Table Of Contents - Honda Motorcycle Service Manual

Table of Contents

How To Use This Manual3
Table Of Contents3
Symbols4
Abbreviations5
General Information Contents7
General Safety7
Carbon Monoxide7
Gasoline7
Nitrogen Pressure8
Hot Components8
Used Engine/Transmission Oil8
Service Rules9
Fasteners12
Types Of Threads12
Thread Sizes12
Width Across Flats13
Hex-Head Bolt Strength Markings13
"Torx" Bolt14
Ct Bolt15
Torque Values (Tightening Force)16
Fastener Loosening18
Locking19
Ball Bearing Replacement22
Removing Ball Bearings22
Installing Ball Bearings23
Tool Compatibility Chart For Standard Bearings24
Bearing Size24
Bearing Remover Compatibility For Wheel Bearing24
Bearing Remover Compatibility Table24
Tool Compatibility Chart25
Maintenance Contents27
Fuel Line28
Fuel Strainer Screen28
Throttle Operation29
Oil Pump And Oil Line30
Oil Strainer30
Carburetor Choke31
Manual Choke31
Starting Enrichment Valve31
Air Cleaner32
Oiled Urethane Foam Element32
Crankcase Breather33
Paper Element33
Aircleaner Housing Drain Tube (Off-Road Motorcycles And Atvs)33
Spark Plug Inspection34
Reusing A Spark Plug34
Replacing A Spark Plug34
Valve Clearance35
4-Stroke, Wet Sump Engines37
Engine Oil 2-137
4-Stroke, Dry Sump Engines38
Leak Inspection38
Oil Change38
Engine Oil Filter 2-139
Egine Oil Filter Screen40
Cartridge-Type Paper Filter40
Element-Type Paper Filter40
Decarbonizing (2-Stroke Engine)41
Carburetor Synchronization42
Carburetor Idle Speed43
Radiator Coolant43
Cooling System44
Level Check44
Pulse Secondary Air Supply (Pair) System45
Evaporative Emission Control System45
Transmission Oil Change46
Transmission Oil (2-Stroke Engine)46
Drive Chain Adjustment47
Adjustment Of Pro-Arm Type48
Inspection Of Chain Replacement Period49
Cleaning, Inspection And Lubrication49
O-Ring Chains49
Replacement Of Endless Chain50
Sprockets50
Non O-Ring Chain50
Refer T O The Model Specific Service Manual50
Drive Chain Slider, Chain Guide, Guide Slider And Rollers53
Drive Belt53
Belt Case Air Cleaner54
Final Drive Oil Level54
Battery55
Fluid Level55
Specific Gravity Of Fluid55
Brake Fluid56
Condition Of Terminal Connections56
Brake Shoe Wear57
Brake Pad Wear57
Brake System58
Inspection For Air In System58
Free Play Adjustment58
Brake Pedal Height Adjustment59
Hydraulic Brake Type59
Drum Brake Type60
Date Of Issue: March, 1995 Honda Motor Co60
Brake Light Switches61
Headlight Aim61
Clutch System62
On Centrifugal Clutch62
Side Stand63
Clutch Fluid Level63
Conventional Type63
Suspension64
Dual Motion Type64
Inspection For Side Stand With Ignition Cut-Off Switch64
Spark Arrester66
Nuts, Bolts, Fasteners66
Wheels/Tires67
Steering Head Bearings69
Wheel Alignment69
Toe-In69
Camber/Caster70
Engine Testing Contents71
Service Information71
Troubleshooting71
Compression Testing72
Leak-Down Twsting73
4-Stroke Leak-Down Test Information73
2-Stroke Pressure/Vacuum Leak-Down Test Information74
Lubrication Contents75
Lubrication Service Information75
Lubrication Service Data75
Lubrication Troubleshooting76
System Description77
4-Stroke Systems77
Typical Oil Flow Pattern77
Four-Stroke Engines78
Wet-Sump Type78
Dry-Sump Type78
General78
Two-Stroke Lubrication Systems79
Separate Oil Systems79
Premixed (Oil In Fuel) Systems80
Oil Pump Descriptions81
Trochoid Type81
Plunger Type82
Oil Pump Operating Principle82
Oil Pressure Check83
Oil Pump Inspection83
Pressure Relief Valve84
In-Set Type Oil Pump84
Oil Pump/Oil Line Bleeding85
Suction Line, Oil Pump Bleeding85
Outlet Line Bleeding85
Oil Cooler Inspection86
Cooling System Contents87
Cooling System Service Information87
Cooling System Troubleshooting87
Cooling System Descriptions88
System Flow Patterns88
Radiator89
Cooling Fan89
Cooling Fan Switch89
Radiator Cap90
Reserve Tank91
Thermostat91
Water Pump91
Coolant Preparation92
Coolant Replacement92
Coolant System Testing93
Air Bleeding93
Hydrometer Test93
Coolant Gravity Chart93
Radiator Cap Test94
System Pressure Test94
Mechanical Seal Inspection94
Water Pump Replacement95
Exhaust System Contents97
Exhaust System Service Information97
Exhaust System Troubleshooting97
Exhaust System Descriptions98
Exhaust Pulse Scavenge Effect98
Common Exhaust Pipe99
Emission Control System Contents101
Emission Control System Service Information101
Emission Control System Troubleshooting101
Emission Control System Descriptions102
Source Of Emissions102
Crankcase Emission Control System102
Exhaust Emissio Control System (Pulse Secondary Air Supply System)103
Evaporative Emission (Evap) Control System104
Noise Emission Control System104
System Inspection105
Evaporative Emission Purge Control Valve (Evap Purge Control Valve)105
Evaporative Emmission Carburetor Air Vent Control Valve (Evap Cav Control Valve)106
Emission Control Information Labels109
Pulse Secondary Air Injection Check Valve (Pair Check Valve)109
Fuel System Contets111
Fuel System Service Information111
Fuel Freshness And Troubleshooting111
Fuel System Troubleshooting112
Fuel System Description113
Carburetor113
Types Of Carburetor113
Principle Of The Vacuum Piston Operated Cv Type113
Operation Of Systems114
Float System114
Starting System114
Slow System (Low Degree Of Opening)115
Honda Motor Co.,Ltd115
Main System (Medium Throttle Opening)116
Main System (Fully Open)116
Date Of Issue: March, 1995116
Accelerator Pump117
Air Cut-Off Valve117
Reed Valve Inspection117
Fuel System117
Fuel Auto Valve118
Fuel Auto Valve Inspection118
Carburetor Disassembly/Inspection119
Throttle Valve/Starting Enrichment Valve Inspection119
Throttle Valve Inspection (Cv Type)119
Starting Enrichment Thermal Valve120
Starting Enrichment Thermal Valve Removal121
Starting Enrichment Valve (Manual)121
Throttle Valve (Piston Valve Type)121
Vacuum Piston (Cv Type)122
Float/Jets123
Carburetor Assembly124
Carburetor Cleaning124
Float/Jets Assembly125
Float Level Inspection126
Pilot (Or Air) Screw Adjustment128
Carburetor Separation/Assembly/Installation128
Pilot (Or Air) Screw Removal128
Limiter Cap Type129
Plug Type129
Pilot (Or Air) Screw Installation130
Idle Drop Procedure130
Pilot (Or Air) Screw Adjustment 8-1130
Air Screw Or Pilot Adjustment132
Best Idle Procedure132
Limiter Cap (Or Plug) Installation133
Accelerator Pump Adjustment134
High Altitude Adjustment134
Cylinder Head Contents135
Cylinder Head Service Information135
Cylinder Head Troubleshooting135
Cylinder Head System Description136
Cylinder Head Construction136
Valve Train137
Valve Lifter Mechanism /Arrangement138
Example Of Sohc-4 Valve System138
Example Of Dohc With Valve Bucket Type138
Hydraulic Tappets139
Hydraulic Tappets Operation139
Decompressor System141
Function Of Decompressor System141
Description141
Construction141
Reverse Decompressor Cam142
Camshaft Inspection143
Camshaft Bearing Inspection143
Camshaft Oil Clearance Inspection143
Rocker Arm, Rocker Arm Shaft144
Cylinder Head Inspection145
Solvent Test145
Warpage Inspection145
Cylinder Head Disassembly146
Valve Springs146
Valves146
Valve Guides Inspection147
Stem-To-Guide Clearance147
Valve Guides Replacement147
When Using A Dial Indicator147
Flangeless Type Guides148
Valve Seats Inspection149
Valve Guide Reaming149
Valve Seat Refacing150
Inspect The Valve Seat Face150
Cylinder Head Assembly152
Initial Camshaft Lubrication153
Cylinder/Piston Contents155
Cylinder/Piston Service Information155
Cylinder/Piston Troubleshooting155
Cylinder/Piston System Description156
Piston157
Piston Ring157
Cylinder159
Wear Inspection159
Piston/Piston Ring Removal160
Piston/Piston Ring Inspection160
Piston Pin Inspection162
Small End Bearing Surface Inspection162
Piston/Piston Ring Installation162
Piston Installation163
Cylinder Installation164
Clutch Contents165
Clutch Service Information165
Clutch Troubleshooting165
Clutch System Descriptions166
Wet Multiplate Manual Clutch (Type A: Outer Push Type)166
Type B (Inner Push Type)167
Judder Spring Purpose167
Damper Spring Purpose167
One-Way Clutch System (Type C: Inner Push Type With Back Torque Limiter Mechanism)168
Operation169
Power Flow Diagram169
Type D (Crankshaft Mounted)170
Wet Multiplate Centrifugal Clutch171
Type A: Shift Clitch Combined171
Gear Shift Lifter172
Type B: Separated Shift Clutch173
Operation Principals173
Clutch Inspection174
Clutch Lifter Disassembly/Inspection174
Clutch Removal/Disassembly175
Lifter Plate Bearing179
Clutch Outer179
Clutch Outer Guide, Needle Bearing179
Clutch Disc180
Lutch Plate180
Lutch Center180
Lifter Push Rod180
Udder Spring, Spring Seat181
Mainshaft181
Clutch Spring181
One-Way Clutch182
Primary Drive Gear182
Clutch Reassembly183
Clutch Center Guide, Collar183
Crankshaft183
Clutch Lifter Reassembly190
Hydraulic Clutch System Service191
Fluid Replacement191
Clatch Master Cylinder Removal/Disassembly192
Clatch Master Cylinder Inspection193
Clatch Master Cylinder Assembly/Installation194
Clutch Slave Cylinder195
Clutch Slave Cylinder Assembly195
V-Matic Belt Drive System Service Information197
V-Matic Belt Drive System Description198
Drive Pulley Operation199
Driven Pulley/Centrifugal Dry Clutch200
Drive Belt Removal201
Drive Belt Inspection201
Drive Belt Installation201
Drive Pulley Removal202
Drive Pulley Disassembly203
Drive Pulley Inspection203
Wet Type203
Dry Type203
Drive Pulley Assembly/Installation204
Drive Pulley Face Installation205
Clutch/Driven Pulley Disassembly206
Clutch Outer Inspection207
Clutch Shoe Inspection207
Driven Pulley Spring Inspection207
Driven Pulley Inspection207
Clutch Shoe Replacement208
Driven Face Bearing Inspection208
Driven Face Bearing Replacement209
Clutch/Driven Pulley Assembly210
Transmission Contents213
Transmission Service Information213
Transmission Troubleshooting213
Transmission System Description214
Gearshift Mechanism214
Planetary Gear Type215
Shift Start216
Shift Finish216
Shift Return216
Constant Mesh Transmission217
Transmission Disassembly218
Transmission Inspection218
Gears Checking218
Bushings Cheking218
Transmission Assembly219
Shift Drum Checking219
Shift Fork Checking219
Shift Fork Shaft Checking219
Crankcase/Crankshaft Contents221
Crankcase/Crankshaft Service Information221
Crankcase/Crankshaft Troubleshooting221
Crankcase/Crankshaft System Descriptions222
Crankshaft Inspection223
Crankshaft Main Bearing223
Side Clearance223
Radial Clearance (Assembly-Type Crankshaft Only)223
Crankcaseicrankshaft224
Main Bearing Selection225
Crankcase/Crankshaft Removal226
Main Beraing Installation227
Connecting Rod Bearings228
Oil Clearance Inspection228
4-Stroke Big End Bearing Selection229
Connecting Rod Selection (Multi Cylinder Engine)230
Bearing Replacement230
Connecting Rod Installation230
Final Drive/Output Shaft Contents233
Final Drive/Output Shaft Service Information233
Final Drive/Output Shaft Troubleshooting233
Nal Driveioutput Shaft233
Final Drive/Output Shaft System Description234
Output Shaft Removal234
Output Shaft Inspection235
Backlash Inspection235
Gear Tooth Contact Pattern Check236
Final Drive Removal237
Output Installation237
Drive Shaft Removal237
Drive Shaft/Damper Disassembly238
Drive Shaft Inspection239
Damper Case Assembly239
Drive Shaft Installation240
Universal Joint Inspection241
Final Drive Inspection242
Ring Gear Removal/Shim Replacement243
Pinion Gear Removal/Shim Replacement247
Pinion Gear Installation249
Case Bearing Replacement250
Breather Hole Cleaning251
Gear Case Assembly/Installation251
Wheels/Tires Contents253
Wheels/Tires Service Information253
Wheels/Tires Troubleshooting253
Wheel Removal/Installation254
Front Wheel254
Axle Nut Type Removal254
Axle Nut Type Installation254
Single Holder Type Removal255
Single Holder Type Installation255
Double Holder Type Removal255
Double Holder Type Disassembly255
Pinch Bolt Type Removal256
Pinch Bolt Type Installation256
Double Holder Type Installation256
Wheelsitires256
Rear Wheel257
Chain Driven Type Removal257
Chain Driven Type Installation257
Shaft Driven Type Removal258
Shaft Driven Type Installation258
Unit Swing Type Removal259
Unit Swing Type Installation259
Pro-Arm Type (Center Lock Type) Removal260
Pro-Arm Type (Center Lock Type) Installation260
Axle Inspection261
Wheel Bearing Replacement262
Wheel Bearing Removal262
Wheel Bearing Installation262
Basic Tire Information263
Tubeless Tire263
Tire Code263
Tire Storage264
Tire Removal265
Tube-Type Tire Only266
Rim Valve Replacement (Tubeless Tire Only)267
Wheel Center Adjustment (Spoke Wheel Only)267
Tire Installation268
Tubed Tires Only269
Wheel Balancing271
Atv Wheel/Tire Removal/Installation271
Tire Removal (Usa Only)272
Tire Removal (Except Usa)273
Tire Repair274
Tire Assembly276
Brakes Contents277
Brakes Troubleshooting277
Brake System Descriptions278
Mechanical Drum Brake278
Single Leading Shoe Type (Or, Leading-Trailing Shoe Type)278
Dual Leading Shoe Type278
Hydraulic Brakes279
General Information For Service282
Eyelet-Type Line And Hose Joints283
Hose Joints Removal283
Hydraulic Disc Brakes284
Brake Fluid Replacement284
Hose Joints Installation284
Metal Brake Lines Removal284
Brake Pad Replacement286
Brake Pad Removal286
Brake Pad Intsllation287
Brake Caliper Removal288
Brake Caliper Disassembly288
Caliper Cylinder Inspection289
Caliper Piston Lnspection289
Brake Caliper Assembly289
Brake Disc Inspection290
Master Cylinder Disassembly290
Master Cylinder Inspection291
Master Cylinder Piston Lnspection291
Master Cylinder Assembly291
Mechanical Drum Brakes292
Mechanical Drum Brakes Inspection292
Brake Drum Id292
Mechanical Drum Brakes Disassembly293
Brake Lining Thickness293
U-Spring Type293
Coil Spring Type293
Mechanical Drum Brakes Assembly294
Front Suspension Contents297
Front Suspension Service Innformation297
Front Suspension Troubleshooting297
Front Suspension System Descriptions298
Basic Damper Operation298
Friction Damper Operating Principles298
Oil Damper Operating Principles299
Fork Removal301
Fork Disassembly301
Fork Inspection303
Fork Assembly304
Fork Installation306
Handlebar(S)307
One-Piece, Tubular Type307
Handlebars Installation307
Two-Piece, Clamp-On Type308
Handlebars Removal308
Handle Grip Installation310
Handlebar Weight Replacement310
Steering Stem Removal311
Steering Stem Inspection312
Race Replacement313
Top Race Removal313
Bottom Race Removal314
Top Race Installation314
Bottom Race Lnstallation314
Steering Stem Bottom Race Replacement314
Steering Stem Installation315
Loose-Ball Type315
Retainer-Type Ball Bearings316
Tapered Roller Bearing Type317
Steering Head Bearing Preload Measurement318
Measurement319
Rear Suspension Contents321
Rear Suspension Service Information321
Rear Suspension Troubleshooting321
Rear Suspension System Descriptions322
Conventional, Dual Spring/Damper Type322
Pro-Link. Progressive Link Type322
Pro-Arm Type323
Damper Design And Operation323
Rear Damper Springs325
Spring Preload Adjuster Designs325
Cam Type325
Threaded Type326
Remote Control Type326
Damping Adjuster326
Shock Absorber Removal327
Shock Absorber Installation327
Shock Absorber Disassembly327
Shock Absorber Compressor Use327
Lock Nut Removal328
Stop Ring Removal328
Spring Inspection328
Damper Unit Inspection328
Shock Absorber Disposal Procedure329
Compression Force329
Shock Absorber Assembly330
Hydraulic Press Use330
Joint Installation330
Swingarm331
Swingarm Inspection331
Pro-Link Suspension Linkage Removal331
Pro-Link Suspension Linkage Inspection331
Pro-Link Suspension Linkage Installation332
Frame/Body Panels Contents333
Frame/Body Panels Service Information333
Frame/Body Panels Troubleshooting333
Frameibody Panels333
Frame/Body Panels Description334
Back-Bone335
Diamond Frame335
Single Cradle Frame335
Double Cradle Frame335
Frame/Body Panels Inspection336
Sub Frames336
Electrical Fundamentals Contents337
Electrical Service Information337
Electrical Fundamentals338
Basic Electronic Knowledge342
Current Flow342
Alternating Current And Direct Current343
Voltage344
Resistance344
Ohm's Law345
Power345
Electrical Circuit345
Semiconductor346
Series Circuit346
Parallel Circuit346
Diode346
Thyristor (Scr)347
Transistor347
Thermistor348
Electrical Symbols349
Basic Electrical Diagnostic Methods350
Voltage Measurement350
How To Measure Voltage Using A Voltmeter350
Measuring Resistance352
Howt Omeasure Resistance Using An Ohmmeter352
Measuring Current354
How To Measure Current Using Ammeter354
Battery/Charging/Lighting System Contents355
Battery/Charging/Lighting System Service Information355
Battery/Charging/Lighting System Troubleshooting357
Battery Descriptions360
The Structure Of A Conventional Battery360
Mainteance-Free Battery362
Motorcycles Without Batteries363
Voltage Regulator363
Dc Voltage Unit363
Battery Removal/Installation364
Battery Testing/Charging365
Before Using The Tester365
Battery Testing365
Battery Charging367
Before Operating The Charger367
Charging System Description368
Alternator Types368
Permanent Magnet Type368
Alternator Function369
Brushless Excited Field Coil Type369
Excited Field Coil Type With Brushes369
Single Phase Output Type369
Regulator/Rectifier370
Triple Phase Output Type370
Type Of Regulator/Rectifier370
Single Phase, Half-Wave Rectifier371
Diode Rectification Method371
Internal Voltage Regulation Method371
Scr Switching Regulation/Ac Regulator Built In Type372
Ac Regulator Function373
Single Phase, Full-Wave Rectifier373
Ac Regulator374
Triple Phase Full-Wave Rectifier374
Triple Phase Full-Wave Rectifiers With Field Coils374
Charging System Inspection375
Charging Voltage Inspection375
Regulator/Rectifier Inspection376
Leak Test376
Headlight Voltage Inspection378
Regulator/Rectifier With Built-In Ac Regulator378
Resistor Inspection378
Ac Regulator Type379
Ac Regulator Inspection380
Alternator381
Charging (Charging/Lighting) Coil Inspection381
Stator Removal381
Stator Installation383
Rotor Installation383
Ignition Systems Connection385
Ignition Systems Service Information385
Ignition Systems Troubleshooting385
23. Ignition Systems385
Ignitions Systems Descriptions388
Operating Principles388
Principle Of Ignition Timing Advance389
Dc-Cdi391
Transostorized Ignition System391
Digitally Controlled Transistorized Ignition System392
Spark Plug393
Spark Plug Heat Range393
Description Of Peak Voltage Adaptor394
Construction And Usage394
Operating Precautions394
Spark Test395
Ignition Timing396
Ignition System Inspection (Peak Voltage Measurement Method)397
Ignition Coil Primary Voltage Inspection397
Exciter Coil399
Ignition Pulse Generator400
Ignition Coil401
Peak Voltage Adaptor Inspection401
Primary Coil Inspection401
Secondary Coil Ispection401
Side Stand Ignition Cut-Off Switch Description403
Operating Principle403
Typical Component Locations403
Component Function404
Side Stand Switch Operation405
Indicator Operation405
Starting Systen (Starter Motor) Operation406
Model With Manual Clutch406
Model With Centrifugal Clutch406
Ignition System Operation407
Cdi System Integrated With Side Stand Switch And/Or Neutral Switch407
Dc-Cdi Systems Integrated With Side Stand Switch And/Or Neutral Switch408
Transistorized Lgnition System Integrated With Side Stand Switch And Neutral Switch409
Electric Starter/Starter Clutch Contents411
Electric Starter/Starter Clutch Service Information411
Electric Starter/Starter Clutch Troubleshooting411
Electric Starteristarter Clutch412
Starter Motor Disassembly413
Starter Motor Inspection413
Starter Motor Assembly414
Starter Relay Switch416
Starter Relay Switch Inspection416
Starter Relay Voltage416
Operation Check417
Starter Relay Switch Ground Line417
Clutch Switch Diode Inspection418
Starter Clutch Inspection418
Disassemble The Housing418
Starter Pinion Inspection419
Light/Meters/Switches Contents421
Light/Meters/Switches Service Information421
Oil Pressure Warning Light422
Oil Level Indicator422
Oil Pressure Warning Light Inspection422
(4-Stroke Engine)422
Oil Level Indicator Inspection423
Timer Type Indicator Theory423
Fan Motor Switch424
Timer Type Indicator Inspection424
Coolant Temperature Gauge425
Fan Motor Switch Inspection425
Coolant Temperature Gauge Inspection426
Thermo Sensor Inspection426
Fuel Gauge427
Fuel Gauge Inspection427
Fuel Unit Inspection427
Low Fuel Indicator428
Low Fuel Indicator Inspection428
Fuel Pump Description429
Fuel Cut-Off Relay430
Fuel Pump Inspection430
Headlight Bulb431
Discharge Volume Inspection431
Switches Inspection432
Contact Base Replacement432
When The Contact Base Is Mounted With Screws432
Switches 25-1432
When The Contact Base Is Secured With Tabs433
Neutral Switch434
Neutral Switch Inspection434
Clutch Switch435
Clutch Switch Inspection435
Brake Light Switch435
Brake Light Switch Inspection435
Turn Signal Lights 25-1436
Horn437
Side Stand Switch Inspection438
Side Stand Switch Replacement438
Side Stand Indicator Description439
Side Stand Indicator Inspection439
Index441