Table of Contents
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Chapters
Table of Contents
Troubleshooting
Related Manuals for Honda Hawk GT NT650 1990
Summarization of Contents
1. GENERAL INFORMATION
General Safety
Important safety precautions for operating and maintaining the motorcycle.
Service Rules
Guidelines for using genuine parts, special tools, and proper maintenance procedures.
Model Identification
Information on how to identify the motorcycle model and its serial numbers.
Specifications
Key technical data including dimensions, frame, engine, and electrical specifications.
Torque Values
Specific torque settings for engine and frame bolts and nuts during assembly/disassembly.
Tools
List of special and common tools required for servicing the motorcycle.
Cable & Harness Routing
Instructions and diagrams for properly routing cables and wire harnesses.
Emission Control Systems
Explanation of the motorcycle's emission control systems and compliance requirements.
2. LUBRICATION
Service Information
General information and safety precautions related to lubrication procedures.
Specifications
Technical specifications for engine oil, including capacity, recommendations, and viscosities.
Oil Filter Change
Step-by-step procedure for changing the engine oil filter, including required tools and torque.
Oil Pump/Relief Valve
Details on the removal, disassembly, and inspection of the oil pump and relief valve.
3. MAINTENANCE
Maintenance Schedule
Detailed schedule of maintenance items based on odometer readings and frequency.
Valve Clearance
Detailed instructions for inspecting and adjusting valve clearance while the engine is cold.
Carburetor Synchronization
Procedure for synchronizing carburetors using a vacuum gauge for optimal engine performance.
Cylinder Compression
Steps for measuring cylinder compression to diagnose engine performance issues.
4. FUEL SYSTEM
Specifications
Fuel system specifications including carburetor type, throttle bore, float level, and pilot screw settings.
Troubleshooting
Common fuel system problems and their potential causes, from starting issues to poor performance.
Carburetor Removal
Detailed steps for removing the carburetors from the motorcycle, including California models.
Pilot Screw Adjustment
Procedure for adjusting pilot screws, including idle drop and initial opening settings.
5. COOLING SYSTEM
Specifications
Cooling system specifications including radiator cap pressure, freezing point, capacity, and thermostat data.
Troubleshooting
Common cooling system problems like overheating, low temperature, and coolant leaks.
Coolant Replacement
Step-by-step guide for draining, refilling, and bleeding the cooling system with coolant.
Thermostat
Instructions for removing, inspecting, and installing the engine thermostat.
6. ENGINE REMOVAL/INSTALLATION
Specifications
Engine dry weight, oil capacity, and coolant capacity specifications.
Torque Values
Comprehensive list of torque values for engine mounting and related bolts.
Engine Removal
Detailed procedure for removing the engine from the motorcycle frame, including draining fluids and disconnecting components.
Engine Installation
Step-by-step instructions for installing the engine back into the motorcycle frame.
7. CLUTCH/GEARSHIFT LINKAGE
Specifications
Clutch specifications including spring free length, disc thickness, and plate warpage.
Torque Values
Torque values for clutch and gearshift linkage related fasteners.
Troubleshooting
Common clutch operation issues like slipping, not disengaging, or rough feel.
Clutch Removal
Detailed steps for removing the clutch assembly, including bolts, plates, and springs.
8. ALTERNATOR/STARTER CLUTCH
Specifications
Specifications for the starter driven gear outside diameter.
Torque Values
Torque specifications for flywheel bolt and starter clutch torx bolts.
Flywheel Removal
Instructions for removing the flywheel using specialized tools, noting left-hand threads.
Starter Clutch
Disassembly and inspection of the starter clutch, including gear and oneway clutch checks.
9. CYLINDER HEAD/VALVES
Specifications
Specifications for camshaft lobe height, runout, oil clearance, and valve stem dimensions.
Troubleshooting
Common cylinder head and valve issues like low compression, noise, and poor idling.
Cylinder Head Cover Removal
Procedure for removing the cylinder head covers for front and rear cylinders.
Camshaft Removal
Steps for removing the camshaft, including aligning timing marks and handling cam chain.
Valve Guide Replacement
Detailed procedure for replacing valve guides, including heating and reaming.
Cylinder Head Assembly
Assembly of the cylinder head, including installing valve seats, stem seals, springs, and retainers.
Cylinder Head Installation
Procedure for installing the cylinder head onto the engine, including gasket and cam chain guide.
10. CYLINDER/PISTON
Specifications
Specifications for cylinder bore, taper, out-of-round, and piston ring clearances.
Troubleshooting
Common cylinder and piston issues like low compression, excessive smoke, overheating, and piston noise.
Cylinder
Procedures for removing, inspecting, and measuring cylinder wear, taper, and out-of-round.
Piston Installation
Procedure for assembling pistons and connecting rods, noting piston orientation and clip installation.
11. CRANKSHAFT/TRANSMISSION
Specifications
Specifications for crankshaft, connecting rod, and transmission component clearances and dimensions.
Troubleshooting
Common issues related to crankshaft/transmission, such as noise, hard shifting, and jumping out of gear.
Crankcase Separation
Detailed procedure for separating the crankcase halves, including removing internal components.
Connecting Rod Assembly
Steps for assembling connecting rods, caps, and bearings onto the crankshaft.
Crankcase Assembly
Steps for assembling the crankcase halves, including sealant application and bolt tightening.
12. FRONT WHEEL/SUSPENSION/STEERING
Specifications
Specifications for axle runout, wheel rim runout, fork spring length, and fluid capacity.
Torque Values
Torque specifications for various front wheel, suspension, and steering components.
Troubleshooting
Common issues related to front suspension and steering, such as hard steering, wobble, and soft/hard suspension.
Front Wheel
Procedure for removing the front wheel, including disconnecting speedometer cable and brake caliper.
Fork
Procedure for removing fork legs, including loosening pinch bolts and fork tube caps.
Assembly
Assembling the fork, including piston, rebound spring, oil lock piece, and tube components.
13. REAR WHEEL/SUSPENSION
Specifications
Specifications for rear wheel rim runout, shock absorber spring length, and preload.
Torque Values
Torque specifications for rear wheel, sprocket, brake disc, and suspension fasteners.
Troubleshooting
Common issues related to rear wheel wobble, soft/hard suspension, and suspension noise.
Rear Wheel
Procedure for removing the rear wheel, including chain slack adjustment and axle removal.
Shock Absorber
Safety warnings and removal procedure for the rear shock absorber.
Swingarm
Procedure for removing the swingarm, including loosening pivot bolts and disconnecting brake hose.
14. HYDRAULIC BRAKE
Specifications
Specifications for brake disc thickness/warpage, master cylinder/caliper dimensions, and fluid type.
Torque Values
Torque specifications for various hydraulic brake system components.
Troubleshooting
Common brake issues like spongy lever, hard lever, drag, grab, chatter, or squeal.
Brake Fluid Replacement/ Air Bleeding
Detailed procedure for replacing brake fluid and bleeding the hydraulic system to remove air.
Front Brake Pad Replacement
Steps for replacing front brake pads, including piston compression and torque specs.
Rear Brake Master Cylinder
Procedure for removing, disassembling, and inspecting the rear brake master cylinder.
Front Brake Caliper
Procedure for removing, disassembling, and inspecting the front brake caliper pistons and cylinder.
15. BATTERY/CHARGING SYSTEM
Specifications
Specifications for battery capacity, voltage, charging current, and alternator output.
Troubleshooting
Troubleshooting guide for battery and charging system issues.
Battery
Safety warnings, removal, installation, and voltage inspection of the motorcycle battery.
Regulated Voltage/Ampere Inspection
Procedure for inspecting regulated voltage and amperage output of the charging system.
Regulator/Rectifier
System inspection of the regulator/rectifier, including checking connector terminals and circuits.
16. IGNITION SYSTEM
Specifications
Specifications for spark plugs, ignition timing, coil resistance, and pulse generator resistance.
Troubleshooting
Troubleshooting guide for ignition system problems, including no spark or poor performance.
Ignition Coil
Inspection of ignition coils, measuring primary and secondary coil resistance.
Ignition Timing
Procedure for inspecting ignition timing using a timing light and checking spark unit components.
17. ELECTRIC STARTER
Specifications
Specification for starter motor brush length.
Troubleshooting
Troubleshooting guide for starter motor issues, including not turning or not starting engine.
Starter Motor
Procedure for removing, disassembling, and inspecting the starter motor, including brush length.
Installation
Installing the starter motor into the engine and connecting cables.
18. LIGHTS/METERS/SWITCHES
Specifications
Specifications for headlights, lights, meters, and fuses.
Troubleshooting
Troubleshooting guide for lighting and meter issues, like no lights or dim lights.
Switches Location
Diagrams showing the location of various switches on the motorcycle.
Headlight
Procedure for removing, installing, and replacing the headlight bulb.
Ignition Switch/Meter
Inspection and removal of the ignition switch and meter assembly.
Handlebar Switches
Checking continuity of left and right handlebar switches for dimmer, turn signals, horn, and starter.
Temperature Sensor
Checking the temperature sensor for continuity and proper function.
Fuel Pump Relay
Inspecting the fuel pump relay, connector, and checking for proper operation.
19. WIRING DIAGRAM
Wiring Diagram
Comprehensive electrical wiring diagram showing all circuits, components, and color codes.
20. TROUBLESHOOTING
Engine Does Not Start
Troubleshooting flowchart for engine starting issues, covering fuel, spark, and compression.
Engine Is Hard to Start or Soon Stops
Troubleshooting steps for engines that are difficult to start or stall shortly after starting.
Engine Lacks Power With Normal Loading
Diagnosing causes for lack of engine power during normal operation, including smoke and mechanical checks.
Poor Engine Performance at Slow and Idle Speeds
Troubleshooting guide for poor engine performance specifically at low and idle speeds.
Poor Engine Performance at High Speeds
Troubleshooting guide for poor engine performance at high speeds, addressing spark, fuel, and timing issues.
Valve Surging
Potential causes for valve surging, including clearance and spring issues.
Clutch Slips
Troubleshooting steps for clutch slippage, covering lever play and component wear.
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