Table of Contents
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Chapters
Table of Contents
Troubleshooting
Related Manuals for Honda Hawk GT NT650 1991
Summarization of Contents
1. General Information
General Safety
Essential safety guidelines for motorcycle operation and maintenance to prevent accidents.
Service Rules
Rules for servicing the motorcycle using recommended parts and tools for optimal performance.
Model Identification
Identifying key features and serial numbers for the specific motorcycle model.
Specifications
Detailed technical specifications including dimensions, weight, capacities, and settings.
Tools
Essential tools for performing maintenance and repairs on the motorcycle.
Emission Control Systems
Details on exhaust and evaporative emission control systems for compliance.
2. Lubrication
Service Information
Important information regarding lubrication procedures, including safety and general tips.
Specifications
Technical specifications for engine oil, including capacity, type, and viscosity recommendations.
Torque Values
Torque specifications for critical lubrication components like oil pressure switch and drain bolt.
3. Maintenance
Service Information
General service information and safety precautions before starting maintenance procedures.
Specifications
Key specifications for engine timing, spark plugs, valve clearance, and chassis settings.
Tires
Tire specifications including size, cold pressure, and brand for front and rear wheels.
Maintenance Schedule
Schedule of recommended maintenance tasks based on odometer readings and frequency.
4. Fuel System
Service Information
Safety warnings and general information for working with the fuel system.
Specifications
Specifications for fuel system components like carburetor and fuel tank.
Carburetor Removal
Detailed steps for safely removing the carburetors from the engine.
Pilot Screw Adjustment
Detailed procedure for adjusting pilot screws to set the correct idle speed.
Purge Control Valve Inspection
Inspection steps for the purge control valve (California models) to ensure proper function.
5. Cooling System
Service Information
General information and safety precautions for servicing the motorcycle's cooling system.
Troubleshooting
Troubleshooting guide for common cooling system issues like overheating or leaks.
Thermostat
Steps for removing, inspecting, and installing the engine thermostat.
Water Pump
Procedures for inspecting, removing, and installing the water pump and its components.
6. Engine Removal/Installation
Service Information
General information and torque values for engine removal and installation procedures.
Engine Removal
Detailed steps for safely removing the engine from the motorcycle frame.
Engine Installation
Procedures for correctly installing the engine back into the motorcycle frame.
7. Clutch/Gearshift Linkage
Service Information
Information on servicing clutch, oil pump drive chain, gearshift linkage, and primary drive gear.
Specifications
Specifications for clutch components, including free length and disc thickness.
Troubleshooting
Troubleshooting common clutch problems like slipping, not disengaging, or rough operation.
8. Alternator/Starter Clutch
Service Information
Information covering removal and installation of alternator, starter clutch, and starter gears.
Specifications
Specifications for starter driven gear O.D. and torque values for related bolts.
Flywheel Removal
Procedure for removing the flywheel using specialized tools.
9. Cylinder Head/Valves
Service Information
General information about cylinder head removal, camshaft lubrication, and assembly procedures.
Specifications
Specifications for camshaft lobe height, oil clearance, valve stem/guide dimensions, and spring lengths.
Troubleshooting
Troubleshooting guide for engine top-end noise, compression, and valve problems.
Camshaft Removal
Detailed steps for removing the camshafts, including timing marks and chain alignment.
10. Cylinder/Piston
Service Information
General information regarding cylinder and piston service, including engine removal requirements.
Specifications
Technical specifications for cylinder bore, piston dimensions, ring clearance, and end gaps.
Troubleshooting
Troubleshooting guide for issues like low compression, excessive smoke, overheating, and piston noise.
Piston
Steps for removing and inspecting pistons, piston rings, and measuring ring-to-groove clearance.
11. Crankshaft/Transmission
Service Information
General information for servicing crankshaft, transmission, oil pump, and related components.
Specifications
Specifications for connecting rod clearances, gear and bushing dimensions, and shaft dimensions.
Troubleshooting
Troubleshooting for noises, shifting problems, and transmission jumping out of gear.
Crankshaft/Connecting Rod
Procedures for inspecting crankshaft side clearance, runout, and connecting rod bearings.
12. Front Wheel/Suspension/Steering
Service Information
General information and safety precautions for front end service.
Troubleshooting
Troubleshooting for hard steering, suspension issues, and wheel wobbling.
Handlebars
Procedures for removing and installing handlebars, including switches and weights.
Front Wheel
Steps for front wheel removal, inspection, and balancing.
Fork
Detailed procedures for front fork removal, disassembly, inspection, and assembly.
13. Rear Wheel/Suspension
Service Information
General service information, safety warnings, and torque values for rear wheel and suspension.
Troubleshooting
Troubleshooting for rear wheel wobble, soft/hard suspension, and suspension noise.
Rear Wheel
Step-by-step instructions for removing and installing the rear wheel.
Eccentric Bearing Carrier
Procedures for removing and installing the eccentric bearing carrier for chain slack adjustment.
Swingarm
Procedures for removing and disassembling the swingarm and its pivot bearings.
14. Hydraulic Brake
Service Information
General information and safety precautions for hydraulic brake system service.
Specifications
Specifications for brake disc thickness, master cylinder and caliper dimensions.
Troubleshooting
Troubleshooting guide for brake lever issues, drag, grab, chatter, and squeal.
Brake Fluid Replacement/Bleeding
Step-by-step guide for replacing brake fluid and bleeding the hydraulic system.
Brake Pads/Discs
Procedures for replacing front and rear brake pads, including caliper piston adjustment.
15. Battery/Charging System
Service Information
General information about battery charging procedures and testing equipment.
Battery
Procedures for removing, installing, and inspecting the motorcycle battery's voltage.
Charging System
Details on charging the battery using specific chargers and inspecting the charging system.
Regulator/Rectifier
How to inspect the regulator/rectifier unit by checking resistance and voltage.
16. Ignition System
Service Information
General information regarding the ignition system, including timing and spark plug inspection.
Troubleshooting
Troubleshooting chart for diagnosing ignition system problems like no spark.
Ignition System Inspection
Inspection procedures for primary and secondary coil resistance and pulse generator.
Ignition Timing
Steps to check ignition timing using a timing light and identifying correct alignment.
17. Electric Starter
Service Information
General information and specifications for the electric starter system.
Troubleshooting
Troubleshooting guide for starter motor not turning or turning engine slowly.
Starter Motor
Procedures for removing, disassembling, and inspecting the starter motor brushes and components.
Starter Relay Switch
How to inspect the starter relay switch operation and voltage.
18. Lights/Meters/Switches
Service Information
General information, safety warnings, and specifications for electrical components.
Troubleshooting
Troubleshooting guide for issues with lights not coming on, dim lights, or headlight beam problems.
Switches Location
Identifying the location of key switches like ignition, starter, and lights on the handlebar.
Headlight
Steps for removing and installing the headlight assembly and bulb.
Ignition Switch/Meter
Procedures for inspecting and removing the ignition switch and instrument cluster.
20. Troubleshooting
Engine Does Not Start
Diagnostic steps for an engine that fails to start, covering fuel, spark, and compression issues.
Engine Is Hard to Start or Soon Stops
Troubleshooting guide for engines that are difficult to start or stall frequently.
Engine Lacks Power with Normal Loading
Diagnostic steps for engine power loss, covering exhaust smoke, spark plugs, and fuel flow.
Poor Engine Performance at Slow and Idle Speeds
Troubleshooting guide for poor engine performance at low speeds and idle.
Poor Engine Performance at High Speeds
Diagnostic steps for poor engine performance at high speeds, checking spark plugs and fuel flow.
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