERY/CHARGING SYSTEM SYSTEM LOCATION···································15-2 BATTERY ···················································· 15-5 SYSTEM DIAGRAM ····································15-2 CHARGING SYSTEM INSPECTION ·········· 15-6 SERVICE INFORMATION ···························15-3 REGULATOR/RECTIFIER ·························· 15-7 TROUBLESHOOTING·································15-4 ALTERNATOR COIL INSPECTION ··········· 15-7 15-1...
  • Page 163 dummyhead dummyhead BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY/CHARGING SYSTEM IGNITION SWITCH REGULATOR/RECTIFIER BATTERY ALTERNATOR MAIN FUSE (20 A) SYSTEM DIAGRAM MAIN FUSE (20 A) Bl: Black G: Green R: Red Y: Yellow W: White REGULATOR/ ALTERNATOR RECTIFIER BATTERY 15-2...
  • Page 164 dummyhead dummyhead BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 165 dummyhead dummyhead BATTERY/CHARGING SYSTEM TROUBLESHOOTING Battery is damaged or weak 1. Battery Test Remove the battery (page 15-5). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM210 or BATTERY MATE or equivalent Is the battery in good condition? –...
  • Page 166 dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the right side cover (page 2-2). Turn the ignition switch OFF. Remove the bolt and battery negative (–) cable [1] from the battery [2]. Remove the bolt and battery positive (+) cable [3] from the battery.
  • Page 167 dummyhead dummyhead BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the right side cover (page 2-2). Turn the ignition switch OFF and disconnect the battery negative (–) cable [1] from the battery. Connect the ammeter (+) probe [2] to the battery negative (–) cable and the ammeter (–) probe [3] to the battery negative (–) terminal.
  • Page 168 dummyhead dummyhead BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER SYSTEM INSPECTION Before inspection, check the main fuse (20 A). Remove the fuel tank (page 2-4). Pull back the connector cover [1]. Disconnect the regulator/rectifier 4P (Black) connector [2], and check it for loose contact or corroded terminals. If the charging voltage reading (page 15-6) is out of the specification, inspect the regulator/rectifier 4P (Black) connector terminals (wire harness side) as follows:...
  • Page 169 dummyhead dummyhead MEMO...
  • Page 170 dummytext 16. LIGHTS/METER/SWITCHES SYSTEM LOCATION···································16-2 BRAKE/TAILLIGHT ···································· 16-4 SERVICE INFORMATION ···························16-2 TURN SIGNAL LIGHT ································ 16-5 HEADLIGHT (II NR/III NR/III DK) ················16-2 SPEEDOMETER ········································· 16-6 HEADLIGHT (Except II NR/III NR/III DK) ···16-3 IGNITION SWITCH······································ 16-7 POSITION LIGHT ········································16-4 TURN SIGNAL RELAY ······························ 16-8 16-1...
  • Page 171 dummyhead dummyhead LIGHTS/METER/SWITCHES SYSTEM LOCATION LIGHTS/METER/SWITCHES FRONT BRAKE LIGHT SWITCH LEFT HANDLEBAR SWITCHES TURN SIGNAL RELAY IGNITION SWITCH HORN NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH SERVICE INFORMATION GENERAL • Be sure to install the dust cover after replacing the bulb. •...
  • Page 172 dummyhead dummyhead LIGHTS/METER/SWITCHES REMOVAL/INSTALLATION Remove the front visor (page 2-3). Remove the following: – Headlight adjusting bolt [1] – Wave washer [2] – Clips [3] – Headlight unit [4] Install the removed parts in the reverse order of removal. Adjust the headlight aim (page 3-14). HEADLIGHT (Except II NR/III NR/III DK) BULB REPLACEMENT Remove the screws [1] and collars [2].
  • Page 173 dummyhead dummyhead LIGHTS/METER/SWITCHES POSITION LIGHT BULB REPLACEMENT Remove the headlight unit (page 16-3). Except II NR/III NR/ II NR/III NR/III DK: III DK Pull the position light bulb socket [1] out of the headlight. Pull the bulb [2] out of the socket and replace it with a new one.
  • Page 174 dummyhead dummyhead LIGHTS/METER/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw [1] and turn signal light reflector [2]. Remove the screws [3] and turn signal light lens [4]. Push the bulb [5] in, turn it counterclockwise and remove it from the bulb socket. Make sure the lens packing [6] is installed in position and is in good condition, replace it with a new one if necessary.
  • Page 175 dummyhead dummyhead LIGHTS/METER/SWITCHES Except II NR/III NR/III DK Remove the headlight unit (page 16-3). Disconnect the wire connectors [2]: – Right side: Light blue and Green – Left side: Orange and Green Remove the mounting nut [1] and front turn signal unit [2].
  • Page 176 dummyhead dummyhead LIGHTS/METER/SWITCHES REMOVAL/INSTALLATION (II NR/III NR/III DK) Release the boot and disconnect the following connectors (page 16-6): – Speedometer 4P connector – Speedometer 3P (Black) connector Disconnect the speedometer cable [1]. Remove the screws [2] and speedometer [3]. Installation is in the reverse order of removal. TORQUE: Speedometer mounting screw: 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)
  • Page 177 dummyhead dummyhead LIGHTS/METER/SWITCHES INSPECTION Remove the front visor (page 2-3). II NR/III NR/III DK II NR/III NR/III DK: Remove the headlight unit (page 16-3). Except II NR/III NR/ III DK: Disconnect the ignition switch 2P connector [1]. Check for continuity between the ignition switch side connector terminals in each switch position (page 17-5).
  • Page 178 dummytext 17. WIRING DIAGRAMS WIRING DIAGRAM (NR/DK)·······················17-2 WIRING DIAGRAM (AG/CL types) ············ 17-4 WIRING DIAGRAM (II NR/III NR/III DK)······17-3 WIRING DIAGRAM (MX/PE types) ············ 17-5 17-1...
  • Page 179 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAM (NR/DK) WIRING DIAGRAMS 17-2...
  • Page 180 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAM (II NR/III NR/III DK) 17-3...
  • Page 181 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAM (AG/CL types) 17-4...
  • Page 182 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAM (MX/PE types) 17-5...
  • Page 183 dummyhead dummyhead MEMO...
  • Page 184 INDEX dummytext INDEX AIR CLEANER (Except NR/DK types) ····························3-4 IGNITION SWITCH······················································· 16-7 AIR CLEANER (NR/DK types) ········································3-4 IGNITION SYSTEM INSPECTION ································· 4-4 AIR CLEANER HOUSING ··············································5-4 IGNITION TIMING ·························································· 4-5 AIR SCREW ADJUSTMENT·········································5-10 INSULATOR ··································································· 5-9 ALTERNATOR COIL INSPECTION······························15-7 INTAKE MANIFOLD A···················································· 5-9 BATTERY KICKSTARTER···························································...
  • Page 185 dummytext INDEX CYLINDER/PISTON ·················································· 8-3 TURN SIGNAL RELAY ················································· 16-8 FRONT WHEEL/BRAKE/SUSPENSION/ VALVE CLEARANCE ····················································· 3-6 STEERING······························································· 13-3 WHEELS/TIRES ··························································· 3-16 FUEL SYSTEM ·························································· 5-3 WIRING DIAGRAM (AG/CL types) ······························· 17-4 IGNITION SYSTEM ··················································· 4-3 WIRING DIAGRAM (II NR/III NR/III DK) ······················· 17-3 LUBRICATION SYSTEM ···········································...