Table of Contents
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ADDITIONAL
ITEMS
REQUIRING
FREOUENT
REPLACEMENT······················ ··································
·· ····4·7
AIR
CLEANER········· ···
···· ····
·· ········
······
····· ·········
··
····
····
···4·
10
AIR CLEANER
HO
USING ····
···
······
···· ···
··· ···
···
··
···
·········
··· 6·
7
ALTERNATOR CHARGING
CQll
···
.. ·· ..
··
.. ···· ..
······ .. ·
..
.. 17·8
AUTO-DECOMPRESSION
SYSTEM (After '07
) ··
···
··
····2·2
BALANCER GEAR/BALANCER
························· ····· ·····
13·8
BATTERy
······································································
17-6
BATTERY/CHARGING SYSTEM SPEC1FICATIONS
· .. 1·
12
BRAKE
FLUiD
·······················
··
······································
4-29
BRAKE
FLUID REPLACEMENT/AIR BLEEDING
····
··
···
16-6
BRAKE
PAD
WEAR
··· ....
· .. ··· ···· .. ·
..
··
....
··
.. · .. ···· ..
····· .. ··· ..
·4-30
BRAKE PAD/DISC
· .. ·· ....
······
..
···
..
····
· ..
···
· ..
·
..
···
..
·····
....
··16-10
BRAKE
PEDAL· .. ····· .. ·····
·
.. ·· ·· ..
··
..
·
.. ··· .. ··· ...... ··· ..
····· .. ··· 16-24
BRAKE
SYSTEM
· .. ·· .... ·· .. · .. ···· .. · .. · .. ··· .. ·· .. ·· .. ··· .... · .. ··· ..
··4-30
CABLE
&
HARNESS
ROUTING ('05
-
'07
) · .. · ..
·
.... ··· .. ··
1-25
CABLE
& HARNESS
ROUTING (After ·07}
··· .... ····
·
.. · ..
1-32
CAM CHAIN
TENSIONERICAM
CHAIN GUIDE
·
.. ....
..
9-25
CAMSHAFT
INSTALLATION
..
··
.. · .. · .... ·· .. · .. ···· ..
··· ····
.. ···
9-39
CAMSHAFT
INSTALLATION
('05
-
·07)· ..
.. ·
............
·
..
·9-37
CAMSHAFT REMOVAL
('05
-
'07)
·
....
· .. ........
.. .... ·
....
·
..
..
·9-S
CAMSHAFT
REMOVAL
(After
'07) ···· ...... ··· ..
··
.. ·· .... · .. ·9-
'6
CARSURETOR ADJUSTMENT
····· .. ··· ...... ··· .. ····· .... ·· .. ···
6-6
CARBURETOR ASSEMBLY
···· .. ····· .. ··· ...... ··· .. ·· .. ·· .. ·· .. ··
6-1S
CARBURETOR
DISASSEMBLY
.... · .... ··· .. · .... · .. · .. ·· .... · ..
·6-13
CARBURETOR INSTALLATION
...... · ...... ·
..
· .......... · ......
6-24
CARBURETOR
REMOVAL
..
··
·· .. ·· ·· .... ·· .. ···
····
..
··
..
·
..
..
·· ..
·6-11
CHARGING
SYSTEM INSPECTION ···
.. ···· ··· ..
··
.. · ....
··
..
·17-7
CLUTCH
..
·
..
···
....
·· ···
..
··
..
·······
..
···
.. ···
··
·
.. ··
......
···
··· ····· ..
···
..
·1 1-7
CLUTCH
LEVER
··· .... ·· .... ·· .. ···
···
.. ····
·
.. ··· .... · ..
··
····
··
....
····14-52
CLUTCH
SWITCH
.........................................................
20-S
CLUTCH SYSTEM
· .. ·· .... ····· .... ·· .. · .. ·· .. ·· .... · .. ·· .. ···· ..
·
.. ·· ..
·4-31
CLUTCHISTARTER
CLUTCH/KICKSTARTER/
GEARSHIFT
LINKAGE
SPECIFICATIONS
· .. ·· ....
··
··· .. ·· .. ·
'
·9
COMPETlnON MAINTENANCE SCHEDULE
..
······
.. ·· .. ·4·
6
COMPONENT
LOCATION
ALTERNATOR
....
..
....
·
..
..
..
..
....
· ..
·
..
.. · ..
..
.... ·
.. · ....
· ....
·
..
·
12·2
BAnERY/CHARGING SYSTEM
· .... · .... · .. · ............ · ..
17·2
CLUTCH/STARTER CLUTCH/KICKSTARTER/
GEARSHIFT
LINKAGE
· .. ·· .. ··· .... ··· .. ··· .. · .... ·· .... ··· .... · ..
1
1·2
CRANKCASEICRANKSHAFTfTRANSMISSIONI
BALANCER
· .. ······ .. ···· .... ··· .. ··· ..
·
.. · .... ··· ...... ·· .. ······· .. ···
13·2
CYLINDER
HEADN
ALVES·
· ...... · .... ··· .. · .. ··· .... ··· .... ·· ..
·9-2
CYLINDERIPISTON
· ..
.... ··
· ..
···
.... ···· ..
···
·· .. ··· ..
···
····
..
·
..
10-2
ELECTRIC
STARTER
·
.. ·· ..
········ ··
.. ··· ..
·····
· ..
···
..
······ .. ·· 19-2
ENGINE REMOVAUINSTALLATION
..
..
.. ·
..
.. ·
......
·
.. ·
..
8-2
FRONT WHEEUSUSPENSION/STEERING .. ....... ... 14-2
FUEL SYSTEM
·· .. · .... ·· .. ·· ..
···
..
··
..
·
.... · .... · .. · .... · ......
··
..
··· ·6-2
HYDRAULIC
BRAKE
·· .. · .. ··· .. ······· .. · .... ····· .. ·· .... ·· .. · .. ·· 16-2
IGNITION
SYSTEM
··· .. · .. · .. · .. ···· .... ·· .. ····· .... ·· .. ······ .. ··
18-2
LlGHTSIMETERISWITCHES .. ··
·· .. ··· ..
······
..
····
.... ··· ..
·20-2
REAR
WHEEUSUSPENSION ....
· ......
..
.... · ......
..
·
....
·
.. 1 5-2
CONTROL
CABLES
·· .... ·· ..
·
..
···
..
·····
.... ·· ..
···
··· .. ··
·
..
······ .. ··4-32
COOLANT
REPLACEMENT
...
..
...
....
................
..
......
..
..
...
7-6
COOLING SYSTEM
··· .... ····· ..
··
.. ·· ···· .. ··· .. ····· .... ·· .. ··· ....
···4-14
COOLING SYSTEM SPECIFICATIONS
.. · .. ··· .. ··· ...... · .. ···
'
-7
CRANKCASE ASSEMBLY
.... · ...... ·
..
.. · ........ · .. · ........ · .. ·
13-25
CRANKCASE
BEARING REPLACEMENT
···· .. ··· ...... ·· '3·
16
CRANKCASE
BREATHER
·· ....
··
.. ···· .... ·· .... ···
·
..
··
......
··
..
··4-11
CRANKCASE SEPARATION
..
···
..
·
..
·
..
····
.. · ....
·
..
···
...... ··13-
'O
CRANKCASE/CRANKSHAFTfTRANSM
ISSIONI
BALANCER SPECIFICATIONS ('05 . ·07)
...... · ...... · ..
....
..
1·9
CRANKCASEICRANKSHAFTfTRANSMISSIONI
BALANCER
SPECIFICATIONS (After '07}
.. ·
..
.. ·
..
·
..
...... 1·
10
CRANKSHAFT
INSTALLATION
.... · .... · ...... ··· .. ··· ..
·
.. · ..
13-21
CRANKSHAFT REMOVAL·
·· ..
··
.. ····· .. ···· .. ·· .. · ........ · .. ···
13-14
CYLINDER COMPRESSION TEST··
.. ···· .. ········· .... · .. ·· .. ···
9-7
CYLINDER
HEAD
ASSEMBLY··
.. ·· ·· .... ·· .. ·· .. ·· .. ··· ..
·
.. ·· ..
·9-33
CYLINDER
HEAD
COVER
INSTALLATlON··
..
···
..
·
..
··
..
·9-42
23.
INDEX
CYLI
NDER
HEAD
COVER
REMOVAL
......
..
..
..
.. ·
..
...... · .. ·
9-7
CYLIN
DER
HEAD DiSASSEMBLy
.. · ..
··
.. ···
·
..
··
....
··
..
··
..
· 9·27
CYLINDER
HEAD
INSPECTION
....
.....
....... ...............
..
.
9-2S
CYLIN
DER HEAD
INSTALLATION·
..
··
..
·
.. ··
··
..
··· ....
..
····
·
9-36
CYLINDER
HEAD REMOVAL
...
............ .......... .......... ...
9-24
CYLINDER
HEADN
ALVES SPECIFICATIONS·
.......... · ..
1-S
CYLINDER
INSTALLATION········ .... ·· .. · .. ··· .. · .... · ........ ·
10-10
CYLINDER
REMOVAL··
..
·
.... ·· .... · .... · .. ·· .. ···· ..
···
.. ······ .. ···
10-5
CYUNDERIPISTON SPECIFICATIONS
........ · .... · ..
..
· ......
1-8
DRIVE CHAIN
·· .... ····· ..
··
..
··
.... ··· .. ·· .. ··· .. ·· .. ·· ..
···· .. · .. ·
..
·
....
· 4·24
DRIVE CHAIN
ROLLER
.......
..
.. ................... ....
..............
4-28
DRIVE
CHAIN SLIDER ........
..
...
..
.......
..
............
...
....
.....
. 4-27
DRIVE
SPROCKET
· ..
··· .. ··
....
··
.. ············ .. ·· ..
.. ······ ...... ···
.. ··
8-4
DRIVE/DRIVEN SPROCKET ......
·
............
· ..
.. ·
.... · ....
..
.... · 4·
28
ELECTRIC
STARTER SPECIFICATION
· ....
· ......
· ...... · ....
1-13
EMISSION
CONTROL SYSTEMS
·· .. ·· .. · .. · ..
·
.. ··· ......
··
.. ·
1-40
ENGINE
&
FRAME TORQUE
VALUES
...... · ....
..
...... · .. ·
1-14
ENGINE
GUARD
· .. · .. ··· .. ·· .. ··· .. ···· .. ··· .. ·· .. ·· ....
·····
· .... · ..
··
.. ··
3-5
ENGINE
IDLE
SPEED···
..
··
.. ···
·
.. ··· .. ···· .. ··· ·· ..
.. ··
.. ·· ·· ...... ··
4-22
ENGINE
INSTALLATION·
..
·····
··
··
.. ···· .. ···
··
....
··· .. ···
.. · ..
··
.. ·
S-S
ENGINE
OIUOIL
FILTER··
....
··
..
··
· .. ··
·
..
··
..
·· ....
··
.. ····
...... ··
4-19
ENGINE REMOVAL
· ..
··
..
··
....
··
.... · .. ···· ..
··
.. · ....
··
..
····
......
··
..
8-5
ENGINE
STOP
BUnON
· .... · .. · ...... · .. · ............ ..............
20-7
EXHAUST
PIPEIMUFFLER
..........................................
4-33
EXHAUST
SYSTEM ..............................................
........
3·9
FLYWHEEL
.... """""
"
",
,,
,,
,,,,
,,,,,,,,,,,,,,,,
,, ,,,,,,,,,,
,,,,
,,
,,,,,,
12-5
FORK
..
..
....
..
...
..
..
.. ...
.......
..
..
....
...
.. ..... ....
..
...
........
....
·····
·
14-13
FRONT
BRAKE CALIPER······
..
··
..
····
···· ..
··
..
···· ..
··
.. ···
····
16-18
FRONT MASTER
CyLINDER
..
....
.. · ..
·
....
..............
.... · ..
16-12
FRONT
VISOR
......... .....
...
...........................
...
..
...
...........
3-5
FRONT
WHEEL
··· ..
·
..
·
.... · ...... · .. ·· .. ···· .. ·· .. · .. ···· .. ·· .... ······ ..
14-S
FRONT
WHEEUSUSPENS ION/STEERING
SPECIFICATIONS
....... ........................ ... ..... .................
1-11
FUEL LINE
··· .. · .... ·· .. • ..
·
..
··
....
.. ·
..
··
..
···
· .. ··
·····
..
····
.. · .... · ..
···
..
· 4-8
FUEL
STRAINER SCREEN
.....
.................... ........
.. .........
4-8
FUEL SYSTEM SPECIFICATIONS ..
....... ..................
..
...
1-7
FUE
L
TANK
.. ··
..
··
·
..
· .. ·············
.. ··
····
·····
·· ···
..
········
.... ··
..
· .. ··
3-8
GEARSHIFT LINKAGE·····
.. ··· .. ···· .. ···· .. · ..
·· ..
..
··
..
····
......
11
·
24
GENERAL
SPECIFICATION
S
· .. ·· .. ···· .. · .. ···· .. ··· .. ··· .. · .. ··· ..
1-5
HANDLEBAR·· .... ··· ....
···
..
··
.. •··· .. ··· .. ···· .. · .. ·· ..
..
··
·
.. ··· .. · .. ·
14-33
HEADLIGHT
.. ............ ...... ..... ....
..
......... .... ...
.... .....
....... ..
20·4
HEADLIGHT
AIM
......
...
..
..
....
...
.. .......... ...
..
..
....
...
..
.........
4-31
HOT
START
.. · .... ·· .. · ..
··· .. ·· .. ·····
··· .. ···· .. ·· ..
··
·· ..
···
·····
..
·
.. ···
4-10
HPSD
(Honda Progressive Steering
Damper):
After
'07
FRONT
WHEEUSUSPENSION/STEERING
....
·····
·
14-38
TECHNICAL
FEATURE·
···· .. · .. ·· ······ .. ·· ..
···
·
.. ··
.. ······· .. ···
2-3
HYDRAULIC
BRAKE
SPECIFICATIONS· ..
···· .. ··
.... ····
·
.. 1·
12
IGNITION
COIL
...... ·· .... · .. ···· .. ··· .. ·· .. ···· .. ·· .. · .. · .. · .... ·· ...... ·
18·7
IGNITION CONTROL MODULE
(ICM)
.. · ..
.. ....
· .. · ...... · ..
18-7
IGNITION SYSTEM
INSPECTION···· .. ·· ........
··
....
··
...... ·
18-5
IGNITION SYSTEM SPECIFICATIONS
.. ·
.... · ....
..
· ..
·
..
.. ·
1-12
IGNITION
TIMING
.......
.. ...
.. ........ ..... .........
.......
.... ... .....
18-8
KICKSTARTER
..
..
..
...... · ......
· ....
..
...... · ..
.. ...... ·
....
..
· ..
..
·
..
·
11
·
15
lEFT
CRANKCASE COVER
INSTALLATION·
.. · ..........
12·6
LEFT CRANKCASE COVER
REMOVAL
.. · ..
·
.. ·
..
·
..
· ...... ·
12·4
LIGHTS/METER/SWITCHES SPECiFiCATIONS
······· ..
'-13
LUBRICATION
&
SEAL
POINTS
· .. · ........................ · ....
1-21
LUBRICATION SYSTEM
DIAGRAM
........
...
...
..
....
....
..... 5-2
LUBRICATION SYSTEM SPECiFiCATIONS
· ........ · ...... ·
1-7
MAINTENANCE SCHEDULE ('05.
'
06
) ......
..
..
....
...........
4-4
MAINTENANCE SCHEDULE (After
·06) ..
........
..
· .. ·· ..
· .. ·
4-5
MODEL IDENTIFICATION
.............. · .... · ..........
..
.. · .. · ...... ·
1-2
NUTS. BOLTS.
FASTENERS
.. · ...... · ........
..
.. .............. · ..
4-36
Oil JET
..................... .....................................................
5·6
OIL PUMp
··· .. · .... · ...... ·· ..
···
..
···
.. ··· .. ···· .. ·· ....
·
.. ·
....
·
..
· .. · .... · ..
5-7
Oil
STRAINER
.. ·· .. ···
··
.... ·· ..
···
.. ··· .. ···· .. ·· ..
··
· .. ·
.. ·
..
···
.. · .. ··· ..
5·4
OPTIONAL PARTS·
· .. · ..
····
..
···
.. ··
·
.. ···· .. ·· .. ·· .. ···
··
....
·
.. · .. ···
1-37
PilOT SCREW ADJUSTMENT
..
..
.....
..
......
..........
........
6-27
PISTON
INSTALLATION·
.. ·· ·· .. ··· .. ···· .. ·· ..
··
..
·····
·· ··· ···· .. ·
10-9
23-1
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