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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 service can create an
unsafe condition that can cause your customer 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 recommended 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 GL150 1WH-C 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: Table Of Contents

    dummyhead dummyhead CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER ALTERNATOR/STARTER CLUTCH CRANKCASE/CRANKSHAFT/TRANSMISSION FRONT WHEEL/BRAKE/SUSPENSION/STEERING REAR WHEEL/BRAKE/SUSPENSION BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX...
  • Page 5 dummyhead dummyhead MEMO...
  • Page 6: General Information

    dummytext 1. GENERAL INFORMATION SERVICE RULES ··········································1-2 FRONT WHEEL/BRAKE/SUSPENSION/ STEERING SPECIFICATIONS ····················· 1-7 MODEL IDENTIFICATION ····························1-2 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS········································· 1-8 GENERAL SPECIFICATIONS ······················1-4 BATTERY/CHARGING SYSTEM LUBRICATION SYSTEM SPECIFICATIONS········································· 1-8 SPECIFICATIONS ·········································1-5 IGNITION SYSTEM SPECIFICATIONS ········ 1-8 FUEL SYSTEM SPECIFICATIONS···············1-5 ELECTRIC STARTER SPECIFICATION ······ 1-8 CYLINDER HEAD/VALVES SPECIFICATIONS ·········································1-5 LIGHTS/METERS/SWITCHES...
  • Page 7: Service Rules

    SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
  • Page 8: Serial Numbers

    dummyhead dummyhead GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identification Number (VIN) is stamped on the left side of the steering head. VEHICLE IDENTIFICATION NUMBER The engine serial number is stamped on the lower left side of the crankcase. ENGINE SERIAL NUMBER The carburetor identification number is stamped on the left side of the carburetor body.
  • Page 9: General Specifications

    dummyhead dummyhead GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,037 mm (80.2 in) Overall width 778 mm (30.6 in) Overall height 1,068 mm (42.0 in) Wheelbase 1,306 mm (51.4 in) Seat height 768 mm (30.2 in) Footpeg height 265 mm (10.4 in) Ground clearance 163 mm (6.4 in)
  • Page 10: Lubrication System Specifications

    dummyhead dummyhead GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil After draining 1.0 liter (1.1 US qt, 0.9 Imp qt) – capacity After disassembly 1.2 liter (1.3 US qt, 1.1 Imp qt) – Recommended engine oil API classification: SG or higher (except oils labeled as energy conserving on the circular API service label)
  • Page 11: Cylinder/Piston Specifications

    dummyhead dummyhead GENERAL INFORMATION CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260) Out-of-round – 0.10 (0.004) Taper – 0.10 (0.004) Warpage – 0.10 (0.004) Piston, Piston O.D. at 10 mm (0.4 in) 57.280 –...
  • Page 12: Crankcase/Crankshaft/Transmission Specifications

    dummyhead dummyhead GENERAL INFORMATION CRANKCASE/CRANKSHAFT/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod big end 0 – 0.008 (0 – 0.0003) 0.05 (0.002) radial clearance Connecting rod big end 0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032) side clearance Runout 0.03 (0.001)
  • Page 13: Rear Wheel/Brake/Suspension

    dummyhead dummyhead GENERAL INFORMATION REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth – 2.0 (0.08) Cold tire pressure 225 kPa (2.25 kgf/cm , 33 psi) – Axle runout – 0.2 (0.01) Wheel rim Radial –...
  • Page 14: Lights/Meters/Switches

    dummyhead dummyhead GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATION Bulbs Headlight (Hi/low beam) 12 V - 35/35 W Position light 12 V - 5 W Brake/tail light 12 V - 21/5 W Turn signal light 12 V - 10 W x 4 Instrument light Turn signal indicator 12 V - 3.4 W x 2...
  • Page 15: Torque Values

    dummyhead dummyhead GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5 (0.5, 3.7) 5 mm screw 4 (0.4, 3.0) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.6)
  • Page 16 dummyhead dummyhead GENERAL INFORMATION ENGINE REMOVAL/INSTALLATION THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Front engine hanger nut (Frame side) 59 (6.0, 44) Front engine hanger nut (Engine side) 26 (2.7, 19) Rear lower engine hanger nut 64 (6.5, 47) Drive sprocket bolt 12 (1.2, 9) CYLINDER HEAD/VALVES...
  • Page 17 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 Spoke BC3.2 3.7 (0.38, 2.7) Front brake arm nut 10 (1.0, 7) Handlebar holder bolt 12 (1.2, 9) Brake lever pivot bolt 1 (0.1, 0.7) Brake lever pivot nut...
  • Page 18: Lubrication & Seal Points

    dummyhead dummyhead GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Sealant (Three bond 1215 Crankcase mating surface See page 11-16 or 1207G or equivalent) Alternator wire grommet seating surface Engine oil Oil pump rotors Oil through sliding area Rocker arm shaft whole surface Rocker arm inner surface and roller surface Cam chain whole surface...
  • Page 19 Brake cam felt seal Silicone grease Throttle cable end boot inside Apply 0.1 cc Throttle cable inside Front fork oil/dust seal Fork fluid Fork cap O-ring Honda Bond A or equivalent Handlebar grip rubber inside Air cleaner case-to-connecting hose mating area 1-14...
  • Page 20: Cable & Harness Routing

    dummyhead dummyhead GENERAL INFORMATION CABLE & HARNESS ROUTING CABLE GUIDE SPEEDOMETER CABLE FRONT BRAKE CABLE LEFT HANDLEBAR SWITCH MAIN HARNESS 3P (NATURAL) CONNECTOR COMBINATION METER WIRE IGNITION SWITCH 2P (NATURAL) CONNECTOR COMBINATION METER IGNITION SWITCH 2P (BLACK) CONNECTOR 2P (NATURAL) CONNECTOR COMBINATION METER LEFT HANDLEBAR SWITCH 6P (NATURAL) CONNECTOR...
  • Page 21 dummyhead dummyhead GENERAL INFORMATION FRONT BRAKE CABLE FRONT BRAKE LIGHT LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE THROTTLE CABLE CLUTCH CABLE RIGHT HANDLEBAR CLUTCH SWITCH WIRE SWITCH WIRE FRONT LEFT HANDLEBAR BRAKE LIGHT SWITCH WIRE SWITCH WIRE CHOKE CABLE RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE...
  • Page 22 dummyhead dummyhead GENERAL INFORMATION FRONT BRAKE CABLE CHOKE CABLE CLUTCH CABLE THROTTLE CABLE FRONT BRAKE LIGHT SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE SPEEDOMETER CABLE RIGHT HANDLEBAR SWITCH WIRE CHOKE CABLE LEFT FRONT TURN SIGNAL LIGHT WIRE SPEEDOMETER CABLE FRONT BRAKE CABLE LEFT HANDLEBAR...
  • Page 23 dummyhead dummyhead GENERAL INFORMATION 5 mm MAX MAIN HARNESS THROTTLE CABLE CHOKE CABLE THROTTLE CABLE MAIN HARNESS SPARK PLUG WIRE MAIN HARNESS SPARK PLUG WIRE CLUTCH CABLE 1-18...
  • Page 24: Choke Cable

    dummyhead dummyhead GENERAL INFORMATION CHOKE CABLE CHOKE CABLE HORN WIRE GROUND CABLE HORN WIRE SPARK PLUG WIRE SPEEDOMETER CABLE FRONT BRAKE CABLE IGNITION COIL PRIMARY WIRE CLUTCH CABLE 1-19...
  • Page 25 dummyhead dummyhead GENERAL INFORMATION ALTERNATOR/ IGNITION PULSE GENERATOR WIRE GEAR POSITION SWITCH WIRE GEAR POSITION SWITCH 1-20...
  • Page 26 dummyhead dummyhead GENERAL INFORMATION REGULATOR/RECTIFIER CHOKE CABLE FUEL HOSE REGULATOR/ RECTIFIER WIRE THROTTLE CABLE CARBURETOR MAIN AIR VENT HOSE HARNESS ICM WIRE STARTER RELAY SWITCH CHOKE CABLE ICM WIRE MAIN HARNESS REGULATOR/RECTIFIER WIRE 1-21...
  • Page 27 dummyhead dummyhead GENERAL INFORMATION MAIN FUSE WIRE STARTER RELAY SWITCH REAR BRAKE LIGHT SWITCH 3P (NATURAL) CONNECTOR STARTER RELAY SWITCH 2P (BLACK) CONNECTOR REAR BRAKE LIGHT STARTER RELAY SWITCH WIRE SWITCH WIRE MAIN FUSE WIRE MAIN HARNESS MAIN FUSE BATTERY NEGATIVE (-) CABLE BATTERY POSITIVE (+) CABLE STARTER MOTOR REAR BRAKE LIGHT SWITCH...
  • Page 28 dummyhead dummyhead GENERAL INFORMATION ALTERNATOR/ GEAR POSITION IGNITION PULSE GENERATOR WIRE SWITCH WIRE REGULATOR/RECTIFIER WIRE ALTERNATOR/ IGNITION PULSE GENERATOR WIRE FUEL LEVEL SENSOR GEAR POSITION SWITCH WIRE 3P (NATURAL) CONNECTOR SUB FUSES INSIDE BOOT CONNECTORS: – IGNITION PULSE GENERATOR 2P (NATURAL) CONNECTOR –...
  • Page 29 dummyhead dummyhead GENERAL INFORMATION ALTERNATOR/ IGNITION PULSE GENERATOR WIRE CARBURETOR AIR VENT HOSE CARBURETOR DRAIN HOSE FUEL HOSE CRANKCASE BREATHER HOSE GEAR POSITION SWITCH WIRE CARBURETOR DRAIN HOSE View from the under side 1-24...
  • Page 30: Main Harness

    dummyhead dummyhead GENERAL INFORMATION INSIDE BOOT CONNECTORS: – BRAKE/TAIL LIGHT 3P (NATURAL) CONNECTOR LEFT REAR TURN – LEFT REAR TURN SIGNAL LIGHT WIRE (ORANGE) CONNECTOR SIGNAL LIGHT WIRE – RIGHT REAR TURN SIGNAL LIGHT WIRE (LIGHT BLUE) CONNECTOR – LEFT/RIGHT REAR TURN SIGNAL LIGHT WIRE (GREEN) CONNECTOR TURN SIGNAL RELAY 2P (NATURAL) CONNECTOR BRAKE/TAIL LIGHT WIRE...
  • Page 31: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes appropriate carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.
  • Page 32 dummyhead dummyhead GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a oxidation catalytic converter and lean carburetor settings. No adjustment should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system.
  • Page 33 dummyhead dummyhead MEMO...
  • Page 34: Frame/Body Panels/Exhaust System

    dummytext 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION ·····························2-2 FRONT EMBLEM ·········································· 2-5 TROUBLESHOOTING···································2-2 REAR CARRIER ··········································· 2-5 LEFT SIDE COVER ·······································2-3 REAR SIDE COWL ······································· 2-6 RIGHT SIDE COVER·····································2-3 REAR FENDER ············································· 2-7 SEAT······························································2-4 DRIVE SPROCKET COVER ························· 2-7 FUEL TANK···················································2-4 SIDESTAND ··················································...
  • Page 35: Service Information

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM GENERAL • This section covers removal and installation of the body panels, fuel tank and exhaust system. • Always replace the gasket when removing the exhaust system. • Always inspect the exhaust system for leaks after installation. •...
  • Page 36: Left Side Cover

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM LEFT SIDE COVER REMOVAL/INSTALLATION Unlock the left side cover with the ignition key. GROMMETS LEFT SIDE COVER Release the two bosses from the grommets, remove the left side cover. Installation is in the reverse order of removal. Be careful not to damage the bosses.
  • Page 37 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION Remove the left side cover (page 2-3). BOLTS HOOK SEAT Remove the right side cover (page 2-3). Remove the two bolts and collars. Move the seat forward and remove it. Install the seat by aligning the hook with the frame groove.
  • Page 38: Front Fender

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the cable guide from the front fender. Be careful not to FRONT FENDER GROMMETS scratch the fender. Remove the four bolts, front fender and stay. COLLARS Remove the four collars and grommets from the front BOLTS fender.
  • Page 39 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR SIDE COWL REMOVAL/INSTALLATION Remove the following: BOLTS REAR SIDE COWL – rear carrier (page 2-5) – seat (page 2-4) Remove the bolts, collars and screws. TABS Release the rear side cowl tabs from the grommets. Remove the rear side cowl.
  • Page 40: Rear Fender

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL/INSTALLATION Remove the following: TURN SIGNAL RELAY – rear side cowl (page 2-6) SPECIAL BOLTS – rear turn signal lights (page 17-8) Remove the turn signal relay from the rear fender. SLOTS Remove the two special bolts and two bolt. TABS Slide the rear fender rearward and release its slots from the two tabs on the frame, then remove the rear fender.
  • Page 41 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL Remove the exhaust pipe joint nuts. JOINT NUTS Remove the bolt and washer. WASHER BOLT Remove the nut, bolt, two washers, and exhaust pipe NUT/ muffler. WASHER WASHER BOLT MUFFLER Remove the exhaust pipe gasket from the exhaust port of the engine.
  • Page 42: Installation

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION EXHAUST PIPE STUD BOLT STUD BOLT Thread two nuts to the stud bolt and tighten them together, then use a wrench on them to turn the stud bolt out. Install and tighten new stud bolts into the cylinder head to the specified torque.
  • Page 43 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Install and tighten the bolt and washer. WASHER BOLT Tighten the exhaust pipe joint nuts. Make sure that the JOINT NUTS exhaust pipe is seated when tightening the joint nuts. 2-10...
  • Page 44: Maintenance

    dummytext 3. MAINTENANCE SERVICE INFORMATION ·····························3-2 ENGINE IDLE SPEED································· 3-12 MAINTENANCE SCHEDULE························3-3 DRIVE CHAIN ············································· 3-12 FUEL LINE·····················································3-4 BRAKE SHOES WEAR ····························· 3-14 FUEL STRAINER SCREEN ··························3-4 BRAKE SYSTEM ········································ 3-15 THROTTLE OPERATION······························3-5 BRAKE LIGHT SWITCH ····························· 3-16 CHOKE OPERATION····································3-6 HEADLIGHT AIM ········································...
  • Page 45: Specifications

    dummyhead dummyhead MAINTENANCE SERVICE INFORMATION MAINTENANCE GENERAL • Place the motorcycle on a level ground before starting any work. • The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
  • Page 46: Maintenance Schedule

    * 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 47: Fuel Strainer Screen

    dummyhead dummyhead MAINTENANCE FUEL LINE Check the fuel hose between the fuel tank and FUEL HOSE carburetor for deterioration, damage or leakage. Replace the fuel hose if necessary. FUEL STRAINER SCREEN Turn the fuel valve to OFF. FUEL VALVE Remove the following: –...
  • Page 48: Throttle Operation

    dummyhead dummyhead MAINTENANCE THROTTLE OPERATION Check for any deterioration or damage of the throttle cable. Check the throttle grip for smooth operation. Check that the throttle opens and automatically closes in all steering positions. If the throttle grip does not return properly, lubricate the throttle cable and clean the throttle housing.
  • Page 49: Choke Operation

    dummyhead dummyhead MAINTENANCE CHOKE OPERATION This model uses a bypass air volume control choke CHOKE LEVER system controlled by the starting enrichment (SE) valve. The SE valve opens the bypass air circuit via a cable when the choke lever on the handlebar is pulled in. Check for smooth choke lever operation.
  • Page 50: Crankcase Breather

    dummyhead dummyhead MAINTENANCE CRANKCASE BREATHER • Service more frequently when ridden in rain, at full CRANKCASE BREATHER HOSE throttle, or after the motorcycle is washed or overturned. Service if the deposits level can be seen in the transparent section of the drain tube. Check the crankcase breather hose for deterioration, damage or loose connection.
  • Page 51: Valve Clearance

    dummyhead dummyhead MAINTENANCE Clean the spark plug electrodes with a wire brush or special plug cleaner. Check the gap between the center and side electrodes 0.80 – 0.90 mm with a wire-type feeler gauge. (0.031 – 0.035 in) SPARK PLUG GAP: 0.80 – 0.90 mm (0.031 – 0.035 in) If necessary, adjust the gap by bending the side electrode carefully.
  • Page 52: Engine Oil

    dummyhead dummyhead MAINTENANCE Adjust by loosening the lock nut and turning the ADJUSTING WRENCH adjusting screw until there is a slight drag on the feeler gauge. TOOL: Valve adjusting wrench 07708-0030400 Apply engine oil to the valve adjusting lock nut to the threads and seating surface.
  • Page 53: Engine Oil Strainer Screen

    dummyhead dummyhead MAINTENANCE OIL CHANGE Start the engine, warm it up and stop it. Change the oil with SEALING WASHER the engine warm Remove the oil drain bolt and filler cap/dipstick, and and the motorcycle drain the engine oil. on its sidestand to After draining the oil completely, install the drain bolt assure complete with a new sealing washer and tighten it to the specified...
  • Page 54: Engine Oil Centrifugal Filter

    dummyhead dummyhead MAINTENANCE ENGINE OIL CENTRIFUGAL FILTER Remove the right crankcase cover (page 9-5). SCREWS GASKET Remove the following: – three screws – filter rotor cover – gasket COVER Clean the inside of the centrifugal filter rotor with a lint- Do not allow dust FILTER ROTOR free cloth.
  • Page 55: Engine Idle Speed

    dummyhead dummyhead MAINTENANCE ENGINE IDLE SPEED • Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. • The engine must be warm for accurate idle speed inspection and adjustment. Ten minutes of stop-and- go riding is sufficient.
  • Page 56 dummyhead dummyhead MAINTENANCE CLEANING, INSPECTION AND LUBRICATION If the drive chain becomes extremely dirty, it should be removed and cleaned prior to lubrication. Remove the chain cover (page 13-17). Carefully remove the retaining clip with pliers. Remove the link plate, master link and drive chain. RETAINING CLIP Clean the chain with non-flammable or high-flash point NON-FLAMMABLE OR HIGH-FLASH...
  • Page 57: Front Brake Shoes

    dummyhead dummyhead MAINTENANCE Install the drive chain onto the sprockets. Install the master link and link plate, and the retaining MASTER clip so that its open end is opposite the normal rotation LINK of the chain. RETAINING CLIP Install the drive chain cover (page 13-20). Rotating Direction LINK PLATE...
  • Page 58: Brake System

    dummyhead dummyhead MAINTENANCE BRAKE SYSTEM FRONT DRUM BRAKE Inspect the brake cable for kinks or damage, and lubricate the cable if necessary. 10 – 20 mm (0.4 – 0.8 in) Measure the brake lever freeplay at the end of the lever.
  • Page 59: Brake Light Switch

    dummyhead dummyhead MAINTENANCE PEDAL FREEPLAY Check the brake pedal and brake rod for deformation or damage. 20 – 30 mm Measure the brake pedal freeplay. (0.8 – 1.2 in) FREEPLAY: 20 – 30 mm (0.8 – 1.2 in) Adjust the freeplay by turning the adjusting nut. ADJUSTING NUT Make sure the cutout of the adjusting nut is seated on Correct...
  • Page 60: Headlight Aim

    dummyhead dummyhead MAINTENANCE HEADLIGHT AIM Support the motorcycle upright on a level surface. Adjust the headlight beam as specified Adjust the headlight beam vertically by turning the by local laws and headlight assembly up or down. regulations. Loosen the mounting bolts to move the headlight. MOUNTING BOLTS CLUTCH SYSTEM Inspect the clutch cable for kinks or damage, and...
  • Page 61: Nuts, Bolts, Fasteners

    dummyhead dummyhead MAINTENANCE SIDESTAND Place the motorcycle on its centerstand. LOCK NUT Check the sidestand spring for damage or loss of tension. Check the sidestand operation for freedom of movement and lubricate the sidestand pivot if necessary. Check that the sidestand pivot bolt and lock nut are PIVOT BOLT tightened.
  • Page 62: Recommended Tire Pressure

    dummyhead dummyhead MAINTENANCE WHEELS/TIRES Support the motorcycle securely and raise the front wheel off the ground. Check for worn wheel bearings by holding the fork leg and move the front wheel sideways. Replace the wheel bearings if any looseness is noted (page 12-11).
  • Page 63: Steering Head Bearings

    dummyhead dummyhead MAINTENANCE STEERING HEAD BEARINGS Place the motorcycle on its centerstand and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. Make sure the control cables do not interfere with the handlebar rotation. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (page 12-27).
  • Page 64: Lubrication System

    dummytext 4. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ············4-2 TROUBLESHOOTING ·································· 4-3 SERVICE INFORMATION ·····························4-3 OIL PUMP ····················································· 4-4...
  • Page 65: Lubrication System Diagram

    dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM ROCKER ARM CAMSHAFT OIL FILTER ROTOR CRANKSHAFT OIL PUMP OIL STRAINER SCREEN MAINSHAFT COUNTERSHAFT...
  • Page 66: Service Information

    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 67: Oil Pump

    dummyhead dummyhead LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the right crankcase cover (page 9-5). Remove the oil pump driven gear. DRIVEN GEAR Remove the two mounting bolts and oil pump. OIL PUMP BOLTS DISASSEMBLY Remove the screw, dowel pins and oil pump cover. DOWEL PINS PUMP COVER SCREW...
  • Page 68 dummyhead dummyhead LUBRICATION SYSTEM Remove the outer rotor from the oil pump body. OUTER ROTOR INSPECTION • Measure at several places and use the largest reading to compare to the service limit. • If any portion of the oil pump is worn beyond the specified service limit, replace the oil pump and pump cover as an assembly.
  • Page 69 dummyhead dummyhead LUBRICATION SYSTEM Remove the rotor shaft. SIDE CLEARANCE: Measure the side clearance. SERVICE LIMIT: 0.12 mm (0.005 in) ASSEMBLY PUMP BODY ROTOR SHAFT PUMP COVER OUTER ROTOR INNER ROTOR SCREW 3 N·m (0.3 kgf·m, 2.2 lbf·ft) Apply engine oil to the outer rotor and install it into the oil pump body.
  • Page 70: Installation

    dummyhead dummyhead LUBRICATION SYSTEM Apply engine oil to the inner rotor, then install the rotor INNER ROTOR shaft and inner rotor. ROTOR SHAFT Install the dowel pins to the oil pump. DOWEL PINS Install the oil pump cover and tighten the screw to the specified torque.
  • Page 71 dummyhead dummyhead MEMO...
  • Page 72: Fuel System

    dummytext 5. FUEL SYSTEM SYSTEM COMPONENTS······························5-2 CARBURETOR DISASSEMBLY/ INSPECTION················································· 5-7 SERVICE INFORMATION ·····························5-3 CARBURETOR ASSEMBLY ······················ 5-11 TROUBLESHOOTING···································5-4 INSULATOR INSTALLATION ···················· 5-14 AIR CLEANER HOUSING·····························5-5 CARBURETOR INSTALLATION ················ 5-15 CARBURETOR REMOVAL···························5-6 PILOT SCREW ADJUSTMENT ·················· 5-16 INSULATOR REMOVAL ·······························5-7 FUEL STRAINER ········································ 5-17...
  • Page 73: System Components

    dummyhead dummyhead FUEL SYSTEM SYSTEM COMPONENTS FUEL SYSTEM 12 N·m (1.2 kgf·m, 9 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft)
  • Page 74: Torque Values

    dummyhead dummyhead FUEL SYSTEM 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 75 dummyhead dummyhead FUEL SYSTEM TROUBLESHOOTING Engine won’t to start • No fuel in tank • No fuel to carburetor – Clogged fuel strainer – Clogged fuel line – Clogged fuel tank breather hose • Too much fuel getting to the engine –...
  • Page 76: Air Cleaner Housing

    dummyhead dummyhead FUEL SYSTEM AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the following: BOOT – fuel tank (page 2-4) – battery (page 14-5) GUIDES – starter relay switch (page 16-13) – ICM (page 15-8) – rear fender (page 2-7) – rear wheel (page 13-5) –...
  • Page 77: Carburetor Removal

    dummyhead dummyhead FUEL SYSTEM CARBURETOR REMOVAL Remove the fuel tank (page 2-4). FUEL HOSE CARBURETOR DRAIN HOSE Disconnect the following: – fuel hose – carburetor air vent hose – carburetor drain hose CARBURETOR AIR VENT HOSE Loosen the SE valve nut and remove the SE valve from the carburetor.
  • Page 78 dummyhead dummyhead FUEL SYSTEM Loosen the insulator band screw. INSULATOR BAND SCREW Remove the carburetor from the insulator and air cleaner housing connecting hose. CARBURETOR INSULATOR REMOVAL Remove the left side cover (page 2-3). INSULATOR BAND SCREW Remove the right side cover (page 2-3). Loosen the insulator band screw.
  • Page 79 dummyhead dummyhead FUEL SYSTEM Remove the SE valve, spring and sealing cap/nut from the choke cable and replace them as a set if necessary. CHOKE CABLE SE VALVE SPRING SEALING CAP/NUT Remove the two screws and SE valve body and O-ring. SE VALVE BODY SCREWS O-RING...
  • Page 80 dummyhead dummyhead FUEL SYSTEM Turn the needle holder counterclockwise by using a Be careful not to NEEDLE HOLDER screwdriver while pressing it in and release the holder damage the from the vacuum piston. diaphragm. Remove the needle holder, spring and jet needle from the vacuum piston.
  • Page 81: Carburetor Body Cleaning

    dummyhead dummyhead FUEL SYSTEM Check the float valve and valve seat for scoring, scratches, clogging or damage. Check the tip of the float valve, where it contacts the FLOAT VALVE valve seat, for stepped wear or contamination. Check the operation of the float valve. VALVE SEAT Remove the following: Handle the jets with...
  • Page 82: Carburetor Assembly

    dummyhead dummyhead FUEL SYSTEM CARBURETOR ASSEMBLY 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) SPRING VACUUM CHAMBER COVER JET NEEDLE COMPRESSION SPRING DIAPHRAGM/ VACUUM PISTON NEEDLE HOLDER FLOAT VALVE FLOAT FLOAT PIN O-RING 2.3 N·m (0.24 kgf·m, 1.7 lbf·ft) WASHER O-RING SPRING SE VALVE BODY WASHER 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
  • Page 83 dummyhead dummyhead FUEL SYSTEM Hang the float valve onto the float arm lip. FLOAT PIN Install the float valve and float, and insert the float pin. FLOAT Check the float level after checking the float valve, FLOAT LEVEL GAUGE valve seat and float. With the float valve seated and the float arm just Set the float level touching the valve, measure the float level with the float...
  • Page 84 dummyhead dummyhead FUEL SYSTEM Turn the needle holder 90 degrees clockwise while NEEDLE HOLDER pressing it until it locks. Install the diaphragm/vacuum piston into the carburetor Be careful not to DIAPHRAGM/PISTON body by aligning the tab of the diaphragm with the air damage the jet passage, then insert the jet needle into the needle jet.
  • Page 85 dummyhead dummyhead FUEL SYSTEM Insert the choke cable into the SE valve sealing cap/nut and spring, and connect it to the SE valve. SPRING SE VALVE INSULATOR INSTALLATION Install the insulator onto the carburetor by aligning the INSULATOR 8 ± 1 mm groove with the lug.
  • Page 86: Carburetor Installation

    dummyhead dummyhead FUEL SYSTEM CARBURETOR INSTALLATION Install the carburetor into the insulator and air cleaner INSULATOR BAND SCREW housing connecting hose, and tighten the insulator band screw (page 5-14). CARBURETOR Tighten the connecting hose band screw. CONNECTING HOSE BAND SCREW Connect the throttle cable to the throttle drum and install it onto the cable holder stay.
  • Page 87: Pilot Screw Adjustment

    dummyhead dummyhead FUEL SYSTEM Connect the following: Route the hoses FUEL HOSE CARBURETOR DRAIN HOSE properly (page 1- – carburetor drain hose 15). – carburetor air vent hose – fuel hose Install the fuel tank (page 2-4). CARBURETOR AIR VENT HOSE PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE •...
  • Page 88: Fuel Strainer

    dummyhead dummyhead FUEL SYSTEM FUEL STRAINER CLEANING Remove the fuel tank (page 2-4). LOCK NUT Drain the fuel from the fuel tank into the approved gasoline container. Loosen the lock nut and remove the fuel valve from the fuel tank. Remove the O-ring and fuel strainer from the fuel valve.
  • Page 89 dummyhead dummyhead MEMO...
  • Page 90: Engine Removal/Installation

    dummytext 6. ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS······························6-2 ENGINE REMOVAL ······································ 6-4 SERVICE INFORMATION ·····························6-3 ENGINE INSTALLATION······························ 6-5...
  • Page 91: System Components

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS ENGINE REMOVAL/INSTALLATION 12 N·m (1.2 kgf·m, 9 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 26 N·m (2.7 kgf·m, 19 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft)
  • Page 92: Service Information

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION 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. • The following components require engine removal for service: –...
  • Page 93 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-10). CLAMP 2P CONNECTOR Place the motorcycle on its centerstand. Remove the following: – left side cover (page 2-3) – right side cover (page 2-3) – drive sprocket cover (page 2-7) –...
  • Page 94 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the following: CHAIN BOLTS – two bolts – fixing plate (by aligning the splines of the plate and countershaft) – drive sprocket (pull it off the countershaft and remove from the chain) FIXING PLATE SPROCKET –...
  • Page 95 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Using a jack or other adjustable support, carefully place During engine the engine into the frame and maneuver it into place. installation, hold the engine securely Carefully align the bolt holes in the frame and engine. and be careful not Align the mounting bolt holes and install the following to damage the...
  • Page 96 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install a new O-ring into the insulator groove. Install the two insulator socket bolts and tighten them to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Connect the following: – spark plug cap BOLTS O-RING PLUG CAP –...
  • Page 97 dummyhead dummyhead MEMO...
  • Page 98: Cylinder Head/Valves

    dummytext 7. CYLINDER HEAD/VALVES SYSTEM COMPONENTS······························7-2 CAMSHAFT··················································· 7-8 SERVICE INFORMATION ·····························7-3 CAMSHAFT HOLDER ································ 7-12 TROUBLESHOOTING···································7-5 CYLINDER HEAD ······································· 7-17 CYLINDER COMPRESSION·························7-6 CAM CHAIN TENSIONER LIFTER············· 7-25 CYLINDER HEAD COVER····························7-6...
  • Page 99 dummyhead dummyhead CYLINDER HEAD/VALVES SYSTEM COMPONENTS CYLINDER HEAD/VALVES 10 N·m (1.0 kgf·m, 7 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 9 N·m (0.9 kgf·m, 6.6 lbf·ft) 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
  • Page 100 dummyhead dummyhead CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves, rocker arms and camshaft. These services can be performed with the engine installed in the frame. • Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike the cylinder head cover and cylinder head too hard during removal.
  • Page 101 dummyhead dummyhead CYLINDER HEAD/VALVES TOOLS Tensioner stopper Valve spring compressor set Seat cutter, 29 mm (45° EX) 070MG-0010100 07757-0010000 07780-0010300 Seat cutter, 33 mm (45° IN) Flat cutter, 30 mm (32° IN) Flat cutter, 27 mm (32° EX) 07780-0010800 07780-0012200 07780-0013300 Interior cutter, 30 mm (60°...
  • Page 102 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 top-end noise 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 a seized piston ring.
  • Page 103: Cylinder Compression

    dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER COMPRESSION Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug (page 3-7). Install the compression gauge into the spark plug hole. Shift the transmission into neutral. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising.
  • Page 104: Installation

    dummyhead dummyhead CYLINDER HEAD/VALVES Remove the dowel pin and O-ring from the camshaft holder. DOWEL PIN O-RING INSTALLATION Install the dowel pin into the camshaft holder. Coat a new O-ring with engine oil and install it onto the DOWEL PIN dowel pin.
  • Page 105 dummyhead dummyhead CYLINDER HEAD/VALVES Install the head cover bolts/mounting rubbers and BOLTS/MOUNTING tighten them to the specified torque. CYLINDER RUBBERS HEAD COVER TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) CAMSHAFT CAM SPROCKET REMOVAL Remove the cylinder head cover (page 7-6). TIMING HOLE CAP Remove the timing and crankshaft hole caps.
  • Page 106: Camshaft Removal

    dummyhead dummyhead CYLINDER HEAD/VALVES Turn the cam chain tensioner lifter shaft clockwise fully TENSIONER STOPPER and secure it using the special tool. TOOL: Tensioner stopper 070MG-0010100 TENSIONER LIFTER SHAFT Remove the cam sprocket bolts. Be careful not to let BOLTS CAM CHAIN Remove the cam sprocket off the camshaft flange and the sprocket bolts...
  • Page 107: Camshaft Installation

    dummyhead dummyhead CYLINDER HEAD/VALVES Measure the height of each cam lobe. SERVICE LIMIT: IN: 32.96 mm (1.298 in) 32.85 mm (1.293 in) Inspect the cam lobes for damage or excessive wear. CAMSHAFT INSTALLATION Lubricate the camshaft bearings with engine oil. BEARINGS Apply molybdenum oil solution to the cam lobes.
  • Page 108 dummyhead dummyhead CYLINDER HEAD/VALVES CAM SPROCKET INSTALLATION Rotate the crankshaft counterclockwise and align the Be careful not to "T" mark on the flywheel with the index notch on the left jam the cam chain. INDEX NOTCH INDEX NOTCH crankcase cover. Make sure the piston is at TDC (Top Dead Center).
  • Page 109: Camshaft Holder

    dummyhead dummyhead CYLINDER HEAD/VALVES Turn the crankshaft counterclockwise one full turn (360°). Be sure that the index line on the cam sprocket aligns with the upper surface of the cylinder head when the "T" mark on the flywheel is aligned with the index notch on the crankcase cover.
  • Page 110 dummyhead dummyhead CYLINDER HEAD/VALVES DISASSEMBLY Remove the bolt and camshaft retainer plate. Remove the camshaft from the camshaft holder. BOLT PLATE CAMSHAFT Remove the rocker arm shaft bolts. BOLTS Remove the rocker arm shafts and rocker arms from ROCKER ARM the holder.
  • Page 111 dummyhead dummyhead CYLINDER HEAD/VALVES Measure the rocker arm shaft O.D. SERVICE LIMIT: 9.91 mm (0.390 in) Calculate the rocker arm-to-shaft clearance. SERVICE LIMIT: 0.10 mm (0.004 in) ASSEMBLY : molybdenum oil solution to cam lobes ROCKER ARMS ROCKER ARM SHAFT BOLTS 5 N·m (0.5 kgf·m, 3.7 lbf·ft) CAMSHAFT...
  • Page 112: Rocker Arms

    dummyhead dummyhead CYLINDER HEAD/VALVES Set the rocker arms in the camshaft holder, then install Note the directions ROCKER ARMS the rocker arm shafts into the camshaft holder through of the bolt holes in the rocker arms. the rocker arm shafts. SHAFTS Align the bolt holes in the camshaft holder and rocker BOLT...
  • Page 113 dummyhead dummyhead CYLINDER HEAD/VALVES Make sure the tab of camshaft is facing the upward. Install the camshaft into the camshaft holder. CAMSHAFT Install the camshaft retainer plate and tighten the bolt securely. BOLT PLATE CAMSHAFT INSTALLATION Install the camshaft holder onto the cylinder head by CAMSHAFT HOLDER aligning the pins with the holes.
  • Page 114 dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Remove the following: CYLINDER HEAD BOLTS – camshaft holder (page 7-12) – spark plug (page 3-7) Remove two cylinder head bolts and cylinder head. Remove the cylinder head gasket and two dowel pins. DOWEL PINS Clean off any gasket materials from the cylinder head Be careful not to...
  • Page 115: Valve/Valve Guide

    dummyhead dummyhead CYLINDER HEAD/VALVES INSPECTION CYLINDER HEAD Remove the carbon deposits from the combustion COMBUSTION CHAMBER chamber Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and a feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) VALVE SPRING Measure the valve spring free length.
  • Page 116: Valve Guide Replacement

    dummyhead dummyhead CYLINDER HEAD/VALVES Ream the valve guide to remove the carbon build-up Take care not to tilt VALVE GUIDE REAMER before checking the valve guide. or lean the reamer Insert the reamer from the combustion chamber side of in the guide while the cylinder head and always rotate the reamer reaming.
  • Page 117: Valve Seat Inspection

    dummyhead dummyhead CYLINDER HEAD/VALVES While the cylinder head is still heated, take off the new VALVE GUIDE DRIVER valve guides from the freezer and install the new clips to the new guides. Drive new guides in the cylinder head from the camshaft side.
  • Page 118: Valve Seat Refacing

    dummyhead dummyhead CYLINDER HEAD/VALVES Inspect the valve seat face for: • Damaged face: – Replace the valve and reface the valve seat. • Uneven seat width: – Bent or collapsed valve stem; Replace the valve and reface the valve seat. DAMAGED FACE UNEVEN SEAT WIDTH •...
  • Page 119: Valve Seat Cutter

    dummyhead dummyhead CYLINDER HEAD/VALVES Use a 45 degree cutter to remove the roughness or Reface the valve VALVE SEAT CUTTER ROUGHNESS irregularities from the seat. seat with a 45 degree cutter when TOOL: a valve guide is Seat cutter, 33 mm (45° IN) 07780-0010800 replaced.
  • Page 120 dummyhead dummyhead CYLINDER HEAD/VALVES After cutting the seat, apply lapping compound to the Excessive lapping HAND LAPPING valve face and lap the valve using light pressure. pressure may TOOL Change the angle of lapping tool frequently to prevent deform or damage uneven seat wear.
  • Page 121 dummyhead dummyhead CYLINDER HEAD/VALVES Install the inner and outer valve springs with the tightly wound coils facing the combustion chamber. Install the spring retainers. Combustion chamber side Compress the valve spring and install the valve cotters. Grease the cotters COTTERS to ease installation.
  • Page 122: Cam Chain Tensioner Lifter

    dummyhead dummyhead CYLINDER HEAD/VALVES Route the cam chain through the cylinder head and CYLINDER HEAD BOLTS install the cylinder head onto the cylinder. Loosely install the cylinder head bolts. Install the spark plug and tighten it to the specified torque. TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft) Install the flowing: –...
  • Page 123 dummyhead dummyhead CYLINDER HEAD/VALVES Check the cam chain tensioner lifter operation: TENSIONER LIFTER – The tensioner lifter shaft should not go into the body when it is pushed. – When it is turned clockwise with a screwdriver, the tensioner lifter shaft should be pulled into the body. The shaft should spring out of the body as soon as the screwdriver is released.
  • Page 124 dummyhead dummyhead CYLINDER HEAD/VALVES Coat a new O-ring with engine oil and install it into the PLUG tensioner lifter groove. Install the plug and tighten it to the specified torque. TORQUE: 4 N·m (0.4 kgf·m, 3.0 lbf·ft) O-RING 7-27...
  • Page 125 dummyhead dummyhead MEMO...
  • Page 126: Cylinder/Piston

    dummytext 8. CYLINDER/PISTON SYSTEM COMPONENTS······························8-2 CYLINDER/PISTON REMOVAL ··················· 8-4 SERVICE INFORMATION ·····························8-3 PISTON/CYLINDER INSTALLATION··········· 8-8 TROUBLESHOOTING···································8-3...
  • Page 127: System Components

    dummyhead dummyhead CYLINDER/PISTON SYSTEM COMPONENTS CYLINDER/PISTON...
  • Page 128: Service Information

    dummyhead dummyhead CYLINDER/PISTON SERVICE INFORMATION GENERAL • This section covers service of the cylinder and piston. These services can be performed with the engine installed in the frame. • Take care not to damage the cylinder wall and piston. • Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal. •...
  • Page 129: Cylinder/Piston Removal

    dummyhead dummyhead CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL Remove the cylinder head. (page 7-17). CYLINDER Remove the cam chain guide. Lift the cylinder and remove it, being careful not to Do not strike the damage the piston. cylinder too hard and do not damage Clean the top of the cylinder thoroughly.
  • Page 130 dummyhead dummyhead CYLINDER/PISTON Clean carbon deposits from the piston ring grooves with Never use a wire a ring that will be discarded. brush; it will scratch the grooves. INSPECTION CYLINDER Inspect the cylinder wall for scratches and wear. Measure and record the cylinder I.D. at three levels in both the X and Y axes.
  • Page 131 dummyhead dummyhead CYLINDER/PISTON PISTON/PISTON PIN/CONNECTING ROD Inspect the piston for cracks or other damage. Measure the piston O.D. at 10 mm (0.4 in) from the 90° bottom, and 90° to the piston pin hole. SERVICE LIMIT: 57.20 mm (2.252 in) Compare this measurement against the maximum 10 mm (0.4 in) cylinder I.D.
  • Page 132: Stud Bolt Replacement

    dummyhead dummyhead CYLINDER/PISTON PISTON RING Insert each piston ring into the bottom of the cylinder squarely using the piston. Measure the ring end gap using a feeler gauge. SERVICE LIMIT: Top: 0.40 mm (0.016 in) Second: 0.40 mm (0.016 in) Oil: 0.85 mm (0.033 in) Reinstall the piston rings into the piston ring grooves...
  • Page 133: Piston/Cylinder Installation

    dummyhead dummyhead CYLINDER/PISTON PISTON/CYLINDER INSTALLATION PISTON INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing up. • Do not damage the piston ring by spreading the ends too far. • Be careful not to scratch the piston surface. •...
  • Page 134: Cylinder Installation

    dummyhead dummyhead CYLINDER/PISTON Place a shop towel over the crankcase opening to prevent piston pin clips from falling into the crankcase. Install new piston pin clips into the grooves in the piston pin holes. • Make sure that the piston pin clips are seated securely.
  • Page 135 dummyhead dummyhead MEMO...
  • Page 136: Clutch/Gearshift Linkage/Kickstarter

    dummytext 9. CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SYSTEM COMPONENTS······························9-2 GEARSHIFT LINKAGE ······························· 9-14 SERVICE INFORMATION ·····························9-3 PRIMARY DRIVE GEAR ····························· 9-17 TROUBLESHOOTING···································9-4 RIGHT CRANKCASE COVER INSTALLATION ·········································· 9-17 RIGHT CRANKCASE COVER REMOVAL ···9-5 KICKSTARTER IDLE GEAR ······················ 9-18 CLUTCH LIFTER ARM··································9-6 KICKSTARTER ··········································· 9-20 CLUTCH ························································9-8...
  • Page 137 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SYSTEM COMPONENTS CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 4 N·m (0.4 kgf·m, 3.0 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft)
  • Page 138: Torque Values

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SERVICE INFORMATION GENERAL • This section covers service of the clutch, gearshift linkage and kickstarter. These services can be performed with the engine installed in the frame. • Engine oil viscosity, oil level and the use of oil additives have an effect on clutch operation. Oil additives of any kind are specifically not recommended.
  • Page 139 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER TOOLS Lock nut wrench Gear holder Pin driver 07716-0020100 07724-0010200 07744-0010200 Clutch center holder 07GMB-KT70101 TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the freeplay. Clutch lever difficult to pull in • Damaged, kinked or dirty clutch cable •...
  • Page 140: Right Crankcase Cover Removal

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-10). ADJUSTING NUT LIFTER ARM Loosen the lock nut and adjusting nut. Disconnect the clutch cable from the clutch lifter arm. STAY Remove the clutch cable from the clutch cable stay. LOCK NUT CLUTCH CABLE Remove the bolt and kickstarter pedal...
  • Page 141 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER CLUTCH LIFTER ARM REMOVAL Remove the right crankcase cover (page 9-5). LIFTER PIECE Remove the clutch lifter piece by turning the lifter arm clockwise slightly. Drive the spring pin into the clutch lifter arm until the pin CLUTCH end is flush with the lifter arm surface, using the pin LIFTER ARM...
  • Page 142: Installation

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER INSTALLATION Apply grease to a new kickstarter spindle dust seal lip and install it into the right crankcase cover as specified. DUST SEALS Apply grease to a new clutch lifter arm dust seal lip and install it into the right crankcase cover as specified. Apply engine oil to the clutch lifter arm sliding surface and install it into the right crankcase cover.
  • Page 143 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER CLUTCH REMOVAL Remove the following: LOCK NUT WRENCH GEAR HOLDER – oil pump driven gear (page 4-4) – oil filter rotor cover and gasket (page 3-11) Install the gear holder between the primary drive and driven gears, and loosen the oil filter rotor lock nut. TOOL: Gear holder 07724-0010200...
  • Page 144 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Remove the washer. WASHER – clutch center PRESSURE PLATE – clutch disc A – three clutch plates and two discs B CLUTCH CENTER – clutch disc A – pressure plate DISCS B / PLATES DISC A DISC A –...
  • Page 145 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER INSPECTION CLUTCH LIFTER BEARING Turn the inner race of the lifter bearing with your finger. LIFTER PLATE LIFTER PLATE BEARING The bearing should turn smoothly and quietly. Also check that the outer race fits tightly in the lifter plate. Replace the bearing if the inner race does not turn smoothly, quietly, or if the outer race fits loosely in the lifter plate.
  • Page 146: Clutch Plate

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER CLUTCH PLATE Check the plate for discoloration. Replace the clutch Check the clutch plate for warpage on a surface plate discs and plates as using a feeler gauge. a set. SERVICE LIMIT: 0.20 mm (0.008 in) CLUTCH OUTER/OUTER GUIDE Check the slots in the clutch outer for nicks, cuts or indentations made by the clutch discs.
  • Page 147: Pressure Plate

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER INSTALLATION Apply molybdenum oil solution to the outer surface of CLUTCH OUTER GUIDE the clutch outer guide and install it onto the mainshaft. Apply engine oil to the primary driven gear teeth. WASHER Install the clutch outer and washer. CLUTCH OUTER Coat the clutch discs whole surface with engine oil.
  • Page 148 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Install the clutch center assembly into the clutch outer. Install the tabs of CLUTCH OUTER SHALLOW SLOT clutch disc A Install the washer onto the mainshaft. (outside) into the WASHER shallow slots in the clutch outer. DISC A CLUTCH CENTER ASSEMBLY (OUTSIDE)
  • Page 149 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Apply engine oil to the threads and seating surface of the oil filter rotor lock nut, and install it. Install the gear holder between the primary drive and driven gears, and tighten the oil filter rotor lock nut to the specified torque.
  • Page 150 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER – dowel pins RETURN SPRING – stopper arm bolt – stopper arm DOWEL PINS – washer WASHER – return spring STOPPER ARM BOLT Inspect the gearshift spindle oil seal for deterioration or damage, replace if necessary. 0.5 - 1.0 mm (0.02 - 0.04 in) If replacing the oil seal, install it as specified.
  • Page 151 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Install the dowel pins into the shift drum holes. STOPPER ARM Hold the stopper arm using a screwdriver and install the Align gearshift cam by aligning the holes with the dowel pins. GEARSHIFT CAM Apply locking agent to the gearshift cam bolt threads GEARSHIFT CAM (page 1-13).
  • Page 152: Primary Drive Gear

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Install the clutch (page 9-12). PINCH BOLT Install the gearshift pedal in the original position noted during removal. Install the pinch bolt and tighten it. GEARSHIFT PEDAL PRIMARY DRIVE GEAR REMOVAL/INSTALLATION Remove the following: PRIMARY DRIVE GEAR –...
  • Page 153: Kickstarter Idle Gear

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Install the right crankcase cover and clutch cable stay, STAY COVER bolts. Tighten the bolts in a crisscross pattern in 2 or 3 steps. BOLTS Install the kickstarter pedal in the original position noted BOLT during removal and tighten the bolt. KICKSTARTER PEDAL Install the clutch cable to the clutch cable stay.
  • Page 154 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Remove the bushing and washer. WASHER BUSHING INSPECTION Measure the kickstarter idle gear I.D. SERVICE LIMIT: 20.58 mm (0.810 in) Measure the bushing I.D. and O.D. SERVICE LIMIT: O.D.: 20.43 mm (0.804 in) I.D.: 17.04 mm (0.671 in) IDLE GEAR BUSHING Measure the countershaft O.D.
  • Page 155 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Apply engine oil to the kickstarter idle gear teeth. WASHER Install the idle gear, washer and snap ring. IDLE GEAR Install the clutch (page 9-12). SNAP RING KICKSTARTER REMOVAL Remove the right crankcase cover (page 9-5). Unhook the return spring from the crankcase.
  • Page 156 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Remove the following: WASHER B DRIVE GEAR – snap ring WASHER A – washer A – kickstarter drive gear – washer B WASHER A WASHER B SNAP RING INSPECTION Check the following: DRIVE GEAR – Ratchet gear and drive gear for excessive wear or damage.
  • Page 157 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Hook the return spring to the hole of the spindle. RETURN SPRING Hook Install the collar to the return spring, aligning the cut-out Align of the collar with the spring. COLLAR INSTALLATION Apply engine oil to the kickstarter drive gear teeth. RATCHET SPRING Install the ratchet spring and washer to the spindle.
  • Page 158: Alternator/Starter Clutch

    dummytext 10. ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS····························10-2 STATOR/IGNITION PULSE GENERATOR ·············································· 10-5 SERVICE INFORMATION ···························10-3 FLYWHEEL/STARTER CLUTCH ··············· 10-6 TROUBLESHOOTING·································10-3 LEFT CRANKCASE COVER INSTALLATION ········································ 10-11 LEFT CRANKCASE COVER REMOVAL ···10-4 10-1...
  • Page 159: System Components

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS ALTERNATOR/STARTER CLUTCH 74 N·m (7.5 kgf·m, 55 lbf·ft) 10-2...
  • Page 160: Service Information

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL • This section covers the removal and installation of the alternator stator, flywheel and starter clutch. These services can be done with the engine installed in the frame. • Alternator inspection (page 14-7). •...
  • Page 161: Left Crankcase Cover Removal

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-10). 3P CONNECTOR Remove the following: – left side cover (page 2-3) – drive sprocket cover (page 2-7) Disconnect the alternator 3P connector and ignition pulse generator 2P connector. 2P CONNECTOR Remove the gear position switch wire from the left crankcase cover.
  • Page 162 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH STATOR/IGNITION PULSE GENERATOR REMOVAL Remove the left crankcase cover (page 10-4). WIRE GUIDE GROMMET Remove the following from the left crankcase cover: ALTERNATOR – socket bolt and wire guide STATOR – grommet – two socket bolts and ignition pulse generator –...
  • Page 163 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Apply liquid sealant to the wire grommet seating IGNITION PULSE surface and install it into the cover groove. GENERATOR Apply locking agent to the bolt threads (page 1-13). GROMMET Install the wire guide and ignition pulse generator onto the cover.
  • Page 164: Starter Clutch Disassembly

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Remove the flywheel using the special tool. FLYWHEEL TOOL: Inside screw puller 07933-KM10001 FLYWHEEL PULLER Remove the woodruff key and needle bearing. Be careful not to NEEDLE BEARING damage the crankshaft. WOODRUFF KEY STARTER CLUTCH DISASSEMBLY Check that starter...
  • Page 165: Reduction Gear

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH INSPECTION Check the starter reduction gear, shaft and collar for REDUCTION GEAR wear or damage. COLLAR SHAFT Remove the starter sprag clutch from the clutch outer. SPRAG CLUTCH Check the starter sprag clutch for abnormal wear or damage.
  • Page 166 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH ASSEMBLY BOLTS 16 N·m (1.6 kgf·m, 12 lbf·ft) DRIVEN GEAR CLUTCH OUTER SPRAG CLUTCH FLYWHEEL Apply engine oil to the starer sprag clutch rolling SPRAG CLUTCH surface. Install the sprag clutch into the clutch outer with its flange side facing the flywheel.
  • Page 167 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Apply locking agent to the starter clutch bolt threads (page 1-13). BOLTS Align the bolt holes in the flywheel and starter clutch, and install the bolts. Hold the flywheel with the special tool and tighten the bolts to the specified torque.
  • Page 168: Left Crankcase Cover Installation

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Apply engine oil to the flywheel nut threads and seating surface. WASHER Install the washer and flywheel nut. FLYWHEEL NUT Hold the flywheel with the special tool and tighten the FLYWHEEL HOLDER flywheel nut to the specified torque. TOOL: Flywheel holder 07725-0040001...
  • Page 169 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Install the left crankcase cover and bolts, and tighten LEFT CRANKCASE the bolts in a crisscross pattern in several steps. COVER BOLTS Route the gear position switch wire onto the left Route the wire GEAR POSITION SWITCH WIRE crankcase cover.
  • Page 170: Crankcase/Crankshaft/Transmission

    dummytext 11. CRANKCASE/CRANKSHAFT/TRANSMISSION SYSTEM COMPONENTS····························11-2 TRANSMISSION ········································· 11-7 SERVICE INFORMATION ···························11-3 CRANKSHAFT ·········································· 11-13 TROUBLESHOOTING·································11-4 CRANKCASE BEARING ·························· 11-14 CRANKCASE SEPARATION······················11-5 CRANKCASE ASSEMBLY ······················· 11-16 11-1...
  • Page 171 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION SYSTEM COMPONENTS CRANKCASE/CRANKSHAFT/TRANSMISSION 10 N·m (1.0 kgf·m, 7 lbf·ft) 11-2...
  • Page 172: Specifications

    dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION SERVICE INFORMATION GENERAL • The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine must be removed from the frame (page 6-4). • Be careful not to damage the crankcase mating surfaces when servicing. •...
  • Page 173 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Bearing driver attachment, 42 x 47 mm Bearing driver attachment, 52 x 55 mm Pilot, 12 mm 07746-0010300 07746-0010400 07746-0040200 Pilot, 17 mm Pilot, 20 mm Pilot, 30 mm 07746-0040400 07746-0040500 07746-0040700 Driver handle Bearing remover head, 12 mm Bearing remover shaft, 12 mm 07749-0010000 07936-1660110...
  • Page 174: Crankcase Separation

    dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION Remove the following: GUIDE PLATE – engine (page 6-4) – cylinder head (page 7-17) – cylinder and piston (page 8-4) – oil pump (page 4-4) – clutch (page 9-8) – kickstarter (page 9-20) – primary drive gear (page 9-17) –...
  • Page 175: Right Crankcase

    dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Loosen the thirteen left crankcase bolts in a crisscross BOLTS pattern in 2 or 3 steps, and remove them. Place the crankcase assembly with the right side down. LEFT CRANKCASE Carefully separate the left crankcase from the right Do not ply the crankcase while tapping them at several locations with crankcase halves.
  • Page 176 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION TRANSMISSION DISASSEMBLY Separate the crankcase halves (page 11-5). SHIFT FORK SHAFTS SHIFT DRUM Remove the shift fork shafts. Remove the shift forks and shift drum. SHIFT FORKS Remove the mainshaft and countershaft as an COUNTERSHAFT MAINSHAFT assembly. Disassemble the mainshaft and countershaft.
  • Page 177 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Measure the I.D. of each gear. SERVICE LIMIT: M4: 20.05 mm (0.789 in) 17.04 mm (0.671 in) 20.55 mm (0.809 in) C2, C3:23.07 mm (0.908 in) Measure the O.D. of each bushing. SERVICE LIMIT: C1: 20.41 mm (0.804 in) C2, C3:22.95 mm (0.904 in) Calculate the gear-to-bushing clearance.
  • Page 178 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Check the shift forks for deformation or abnormal wear. Measure each shift fork claw thickness. SERVICE LIMIT: 4.50 mm (0.177 in) Measure I.D. of each fork. SERVICE LIMIT: 10.05 mm (0.396 in) Check the shift fork shafts for damage and straightness. Measure the shift fork shaft O.D.
  • Page 179 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION MAINSHAFT : Gear and bushing sliding surfaces SNAP RING SPLINE WASHER M4 GEAR (26T) M1 GEAR (13T) THRUST WASHER MAINSHAFT M3 GEAR (23T) M2 GEAR (19T) M5 GEAR (28T) THRUST WASHER SPLINE WASHER SNAP RING THRUST WASHER THRUST WASHER M2 GEAR (19T) M3 GEAR (23T)
  • Page 180 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION COUNTERSHAFT C3 GEAR (30T) THRUST WASHER : Gear and bushing sliding surfaces C3 BUSHING C4 GEAR (28T) SPLINE WASHER SNAP RING C1 GEAR (40T) THRUST WASHER C1 BUSHING THRUST WASHER THRUST WASHER C2 BUSHING C2 GEAR (34T) THRUST WASHER C5 GEAR (26T) COUNTERSHAFT...
  • Page 181 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Apply molybdenum oil solution to the gear shifter grooves. Apply clean engine oil to the gear teeth and engage the mainshaft and countershaft gears. Install the mainshaft and countershaft assemblies as a MAINSHAFT COUNTERSHAFT set into the left crankcase. Each shift fork has an identification marks;...
  • Page 182 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Apply engine oil to the shift fork shafts whole surface and insert them through the shift forks into the right SHIFT FORK SHAFTS crankcase. Assemble the crankcase (page 11-16). CRANKSHAFT REMOVAL Remove the crankshaft from the right crankcase. CRANKSHAFT INSPECTION Set the crankshaft in a stand or V-blocks and measure...
  • Page 183: Installation

    dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Measure the radial clearance at the connecting rod big end in an X and Y directions. SERVICE LIMIT: 0.05 mm (0.002 in) Turn the outer race of the crankshaft bearing with your BEARING finger. The bearing should turn smoothly and quietly. Also check that bearing inner races fit tightly in the crankshaft.
  • Page 184: Crankshaft Bearing

    dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION RIGHT CRANKCASE BEARING REPLACEMENT CRANKSHAFT BEARING Remove the crankcase bearing inner race. CRANKSHAFT BEARING Press the crankshaft bearing out of the crankcase. Lubricate bearing rotating surface with molybdenum oil solution. Press a new crankcase bearing into the crankcase using the special tools.
  • Page 185: Crankcase Assembly

    dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Apply locking agent to the setting plate bolt threads BOLTS (page 1-13). Install the mainshaft bearing setting plates and bolts, and tighten the bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) PLATES LEFT CRANKCASE BEARING REPLACEMENT Drive the countershaft bearing out of the crankcase.
  • Page 186 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Apply liquid sealant (Three Bond 1215 or Three Bond 1207G or equivalent) to the mating surface (shadowed area) of the left crankcase except the oil passage area as shown.
  • Page 187 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Install the right crankcase bolt and tighten it. BOLT BOLT Install the bearing retainer plates and bolts. When installing the PLATES PLATE BOLT retainer plate, pull Tighten the bolts securely. the crankshaft and Hook hook the plate tab to the crankshaft bearing groove as shown.
  • Page 188 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION Install the cam chain and cam chain guide. GUIDE PLATE Install the setting plate with the two bolts and tighten the bolts. Install the following: – gear position switch (page 17-17) – starter motor (page 16-11) – flywheel (page 10-10) –...
  • Page 189 dummyhead dummyhead MEMO...
  • Page 190: Front Wheel/Brake/Suspension/Steering

    dummytext 12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING SYSTEM COMPONENTS····························12-2 FRONT WHEEL ········································ 12-10 SERVICE INFORMATION ···························12-3 FRONT DRUM BRAKE ···························· 12-16 TROUBLESHOOTING·································12-5 FORK························································· 12-20 HANDLEBAR ··············································12-6 STEERING STEM ····································· 12-27 12-1...
  • Page 191: System Components

    dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING SYSTEM COMPONENTS FRONT WHEEL/BRAKE/SUSPENSION/STEERING 12 N·m (1.2 kgf·m, 9 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 12-2...
  • Page 192: Service Information

    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 193 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING TOOLS Spoke wrench, 5.8 x 6.1 mm Bearing driver attachment, 37 x 40 mm Bearing driver attachment, 42 x 47 mm 07701-0020300 07746-0010200 07746-0010300 Pilot, 12 mm Bearing remover shaft Remover head, 12 mm 07746-0040200 07746-0050100 07746-0050300 Oil seal remover Driver handle...
  • Page 194 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING TROUBLESHOOTING Hard steering • Steering bearing adjustment nut too tight • Worn or damaged steering head bearings • Worn or damaged steering head bearing races • Damaged steering stem • Insufficient tire pressure • Faulty front tire Steers to one side or does not track straight •...
  • Page 195 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the following: The right rearview – two wire bands mirror lock nut has MIRRORS – rearview mirrors left-hand threads. BANDS – screw and handlebar weight (from each handlebar end) WEIGHT SCREW – brake light switch connectors BRAKE LEVER BRACKET HOLDER –...
  • Page 196 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING – throttle cable (disconnect from the throttle grip) SWITCH – right handlebar switch – throttle pipe THROTTLE PIPE THROTTLE CABLE – clutch switch connectors CLUTCH LEVER BRACKET CONNECTORS – two bolts, holder and clutch lever bracket HOLDER BOLTS –...
  • Page 197 Install the choke lever to the handlebar. HANDLEBAR GRIP Apply Honda Bond A or equivalent to the inside surface of the grip and to the clean surface of the left handlebar. Wait 3 – 5 minutes and install the grip.
  • Page 198 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the clutch lever bracket aligning its end with the BRACKET Align CONNECTORS punch mark on the handlebar. Install the holder, bolts and tighten the upper bolt first, Install the holder then the lower bolt. with the "UP" mark facing up.
  • Page 199 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install each handlebar weight with a new weight screw WEIGHT by aligning the flats each other. SCREW Align Install each rearview mirror and tighten the lock nut to The right rearview MIRRORS the specified torque. mirror has left-hand threads.
  • Page 200 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the brake panel. BRAKE PANEL Remove the side collar. COLLAR INSPECTION AXLE Set the axle in V-blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) WHEEL RIM Check the rim runout by placing the wheel in a turning...
  • Page 201: Wheel Bearing

    dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if they do not turn Replace the smoothly, quietly, or if they fit loosely in the hub.
  • Page 202 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY BEARING (6301U) DISTANCE COLLAR DUST SEAL BEARING (6301U) WHEEL CENTER ADJUSTMENT Adjust the hub position so that the distance from the left end surface of the hub center to the side of rim is 18 ± 1 18 ±...
  • Page 203: Wheel Assembly

    dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING WHEEL ASSEMBLY Pack new bearing cavities with grease. Drive in a new left side (brake drum side) bearing squarely with the sealed side facing up until it is fully seated. DRIVER Install the distance collar. Drive in a new right side bearing squarely with the sealed side facing up until it is fully seated.
  • Page 204 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the side collar. COLLAR Install the wheel between the fork legs and align the BRAKE PANEL groove of the brake panel with the boss on the left fork leg. Insert the front axle through the fork and wheel from the right side.
  • Page 205 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Coat a new O-ring with grease and install it into the cable groove. O-RING Connect the speedometer cable by aligning the groove with the blade. Align Install the speedometer cable setting screw and tighten SCREW FRONT DRUM BRAKE REMOVAL Remove the wheel and the brake panel (page 12-10).
  • Page 206 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING DISASSEMBLY Expand the brake shoes and remove them from the Always replace the SHOES brake panel. brake shoes in pairs. Remove the shoe springs from the brake shoes. SPRINGS Remove the following: – dust seal GEAR AND WASHER –...
  • Page 207 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY *1: 3 g to gear teeth/0.2 - 0.3 g to inner surface BRAKE SHOES *2: Gear oil DUST SEAL SPEEDOMETER GEAR WASHER SHOE SPRINGS WEAR INDICATOR BRAKE ARM BRAKE CAM FELT SEAL RETURN SPRING BRAKE ARM NUT BOLT 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply 0.2 –...
  • Page 208 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the brake arm by aligning the punch marks. Install the bolt from the opposite side of the punch mark SPRING and tighten the nut to the specified torque. Align TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Hook the return spring onto the brake arm.
  • Page 209 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK REMOVAL Remove the following: FORK CAP – headlight case (page 17-6) – front wheel (page 12-10) – front fender (page 2-5) – front emblem (page 2-5) When the fork is ready to be disassembled, loosen the fork cap, but do not remove it.
  • Page 210 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING – fork spring Pour out the fork fluid by pumping the fork tube up and FORK SPRING down several times. – dust seal Be careful not to DUST SEAL – stopper ring scratch the fork pipe. STOPPER RING Hold the fork slider in a vise with soft jaws or shop FORK PISTON...
  • Page 211: Fork Spring

    dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING – fork tube – oil lock piece FORK TUBE OIL LOCK PIECE – fork piston FORK PISTON – rebound spring FORK TUBE REBOUND SPRING – oil seal TOOL: OIL SEAL Oil seal remover 07748-0010001 REMOVER OIL SEAL INSPECTION FORK SPRING Measure the fork spring free length.
  • Page 212 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK TUBE/SLIDER/PISTON Check the fork tube, slider, oil lock piece and fork piston OIL LOCK PIECE for score marks, and excessive or abnormal wear. Check the fork piston ring for wear or damage. FORK SLIDER Check the rebound spring for fatigue or damage. Replace any damaged component if necessary.
  • Page 213 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply silicone grease to a new oil seal lip. DRIVER HANDLE Install the oil seal with the marking facing up. Drive the oil seal until the stopper ring groove is visible. TOOL: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 ATTACHMENT OIL SEAL...
  • Page 214: Fluid Capacity

    dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Clean and apply a locking agent to the socket bolt SEALING WASHER SOCKET BOLT threads. Install the socket bolt with a new sealing washer. Tighten the socket bolt to the specified torque while holding the fork piston. TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft) SOCKET BOLT Install the oil seal stopper ring into the groove securely.
  • Page 215 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the washer and collar. COLLAR WASHER Coat a new O-ring with fork fluid and install it into the Tighten the fork cap O-RING fork cap groove. FORK CAP after installing the Hold the fork cap securely and install it into the fork fork tube into the tube, being careful not to cross-thread the cap.
  • Page 216: Steering Stem

    dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING STEERING STEM REMOVAL Remove the following: IGNITION SWITCH 2P (BLACK) CONNECTOR – headlight case (page 17-6) – combination meter (page 17-8) – handlebar (page 12-6) – front wheel (page 12-10) – front fender (page 2-5) Disconnect the ignition switch 2P connector from the wire harness.
  • Page 217 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Loosen the steering bearing adjustment nut. TOOL: SOCKET Stem socket wrench 07916-3710101 WRENCH While holding the steering stem, remove the adjustment nut. ADJUSTMENT Remove the following: UPPER INNER RACE – steering stem – upper inner race –...
  • Page 218 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the stem nut onto the stem to prevent the threads DUST SEAL from being damaged when removing the inner race. AND WASHER Remove the lower inner race with a chisel or equivalent tool, being careful not to damage the stem. Remove the dust seal and washer.
  • Page 219 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Drive in new upper and lower bearing outer races into the steering head pipe. DRIVER TOOL: Driver 07749-0010000 ATTACHMENT Attachment, 42 x 47 07746-0010300 UPPER OUTER RACE LOWER OUTER RACE ATTACHMENT DRIVER Apply 3 g (0.1 oz) of grease to new bearing and fill it up. UPPER INNER RACE Attach the upper steering bearing and upper inner race onto the upper outer race.
  • Page 220 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING 1. Tighten the adjustment nut to the initial torque. SOCKET WRENCH TOOL: Stem socket wrench 07916-3710101 TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft) ADJUSTMENT 2. Turn the steering stem left and right, lock-to-lock several times to seat the bearings. Completely loosen the adjustment nut.
  • Page 221 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the wire harness guide plate with the bolt and BOLT tighten the bolt. GUIDE PLATE Temporarily install the fork legs into the bottom and top STEM NUT bridges. Tighten the stem nut to the specified torque. TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft) Move the steering stem lock-to-lock and make sure the steering stem moves smoothly without play or binding.
  • Page 222: Rear Wheel/Brake/Suspension

    dummytext 13. REAR WHEEL/BRAKE/SUSPENSION SYSTEM COMPONENTS····························13-2 REAR DRUM BRAKE ······························· 13-12 SERVICE INFORMATION ···························13-3 BRAKE PEDAL/CENTERSTAND············· 13-14 TROUBLESHOOTING·································13-4 SHOCK ABSORBER ································ 13-16 REAR WHEEL ·············································13-5 SWINGARM ·············································· 13-17 13-1...
  • Page 223: System Components

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION SYSTEM COMPONENTS REAR WHEEL/BRAKE/SUSPENSION 39 N·m (4.0 kgf·m, 29 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 68 N·m (6.9 kgf·m, 50 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 13-2...
  • Page 224: Service Information

    • 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 3-12).
  • Page 225 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Pilot, 25 mm Bearing remover shaft Bearing remover head, 15 mm 07746-0040600 07746-0050100 07746-0050400 Driver handle 07749-0010000 TROUBLESHOOTING Rear wheel wobbles • Bent rim • Worn or damaged rear wheel bearings • Faulty rear tire • Worn or damaged swingarm bushings •...
  • Page 226 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Place the motorcycle on its centerstand. JOINT PIN Remove the exhaust pipe muffler (page 2-8). Disconnect the brake rod by removing the adjusting nut, and remove the spring and joint pin. ADJUSTING NUT SPRING Disconnect the stopper arm from the brake panel by COTTER PIN...
  • Page 227 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Remove the side collar from the driven flange. SIDE COLLAR INSPECTION AXLE Set the axle in V-blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) WHEEL BEARING Turn the inner race of each bearing with your finger.
  • Page 228 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION SPROCKET Check the condition of the driven sprocket teeth. Replace the sprocket if it is worn or damaged. • If the driven sprocket requires replacement, inspect the drive chain and drive sprocket. REPLACE GOOD • Never install a new drive chain on a worn sprocket or a worn chain on new sprockets.
  • Page 229 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Drive the bearing out of the driven flange. BEARING Install the bearing remover head into the wheel bearing. REMOVER HEAD From the opposite side of the wheel, install the bearing remover shaft and drive the bearing out of the wheel hub.
  • Page 230 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION WHEEL CENTER ADJUSTMENT Adjust the hub position so that the distance from the left end surface of the hub center to the side of rim is 14.5 ± 14.5 ± 1 mm 1 mm (0.57 ± 0.04 in) as shown. (0.57 ±...
  • Page 231: Installation

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Install the sleeve into the new driven flange bearing. SLEEVE Install the rubber dampers as shown. RUBBER DAMPERS Coat a new O-ring with grease and install it into the groove. O-RING Install the driven flange to the wheel hub. DUST DRIVEN SPROCKET SEAL...
  • Page 232 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Install the brake panel assembly into the wheel hub. Do not get grease BRAKE PANEL on the brake drum and shoe linings. Place the rear wheel in the swingarm and install the COLLAR drive chain onto the final driven sprocket. AXLE NUT Insert the axle with the chain adjuster from the left side, then install the right side collar.
  • Page 233: Rear Drum Brake

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION REAR DRUM BRAKE REMOVAL Remove the rear wheel and the brake panel (page 13- INSPECTION Measure the rear brake drum I.D. SERVICE LIMIT: 131 mm (5.2 in) DISASSEMBLY Expand the brake shoes and remove them from the Always replace the SHOES brake panel.
  • Page 234 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION – wear indicator – brake cam – felt seal BRAKE CAM INDICATOR FELT SEAL ASSEMBLY *: Gear oil BRAKE CAM WEAR INDICATOR SPRINGS BOLT BRAKE SHOES BRAKE PANEL FELT SEAL BRAKE ARM 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply 0.2 –...
  • Page 235: Brake Pedal/Centerstand

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Apply gear oil to the felt seal and install it onto the brake BRAKE CAM panel. Install the wear indicator by aligning the wide tooth with the wide groove in the brake cam. Align INDICATOR FELT SEAL Install the brake arm by aligning the punch marks.
  • Page 236 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION – centerstand return spring PIVOT SHAFT COTTER PIN – cotter pin and washer WASHER RETURN SPRING – brake light switch rod PIVOT SHAFT – pivot shaft – centerstand – brake pedal BRAKE PEDAL CENTERSTAND – brake pedal dust seals BRAKE BRAKE –...
  • Page 237: Shock Absorber

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Apply grease to the grooves in the pivot shaft. BRAKE PEDAL Place the centerstand and brake pedal in the frame. Insert the pivot shaft from the right side through the brake pedal, frame and centerstand. Install the brake light switch rod. PIVOT SHAFT Install the washer and new cotter pin into the pivot PIVOT SHAFT...
  • Page 238: Rear Wheel

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION INSPECTION Visually inspect the shock absorber for wear or Do not disassemble SHOCK ABSORBER damage. the shock absorber. Replace the shock Check the following: absorber as an – damper rod for bending or damage assembly. – damper unit for leakage or other damage –...
  • Page 239 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Remove the shock absorber lower mounting nuts and SHOCK washers. ABSORBER Release the both shock absorber lower mounts from the swingarm. LOWER MOUNTING NUTS/WASHERS – swingarm pivot nut Pull the swingarm pivot bolt out and remove the PIVOT NUT swingarm from the frame.
  • Page 240 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION INSPECTION Check the pivot bushings for wear, deterioration or damage. BUSHINGS Check the chain slider for wear or damage. LIMIT GROOVE The chain slider must be replaced if it is worn to the wear limit groove. ASSEMBLY Install the following: –...
  • Page 241: Swingarm

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Install the chain slider by setting the bosses into the CHAIN SLIDER holes in the swingarm securely and aligning the slits with the swingarm tab. Align Align Align INSTALLATION Set the swingarm into the frame through the drive chain and insert the pivot bolt from the left side.
  • Page 242 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Install the crankcase breather drain tube (to the frame Route the tube DRAIN TUBE clamp). properly (page 1-15). Install the chain cover, aligning the locating tab of the cover with the slit in the swingarm. Align Install the two bolts and tighten them.
  • Page 243 dummyhead dummyhead MEMO...
  • Page 244: Battery/Charging System

    dummytext 14. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM ····································14-2 CHARGING SYSTEM INSPECTION ·········· 14-6 SERVICE INFORMATION ···························14-3 REGULATOR/RECTIFIER ·························· 14-7 TROUBLESHOOTING·································14-4 ALTERNATOR CHARGING COIL ·············· 14-7 BATTERY ····················································14-5 14-1...
  • Page 245: System Diagram

    dummyhead dummyhead BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM IGNITION SWITCH BATTERY MAIN FUSE (20 A) REGULATOR/RECTIFIER ALTERNATOR IGNITION SWITCH MAIN FUSE Bl: Black 20 A G: Green R: Red Y: Yellow R/Bl BATTERY REGULATOR/RECTIFIER ALTERNATOR 14-2...
  • Page 246: Service Information

    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 247: Regulator/Rectifier System Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM TROUBLESHOOTING Battery is damaged or weak 1. Battery Test Remove the battery (page 14-5). 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 248: Voltage Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the right side cover (page 2-3). HOLDER POSITIVE (+) CABLE Turn the ignition switch OFF. Remove the bolt and battery negative (–) cable from the battery. Remove the bolt and battery positive (+) cable from the battery.
  • Page 249: Charging System Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the right side cover (page 2-3). (+) PROBE Turn the ignition switch OFF and disconnect the battery negative (–) cable from the battery. Connect the ammeter (+) probe to the battery negative (–) PROBE (–) cable and the ammeter (–) probe to the battery negative (–) terminal.
  • Page 250: Battery

    dummyhead dummyhead BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the fuel tank (page 2-4). 6P BLACK CONNECTOR Pull back the connector cover. Disconnect the regulator/rectifier 6P (black) connector, and check it for loose contact or corroded terminals. If the charging voltage reading (page 14-6) is out of the specification, inspect the regulator/rectifier 6P (Black) connector terminals (wire harness side) as follows: Item...
  • Page 251 dummyhead dummyhead MEMO...
  • Page 252: Ignition System

    dummytext 15. IGNITION SYSTEM SYSTEM DIAGRAM ····································15-2 IGNITION TIMING ······································· 15-7 SERVICE INFORMATION ···························15-3 IGNITION COIL ··········································· 15-8 TROUBLESHOOTING·································15-4 ICM ······························································ 15-8 IGNITION SYSTEM INSPECTION ··············15-5 15-1...
  • Page 253 dummyhead dummyhead IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SYSTEM IGNITION SWITCH IGNITION COIL BATTERY MAIN FUSE (20 A) SPARK PLUG IGNITION PULSE GENERATOR IGNITION SWITCH MAIN FUSE 20 A Bl/Y Bl: Black Bu: Blue G: Green R: Red Bu/Y Bu/Y Bl/Y R/Bl IGNITION Y: Yellow...
  • Page 254: Torque Value

    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 255 dummyhead dummyhead IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. – Faulty spark plug – Loose spark plug cap or spark plug wire connection – Water got into the spark plug cap (Leaking the ignition coil secondary voltage) No spark at plug Unusual condition Probable cause (check in numerical order)
  • Page 256: Ignition System Inspection

    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 257 dummyhead dummyhead IGNITION SYSTEM With the connector connected, connect the Imrie IGNITION COIL diagnostic tester or peak voltage adaptor probes to the CONNECTOR ignition coil primary wire connector and body ground. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter (impedance 10 MΩ/DCV minimum)
  • Page 258: Ignition Timing

    dummyhead dummyhead IGNITION SYSTEM If the peak voltage measured at the ICM 4P connector CONNECTOR COVER CLAMP is abnormal, measure the peak voltage at the ignition pulse generator side. Remove the left side cover (page 2-3). Open the clamp and pull back the connector cover. Disconnect the ignition pulse generator 2P connector and connect the tester probes to the ignition pulse generator side 2P connector terminals.
  • Page 259: Ignition Coil

    dummyhead dummyhead IGNITION SYSTEM The ignition timing is correct if the "F" mark on the INDEX NOTCH flywheel aligns with the index notch on the left crankcase cover. "F" MARK Coat a new O-ring with engine oil and install it onto the timing hole cap.
  • Page 260: Power/Ground Line Inspection

    dummyhead dummyhead IGNITION SYSTEM POWER/GROUND LINE INSPECTION Remove the ICM (page 15-8). 4P CONNECTOR Turn the ignition switch OFF. Check for continuity between the ICM 4P connector of the wire harness side. CONNECTION: Green – Body ground There should be continuity at all time. If there is no continuity, check the open circuit in green wire.
  • Page 261 dummyhead dummyhead MEMO...
  • Page 262: Electric Starter

    dummytext 16. ELECTRIC STARTER SYSTEM DIAGRAM ····································16-2 STARTER MOTOR ····································· 16-6 SERVICE INFORMATION ···························16-3 STARTER RELAY SWITCH ····················· 16-12 TROUBLESHOOTING·································16-4 NEUTRAL DIODE ····································· 16-13 16-1...
  • Page 263 dummyhead dummyhead ELECTRIC STARTER SYSTEM DIAGRAM ELECTRIC STARTER IGNITION SWITCH STARTER SWITCH CLUTCH SWITCH STARTER RELAY SWITCH BATTERY MAIN FUSE (20 A) NEUTRAL DIODE STARTER MOTOR GEAR POSITION SWITCH SUB FUSE A (10 A) STARTER RELAY SWITCH BATTERY IGNITION MAIN FUSE 20 A SWITCH R/Bl STARTER...
  • Page 264 dummyhead dummyhead ELECTRIC STARTER SERVICE INFORMATION GENERAL If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. • Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. •...
  • Page 265 dummyhead dummyhead ELECTRIC STARTER TROUBLESHOOTING • The starter motor should operate when the transmission is in neutral or when the clutch lever is squeezed. Starter motor does not turn 1. Fuse Inspection Check for blown main fuse (20 A) or sub fuse A (10 A). Is the fuse blown? –...
  • Page 266: Yes - Go To Step

    dummyhead dummyhead ELECTRIC STARTER 8. Relay Coil Power Input Line Inspection Check the power input line of the starter relay switch (page 16-12). Is the power input line normal? – GO TO STEP 9. – • Faulty ignition switch (page 17-11). •...
  • Page 267: Starter Motor

    dummyhead dummyhead ELECTRIC STARTER STARTER MOTOR REMOVAL Disconnect the negative (–) cable from the battery MOTOR CABLE RUBBER CAP (page 14-5). Slide the rubber cap off the starter motor terminal, and remove the starter motor terminal nut and starter motor cable.
  • Page 268 dummyhead dummyhead ELECTRIC STARTER Remove the following: SEAL RING REAR COVER – Rear cover – Seal ring – Armature ARMATURE Check the oil seal and bushing in the front cover for BUSHING deterioration, wear or damage. OIL SEAL Check the commutator bars of the armature for Do not use emery discoloration.
  • Page 269 dummyhead dummyhead ELECTRIC STARTER Check for continuity between each commutator bar and NO CONTINUITY: the armature shaft. There should be no continuity. Check for continuity between the insulated brush and CONTINUITY: cable terminal. There should be continuity. Check for continuity between the insulated brush and NO CONTINUITY: rear cover as shown.
  • Page 270 dummyhead dummyhead ELECTRIC STARTER Remove the following: CABLE TERMINAL INSULATOR PLATE – Nut – Insulators – O-ring – Cable terminal – Insulator plate O-RING INSULATORS Check the bushing in the rear cover for wear or BUSHING damage. ASSEMBLY INSULATOR PLATE INSULATORS CABLE TERMINAL O-RING...
  • Page 271 dummyhead dummyhead ELECTRIC STARTER Install the following: CABLE TERMINAL INSULATOR PLATE – Insulator plate – Cable terminal – O-ring – Insulators – Nut O-RING INSULATORS Install the brush holder into the rear cover by aligning Align BRUSH HOLDER the cutouts with the insulator plate. Install the brushes into the brush holder.
  • Page 272: Installation

    dummyhead dummyhead ELECTRIC STARTER Install the same number of shim(s) in the same SHIM(S) FRONT COVER locations as noted during disassembly if they are installed. Install the seal ring onto the motor case. Install the front cover. SEAL RING Align the index lines on the motor case, rear cover and front cover.
  • Page 273: Starter Relay Switch

    dummyhead dummyhead ELECTRIC STARTER Install the starter motor into the left crankcase cover MOTOR CABLE RUBBER CAP and onto the crankcase. Install the mounting bolts with the battery (–) cable, and tighten the bolts. Install the starter motor cable and terminal nut onto the motor terminal and tighten the nut as specified angle.
  • Page 274: Function Inspection

    dummyhead dummyhead ELECTRIC STARTER FUNCTION INSPECTION Remove the starter relay switch (page 16-13). STARTER RELAY Connect an ohmmeter to the starter relay switch cable SWITCH terminals. Connect a fully charged 12 V battery positive (+) wire to the starter relay switch Yellow/red wire and negative (–) wire to the Green/red wire.
  • Page 275 dummyhead dummyhead ELECTRIC STARTER Check for continuity between the neutral diode NEUTRAL DIODE terminals. When there is continuity, a small resistance value will register. If there is continuity in one direction, the neutral diode is normal. Install the removed parts in the reverse order of removal.
  • Page 276: Lights/Meters/Switches

    dummytext 17. LIGHTS/METERS/SWITCHES COMPONENT LOCATION ··························17-2 HANDLEBAR SWITCH ····························· 17-12 SERVICE INFORMATION ···························17-3 CLUTCH SWITCH ····································· 17-14 HEADLIGHT ················································17-4 BRAKE LIGHT SWITCH ··························· 17-15 BRAKE/TAIL LIGHT····································17-6 GEAR POSITION SWITCH ······················· 17-16 TURN SIGNAL LIGHT·································17-7 FUEL GAUGE/FUEL LEVEL SENSOR ···· 17-18 COMBINATION METER······························17-8 HORN ························································...
  • Page 277: Component Location

    dummyhead dummyhead LIGHTS/METERS/SWITCHES COMPONENT LOCATION LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCHES FRONT BRAKE LIGHT SWITCH CLUTCH SWITCH IGNITION SWITCH RIGHT HANDLEBAR SWITCHES TURN SIGNAL RELAY FUEL LEVEL SENSOR HORN GEAR POSITION SWITCH REAR BRAKE LIGHT SWITCH 17-2...
  • Page 278 dummyhead dummyhead LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL • Note the following when replacing the halogen headlight bulb. – Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break.
  • Page 279: Headlight Bulb Replacement

    dummyhead dummyhead LIGHTS/METERS/SWITCHES HEADLIGHT REMOVAL Remove the two screws, collars and the headlight from the headlight case by releasing the tab. 3P CONNECTOR Disconnect the headlight 3P connector and position light wire connectors. COLLARS SCREWS HEADLIGHT WIRE CONNECTORS HEADLIGHT BULB REPLACEMENT Remove the headlight (page 17-4).
  • Page 280: Position Light Bulb Replacement

    dummyhead dummyhead LIGHTS/METERS/SWITCHES Install the dust cover onto the headlight with the drain DUST COVER hose facing down as shown. Install the headlight (page 17-5). POSITION LIGHT BULB REPLACEMENT Remove the headlight (page 17-4). SOCKET Pull the position light bulb socket out of the headlight. Pull the bulb out of the socket and replace it with a new one.
  • Page 281: Brake/Tail Light

    dummyhead dummyhead LIGHTS/METERS/SWITCHES HEADLIGHT CASE REMOVAL/ INSTALLATION Remove the headlight (page 17-4). HEADLIGHT CASE Remove the wires from the clamps. Remove the two mounting bolts, nuts/clamps, washers. Remove the headlight case from the brackets while NUTS/ removing the wires from the headlight case. CLAMPS Remove the collars from the headlight case.
  • Page 282: Turn Signal Light

    dummyhead dummyhead LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal light assembly from Align the turn signal TURN SIGNAL the case. light tab with the LIGHT groove in the case ASSEMBLY when installing. GROOVE SCREW Remove the screw and turn signal light lens. RUBBER GASKET Push the bulb in, turn it counterclockwise and remove it.
  • Page 283: Combination Meter

    dummyhead dummyhead LIGHTS/METERS/SWITCHES Remove the headlight case (page 17-6). MOUNTING NUT Remove the mounting nut and turn signal light assembly from the headlight bracket. Installation is in the reverse order of removal. Install the turn signal light assembly to the headlight bracket by aligning the flat surfaces.
  • Page 284 dummyhead dummyhead LIGHTS/METERS/SWITCHES Disconnect the speedometer cable. SPEEDOMETER CABLE Remove the two mounting bolts and the combination meter. Install the combination meter in the reverse order of removal. COMBINATION METER BOLTS DISASSEMBLY/ASSEMBLY Remove the four screws and combination meter lower LOWER COVER cover.
  • Page 285 dummyhead dummyhead LIGHTS/METERS/SWITCHES Remove the three screws and meter upper case. UPPER CASE SCREWS Remove the O-ring from the lower case groove. Do not touch the meter panel surface. O-RING Remove the screws and trip mete reset knob. RESET KNOB SET PLUG Remove the wire set plug.
  • Page 286: Ignition Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES TACHOMETER INSPECTION Before this inspection check that the combination meter DIGITAL MULTIMETER power/ground lines (page 17-8). Connect the peak voltage adaptor to the digital multimeter, or use the Imrie diagnostic tester. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter...
  • Page 287: Handlebar Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the top bridge (page 12-27). BOLTS SETTING PLATE Remove the ignition switch mounting bolts and ignition switch from the top bridge. Remove the bolts, setting plate and key shutter from the top bridge. Install the ignition switch in the reverse order of removal.
  • Page 288: Right Handlebar Switch Inspection

    dummyhead dummyhead LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT SWITCH COLOR HORN SWITCH FREE PUSH COLOR Bl/Bu RIGHT HANDLEBAR SWITCH INSPECTION Remove the headlight (page 17-4). CONNECTORS Disconnect the following of the right handlebar switch wire harness: – 2P (Natural) connector – Black wire connector –...
  • Page 289: Clutch Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES CLUTCH SWITCH INSPECTION Disconnect the clutch switch connectors and check for continuity between the switch side terminals. There should be continuity with the clutch lever squeezed and no continuity with the lever released. If the clutch switch function abnormal, replace it as CLUTCH SWITCH PIVOT BOLT follows:...
  • Page 290 dummyhead dummyhead LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT Remove the headlight (page 17-4). Disconnect the front brake light switch (Green/yellow and Black) wire connectors and check for continuity between the switch side connectors. There should be continuity with the front brake lever squeezed and no continuity with the lever released.
  • Page 291: Gear Position Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES GEAR POSITION SWITCH INSPECTION Remove the left side cover (page 2-3). CLAMP Open the clamp and disconnect the gear position switch 6P connector. Check for continuity at the switch side connector terminals. There should be continuity in each gear position as follows: Gear position Connection Neutral...
  • Page 292 dummyhead dummyhead LIGHTS/METERS/SWITCHES Separate the gear position switch and gear position GEAR POSITION GEAR POSITION SWITCH switch holder. SWITCH HOLDER Remove the O-rings from the gear position switch and holder. O-RINGS INSTALLATION Apply engine oil to new O-rings, then install it to the Align GEAR POSITION SWITCH gear position switch groove and holder groove.
  • Page 293: Fuel Gauge/Fuel Level Sensor

    dummyhead dummyhead LIGHTS/METERS/SWITCHES Connect the gear position switch 6P connector. WIRE GUIDE CLAMP Install the wires to the wire guides. Clamp the connector cover in position. Install the following: – Left side cover (page 2-3) – Drive sprocket cover (page 2-7) Fill the crankcase with the recommended engine oil (page 3-10).
  • Page 294: Fuel Level Sensor

    dummyhead dummyhead LIGHTS/METERS/SWITCHES FUEL LEVEL SENSOR Remove the fuel tank (page 2-4). FUEL LEVEL NUTS Remove the nuts, O-ring and fuel level sensor. SENSOR Be careful not to damage the float arm. O-RING Measure the resistance between the fuel level sensor connector terminals in each float position.
  • Page 295: Turn Signal Relay

    dummyhead dummyhead LIGHTS/METERS/SWITCHES HORN INSPECTION Disconnect the wire connectors from the horn. Connect the fully charged 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals. HORN REMOVAL/INSTALLATION Disconnect the wire connectors from the horn.
  • Page 296: Wiring Diagram

    dummytext 18. WIRING DIAGRAM WIRING DIAGRAM······································18-2 18-1...
  • Page 297 dummyhead dummyhead WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM 18-2...
  • Page 298: Troubleshooting

    dummytext 19. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO POOR PERFORMANCE AT HIGH START ·························································19-2 SPEED························································· 19-6 ENGINE LACKS POWER ···························19-3 POOR HANDLING ······································ 19-6 POOR PERFORMANCE AT LOW AND IDLE SPEED ·························································19-5 19-1...
  • Page 299: Engine Does Not Start Or Is Hard To

    dummyhead dummyhead TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START TROUBLESHOOTING 1. Fuel Line Inspection Check fuel flow to the carburetor. Does fuel reach the carburetor? – GO TO STEP 2. – • Clogged fuel hose or fuel strainer •...
  • Page 300: Engine Lacks Power

    dummyhead dummyhead TROUBLESHOOTING ENGINE LACKS POWER 1. Drive Train Inspection Raise the rear wheel off the ground and spin by hand. Does the wheel spin freely? – GO TO STEP 2. – • Brake dragging • Worn or damaged wheel bearings •...
  • Page 301 dummyhead dummyhead TROUBLESHOOTING 7. Engine Oil Inspection Check the oil level and condition. Is the oil level correct and the oil in good condition? – GO TO STEP 8. – • Oil level too high • Oil level too low •...
  • Page 302: Poor Performance At Low And Idle

    dummyhead dummyhead TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Pilot Screw Inspection Check carburetor pilot screw adjustment. Is the adjustment correct? – GO TO STEP 2. – See page 5-16 2. Intake Air Leak Inspection Check for leaking carburetor insulator. Is the carburetor insulator manifold leaking? –...
  • Page 303: Poor Performance At High

    dummyhead dummyhead TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Fuel Line Inspection Disconnect fuel line at carburetor. Does fuel flow freely? – GO TO STEP 2. – • Clogged fuel line • Clogged fuel tank breather • Faulty fuel valve •...
  • Page 304: Index

    INDEX dummytext INDEX AIR CLEANER ································································3-6 IGNITION TIMING ························································ 15-7 AIR CLEANER HOUSING ··············································5-5 INSULATOR INSTALLATION······································· 5-14 ALTERNATOR CHARGING COIL ································14-7 INSULATOR REMOVAL················································· 5-7 BATTERY······································································14-5 KICKSTARTER····························································· 9-20 BRAKE LIGHT SWITCH KICKSTARTER IDLE GEAR ········································ 9-18 LIGHTS/METERS/SWITCHES·······························17-15 LEFT CRANKCASE COVER INSTALLATION ··········· 10-11 MAINTENANCE ·······················································3-16 LEFT CRANKCASE COVER REMOVAL ·····················...
  • Page 305 dummytext INDEX STARTER RELAY SWITCH······································· 16-12 ALTERNATOR/STARTER CLUTCH ························ 10-3 STATOR/IGNITION PULSE GENERATOR ················· 10-5 BATTERY/CHARGING SYSTEM····························· 14-4 STEERING HEAD BEARINGS····································· 3-20 CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER····· 9-4 STEERING STEM ······················································ 12-27 CRANKCASE/CRANKSHAFT/TRANSMISSION ····· 11-4 SUSPENSION ······························································ 3-18 CYLINDER HEAD/VALVES ······································· 7-5 SWINGARM ······························································· 13-17 CYLINDER/PISTON ···················································...

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