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Honda VT600C Shadow VLX Service Manual

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  • Page 2 Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself...
  • Page 3 HYDRAULIC DISC BRAKE RECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL ABLE AT THE BATTERY /CHARGING SYSTEM TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., L TO. RESERVES THE RIGHT TO MAKE CHANGES TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI­...
  • Page 5: Service Rules

    1 . GEN E RAL INFORMATION G E N ERAL SAFETY 1 -8 1 - 1 TOOLS S ERVI C E R U LES 1 - 1 CABLE & HARNESS ROUTING 1 - 1 0 1 - 2 1 M O D E L I D EN T I F I CATI O N 1 -2 EMISSION CONTROL SYSTEMS SPECIFICATI O N S...
  • Page 6 GENERAL I N F O RMATION MODEL I DENTI FICATION VEHI CLE I DENTIFICATIO N N U M BE R (1 ) The vehicle identification number (VIN) is attached on the left side of the steering head . The frame serial number i s stamped o n the right side o f the The engine serial number is stamped on the right crank­...
  • Page 7: Specifications

    G E N ERAL I N FO R MATIO N SPECIFICATIONS ITEM S PECI F I CATIO N S DIME N S I O N S Overall length 2 , 3 1 0m m (90 . 9 in) Overall width '88 , '89 , ' 9 1 -'94: 7 60mm (29 .
  • Page 8 G E N ERAL I N FO RMATIO N ITEM S PECI F I CATI O N S I ntake valve O pens 1 0" ( BTDC) at 1 mm lift Closes 3 0" (AB DC) Exhaust valve O pens 3 0"...
  • Page 9 G E N ERAL I N FO RMAT IO N TORQU E VALU ES E N G I N E Thread dia . Torque ITEM Q'ty Remark (mm) m ( kg-m , ft-lb) Cylinder head cover bolt 1 0 ( 1 . 0 , 7 . 2) Special bolt Camshaft holder bolt 23 (2 .
  • Page 11 GEN ERAL I N FORMATION Torque specifications listed above are for specific tightening points. If a specification is not listed, follow the standard torque values below . STANDARD TORQUE VALUES TORQU E N·m (kg-m, ft-lbl TYPE TORQU E N•m ( kg-m, ft-lbl TYPE 5 mm bolt, nut 5 (0.50, 3.6)
  • Page 12 G E N ERAL I N FO RM ATIO N TOOLS S P E C I A L Refer to Description Tool number Alternate tool Tool number section 07 506 - 3000000 Oil pressure gauge 07 5 1 0 - 4220 1 00 Oil pressure gauge attachment Oil filter wrench 07HAA - PJ 7 0 1 00...
  • Page 13 G E N ERAL I N FO RMATIO N C O M M O N Refer to Description Tool number Alternate tool Tool number section Float level gauge 0740 1 - 00 1 0000 07 7 1 6 - 0020300 Lock nut wrench , 1 7 x 2 7 m m Equivalent 07724 - 00 1 0 1 00...
  • Page 14 G E N ERAL I N FORMATI O N CABLE & HARN ESS ROUTI N G Note the following when routing cables and wire harnesses: • A loose wire, harness or cable can be a safety hazard . After clamping, check each wire to be sure it is secure . •...
  • Page 17 GENERAL INFORMATION '88-'89 '9 1 : (2 ) HANDLEBAR SWITCH W I RE BANDS TUBE (12) WATER HOSE ( 11 ) ENGINE BREATHER T UBE I G N ITI O N P U LS E GENERATOR CLUTCH CABLE W I RE (1 ) HANDLEBA R SWITCH '92-'93: WI RE BANDS...
  • Page 21 GENERAL INFORMATION T U RN SIGNAL RELAY (2) FUEL FILTER (9) COOLANT RESERVE (6) BATTERY TANK OVERFLOW TUBE SUB-FUSE BOX ( 8 ) REAR BRAKE LIGHT SWITCH (23) S I DE STAND T U RN SIGNAL RELAY 2P G REEN CONNEC 1 1 ) FUEL PU M P •REGULATOR/...
  • Page 22 GENERAL INFORMATION ( 1 ) ( 2 ) ( 9 1 GROUND STATOR COIL CLAMPS PO INT GROM METS (7) THERMOSTATI C SWITCH W I RE ( 6 1 RIGHT ( 5 ) I G NITION P ULSE CRANKCASE GENERATOR ( 1 1 I BRAKE/TA ILLIGHT CASE...
  • Page 25: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co . , Ltd . utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro­ carbons.
  • Page 26 G E N ERA L I N FORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) This model complies with California Air R eso u rces Board evaporative emissio n requirements. Fuel vapor from the fuel tan k and carbureto r is d irected into the evaporative emission canister where it is adsorbed a n d sto red while the engine is stopped.
  • Page 27 G E N ERAL I N F O RMATI O N VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) The Vacuu m Hose Routing Diagram label is on the inside of the left side cover. Route the vacuum hoses as shown on this label.
  • Page 29 2. LU B R I CATI O N After '89: ROCK E R A R M CAMSH A FT ( 12) PISTO N (11) O I L JET (10) (9) C R A N KSH A FT MA I NSH A FT ( 2) ( 8) CO U NT E R S H A F T �...
  • Page 30 L U BRICATI O N S ERVIC E I N FO R M ATIO N O I L P R ESS U R E C H ECK 2- 6 2- 3 TROUBLESHO OT I N G OIL P U MP E N G I N E O I L LEVEL CO NTROL CABLE L U BR I CATI O N 2- 1 2...
  • Page 31 L U BRICATI O N T O O LS Special Oil filter wrench 07HAA - PJ 70 1 00 Oil pressure gauge 07 506 - 3000000 or equivalent commercially available in U . S . A . Oil pressure gauge attachment 0 7 5 1 0- 4220 1 00 Snap ring pliers 079 1 4 - 323000 1 - or equivalent commercially available in U .
  • Page 32 2.25 lit (2.36 US qt, 1 .9 8 Imp qt) at oil filter and oil change 2.1 lit (2.21 US qt, 1 . 8 5 Imp qtl after draining GN4 4-stroke oil or equivalent RECOMMENDED OIL: Honda API service classification: SF or SG VISCOSITY: SAE 1 0W - 40 Install the oil filler cap/dipstick.
  • Page 33 LUB R I CATION O I L FI LTER CHANGE Drain the engine o i l ( page 2-4) . CAUTION Do not replace the oil filter when the exhaust system is hot. • Remove the oil filter with a filter wrench . TOOL: Oil filter wrench 07HAA - PJ70 1 00...
  • Page 34 LU BRICATION � O I L PUM P ( 1 ) PRESSUR E RELIEF VALVE COVER- PRESS U R E R E L I E F VALVE R E M OV A L Separate the crankcase (Section 1 1 ) . Remove the bolt and pressure relief valve cover.
  • Page 35 L UB R I CATIO N O I L STRA I N ER Remove the oil strainer and oil pipe from the oil pump. Check the 0-rings and oil seal for fatigue or damage. O I L SEAL (21 OIL STRA I N E R Clean the oil strainer and oil pipe w ith non-flammable or high flash point solvent.
  • Page 36 LUBRIC ATI O N Remove the oil pump shaft from the oil pump and measure the pump end clearance. SERVICE LIMIT: 0.1 0 (0.004 in) Temporarily install the shaft i n the pump body. Measure the inner rotor tip clearance. SERVICE LIMIT: 0.20 (0.008 in) Replace the oil pump, if necessary as a n assembly.
  • Page 37 LUB R I CATI O N After '93: (4) P R ESS U R E R ELI EF VALVE B O DY ( 1 ) PU M P B O DY ( 2 ) 0 UT E R R OTO R (3 ) 1 N N E R R OTO R (8)WASHER ( 9 ) S P R I N G...
  • Page 38 LABRICATION After '93: ( 1 ) O I L P U M P B O DY I nstall the dowel pins on the p u m p cover,then i nstall the pump body. ( 3 ) 0 1 L P U M P COVER ( 1 ) COVER BOLTS Tighten the cover bolts securely .
  • Page 39 L UB R I CATI O N O I L PU M P I N STALLAT I O N I nstal l the dowel pins a n d n e w 0-rings. I nstall the oil pump as an assembly . ( 2 ) DOWEL PIN I nstall the pressure relief valve in the oil pump.
  • Page 40 LUBRICATI O N CONTROL CABLE LUBRICATION Periodically disconnect the throttle and choke cable a t their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil . LUBRICATION POI NTS Use gen ral purpose grease when not otherwise specified here .
  • Page 41 3. MAI NTENANCE S E R V I C E I N FORMAT I O N 3- 1 C Y LI N D E R CO MP RESS IO N 3 - 1 2 M A I NTENANC E S C H E D U L E '88;...
  • Page 42 MAINTENAN CE �C H A S S I S� Rear brake free play 20 - 30 mm (3/4 - 1 -3/1 6 in) Brake pedal height 43 mm ( 1 . 7 in) C l utch lever free play 1 0 - 20 mm ( 3/8 - 3/4 in) D rive chain slack 20 - 30 mm ( 3/4 - 1 -3/ 1 6 in) Tires...
  • Page 43 ** STE E R I N G HEAD BEA R I N G S 3 -2 1 * Should be serviced by a n authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified .
  • Page 44 3-2 1 STEERING HEAD BEARI N G * SHOU L D BE SERVICED BY AN AUTHORIZED HONDA DEALER, U N LESS THE OWN ER HAS PROPER TOOLS A N D SER­ VICE DATA AND IS M ECHANICALLY QUALI FIED. ** I N THE I NTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED O N LY BY AN AUTHORIZED HONDA DEALE R .
  • Page 45 • • • i nformatio n and tools, Consu lt their a uth orized Honda dealer. F R EQU E N CY O D O M ET E R R EAD I N G ( N OTE 1 ) R E F E R TO 1 , 000mi 0 .
  • Page 46 MAI NTENAN C E FUEL LI N E Remove the seat . Check the fuel li nes for deterioration, damage or leakage . Replace the fuel l ines if necessary . F U E L F I LTER Pul l the fuel filter out, clip the inlet line closed and remove the filter.
  • Page 47 M A I NTENANC E CARBU RETOR CHOKE NOTE C hoke knob operating friction can be adjusted by turning • the adjuster. Check for smooth operation of the choke knob. Lubricate the choke cable and/or adjust the choke knob operat­ ing friction if operation is not smooth.
  • Page 48: Spark Plugs

    MAINTENANCE CRAN KCASE BREATHE R The crankcase breather drain tube i s behind the left frame pipe and front cylinder head . Pull the drain tube out of the frame clamp. Remove the drain plug from the tube to empty any deposits . Reinstal l the drain plug.
  • Page 49 MAINTENAN CE Remove the crankshaft and timing hole caps. Remove the valve adjusting covers from the cylinder head cov­ ers. NOTE Adjust the front cylinder valves first. • F R O N T C Y L I N D E R H EA D Rotate the flywheel counterclockwise to align the "...
  • Page 50 MAINTENANCE R E A R C Y L I N D E R H EA D Rotate the flywheel counterclockwise to align the " RT" mark with the index notch on the left crankcase cover. Make sure the piston is at TDC on the compression stroke. Check the 0-rings of the valve adjusting covers ( I N/EX) for damage and replace if necessary .
  • Page 51: Radiator Coolant

    M A I NTENANC E Check that the difference in vacuum readings is 40 mm ( 1 . 6 or less. i n ) Hg NOTE The rea r cylinder carburetor is the base carburetor . • If necessary, synchronize t o t h e specification b y turning the synchronization adjusting screw.
  • Page 52 MAI NTENAN C E COOLI NG SYSTEM Remove the radiator shroud and check the radiator air pas­ sages for clogging or damage . llllf Straighten bent fins or collapsed core tubes with a small flat blade screwdriver as shown and remove insects, mud or any obstructions with compressed air or low pressure water.
  • Page 53: Drive Chain

    MAINTENAN CE EVAPORATIVE EM ISSION CONTROL SYSTEM (California model only) Check the hoses between the fuel tan k,evaporative emission canister,evaporative emissio n purge control valve(EVAP PU R G E CONTRO L VALVE),evaporative emission carburetor air vent control valve(EVAP CAV C O NTRO L VALVE),and carbu retor for deterioration,damage o r loose connections.
  • Page 54 MAINTENANCE Recheck chain slack and free wheel rotation . Lubricate the d rive chain with Pro Honda Chain Lube o r equiv­ alent chain l ubrica nt designed specifically for use on 0-ring chains . Check the chain wear label. If the red zone on the label aligns with the arrow mark of the chain adjuster after the chain has been adjusted , the chain must be replaced .
  • Page 55 MAINTENANCE ( 2 ) 0 - R I N G S Assemble the new master link, 0-rings and plate . • CAUTION Insert the master link from the inside of the drive chain and in­ stall the plate with the identification mark facing the outside. Make sure that the master link pins are installed properly.
  • Page 56: Brake System

    MAINTENAN C E BRAKE SHOE/ PAD WEAR BRAKE PAD W E A R '88 , '89 , '9 1 -93 : Check the brake pads for wear by looking through the slot indi­ cated by the arrow cast on the caliper assembly. Replace the brake pads if the wear grooves in the pads are visi­...
  • Page 57 MAINTENANCE To Adjust : Loosen the stopper bolt lock nut and turn the stopper bolt . Retighten the lock nut . NOTE After a djusting the brake pedal height, check the rear brake • light switch and brake pedal free play and adjust if neces­ sary.
  • Page 58: Clutch System

    MAINTENANCE HEADLIGHT AI M ( 1 ) HORIZONTAL ADJUSTING SCREW Adjust vertically by turning the vertical adjustment screw . Adjust horizontally by turning the horizontal adjusting screw . NOTE • Adjust the headlight beam as specified by local laws and regulations.
  • Page 59 MAI NTENANCE SI DE STAND Check the spring for damage o r loss of tension. Check the side stand assembly for freedom of movement. Lubricate the pivot bolt and the side stand pivot area if neces­ sary. Tighten the pivot bolt and nut. TORQUE: BOLT: 10 N·m 1 1 .
  • Page 60 MAI NTENAN C E N UTS, BOLTS, FASTEN ERS Tighten the bolts, nuts and fasteners at the i ntervals shown in the Maintenance Schedule (page 3-3 ) . Check that a l l chassis nuts and bolts are tightened t o their cor­ rect torque values ( page 1 -5 , 6 and 7 ) .
  • Page 62 FUEL SYSTEM 1 9 N · m ( 1 . 9 kg-m, 1 3 . 7 ft-lbl...
  • Page 63 FU EL SYSTEM S ERV I C E I N FO RMATIO N 4- 1 4- 1 5 CARBU R ETO R I NS TALLATIO N T RO U BLESHOO T I N G PILO T S C R EW ADJ USTMENT 4- 1 5 F U EL TAN K H I G H ALTIT U D E ADJ USTMENT...
  • Page 64 F U E L SYSTEM TO R Q U E VA LU E Fuel tank mounting bolt 1 9 N•m ( 1 . 9 kg-m , 1 3 . 7 ft-lb) TOOLS Special Vacuum/Pressure pump A937X - 04 1 - XXXXX or Pressure pump ST - AH- 2 5 5 - M C 7 ( U A .
  • Page 65 F U EL SYSTEM FUEL TAN K ( 2 ) FUEL TAN K MOUNTING BOLT R E M O V A L • Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
  • Page 66 FUEL S YSTEM AI R C LEA N ER HOUSING ( 1 ) A I R CLEAN ER H O U S I N MOUNTING BOLTS R E M O V A L Remove the fuel tank mounting, and lift the tank and remove the air cleaner housing mounting bolts .
  • Page 67 F U E L SYSTEM Wash the element in non-flammable or high flash point sol­ vent, squeeze out the solvent thoroughly, and allow the ele­ ment to dry. Soak the element in gear oil (SAE #80 - 90) and squeeze out ¢...
  • Page 68: Carburetor Removal

    FUEL SYSTEM CARBURETOR REMOVAL • Gasoline extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the work area or where gasoline is stored. Loosen the drain screws and drain the fuel into a container.
  • Page 69 FUEL SYSTEM (2) SPRING D IAPHRAG M/PISTON Remove the spring, and diaphragm/vacumm piston. Inspect the vacuum piston for wear, nicks, scratches or other damage. Make sure the piston moves up and down freely in the cham­ ber. Push the needle jet holder in and turn it in 90 degrees counter­ clockwise.
  • Page 70 F U E L SYSTEM Remove the float pin, float and float valves. Check the float valve and valve seat for scratches, clogging or damage. Inspect the operation of the float valve. Remove the main jet, needle jet holder, slow jet and valve seat/ filter.
  • Page 71 FUEL SYSTEM Center punch the pilot screw plug to center the drill point. Drill throug h the plug with a in) drill bit. Attach a ( 5/32 drill stop to the bit i n ) from the end to prevent ( 1/8 drilling into the pilot screw .
  • Page 72 FUEL SYSTEM 0-RING Visually check the following : - diaphragm for deterioration, pin hole or other damage. - spring for deterioration or other damage. - diaphragm needle for excessive wear at the tip or other damage. (3) DIAPHRA G M - orifice of air vent for clogging.
  • Page 73 F U E L SYSTEM P I LOT S C R EW · I nstall the pilot screws and return them to their original posi­ tion as noted during remova l . Perform pilot screw adjustment if n e w pilot screws are in­ stalled .
  • Page 74 FUEL SYSTEM I nstall the 0-ring on the float chamber groove. I nstall the float chamber and tighten the screws securely . NOTE I nstall the fuel tube clamp. • VAC U U M CHAM B E R I nstall t h e washer, jet needle, spring and needle holder t o the vacuum piston.
  • Page 75 FUEL SYSTEM Install the right choke valve and choke knob. CHOKE KNOB ( 2 1 FUEL TUBE ;:, p:s ..( 1 I Install the fuel and air tubes as shown. CARBU RETOR SEPARATIO N / ASSEM BLY SEPARATION Loosen the synchronization adjusting screw.
  • Page 76 FUEL SYSTEM THRUST ASSEMBLY SPRING loosen the synchronization adjusting screw until there is no spring tension. Install the thrust spring between the throttle links. Secure the carburetors together with the two screws. SYN C H RON IZATION Install the synchronization spring and synchronization adjust­ 1 2 1 ADJUSTING SCREW ing screw.
  • Page 77 FUEL SYSTEM CARB U RETOR I NSTALLATION I nstall t h e carburetors onto the cylinder heads a n d tighten the insulator bands securely. I nstal l the following parts - air cleaner chamber - air cleaner housing - fuel tank - throttle cables Adjust as follows: - pilot screw ( page 4- 1 51...
  • Page 78 Do not attach the label to any part that can be easily re­ • moved from the vehicle. ALmuDE PERFORMANCE ADJUSTMENT INSTRUCTIONS ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER. Sustained operation at an altitude lower than 1, 500 m • f eet) with the carburetors ad justed f or high alti­...
  • Page 79 F U E L SYSTEM Disconnect the EVAP P U R G E CONTROL VALVE hoses from ( 1 ) EVAPO RATIVE E M I S S I O N their connections and rem ove the EVAP P U R G E CONTRO L P U R G E CONT R O L VALVE VALVE from its mou nt.
  • Page 80 F U EL SYSTEM Connect a vac u u m pump to the No. 1 hose that goes to the (21 TO OPEN A I R rig ht carbu retor body. ( 1 1 TO A I R J O I NT PIPE ( 3 ) EVAPO RATIVE E M I SS I O N Apply t h e specified vacuum t o t h e EVAP CAV CONTR O L N o .
  • Page 81 M EMO...
  • Page 82 COO L I N G SYSTEM...
  • Page 83 5. COOLI NG SYSTEM 5 - 1 S ERV ICE I N FO RMAT I O N T HE RMOSTAT T R O U BL ES HOO T I N G 5 - 1 RADIATOR/CO O LING FAN S Y S T E M TESTING 5 -2 WATER P U M P C O O LA N T REPLAC E M E N T...
  • Page 84 COO LING SYSTEM SYSTEM TESTI NG C O O LANT M I XT U R E Remove the fuel tank (page 4-3) . Remove the steering covers by removing the bolt. Remove the radiator cap. • Be sure the engine is cool before removing the cap or you may be severely scalded.
  • Page 85 COOLING SYSTEM COOLANT R E P LACE M ENT (2) REAR CYLINDER DRAIN BOLT • The engine must be cool before replacing the coolant or severe scalding may result. Remove the radiator cap ( page 5-2 ) . Drain the coolant from the system by removing the drain bolt on the water pump cover.
  • Page 86 COOLI N G SYSTEM Remove the thermostat from the housing . I N S P E CT I O N ( 1 ) THERMOSTAT I nspect t h e thermostat visually for damage . Suspend the thermostat in heated water to check its opera­ tion.
  • Page 87 COOLING SYSTEM Tighten the thermostat housing cover mounting bolts . NOTE Be sure to secure the thermostat ground wire with the cover mounting bolt shown. I nstall a new 0-ring on the radiator filler, and connect the u pper radiator hose to the radiator. I nstall the radiator filler onto the thermostat housing.
  • Page 88 COOLI N G SYSTE M U nhock the radiator mounts from the grommets from in frame. Unclamp the upper radiator hose and disconnect the hose from the radiator. ( 1 ) G R O U N D D I SAS S E M B LY TERM INAL Disconnect the thermostatic switch wire connector from the switch and remove the wire from the clamp.
  • Page 89 COOLING SYSTEM A S S EM B LY Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc . , are clogging the radiator, wash them off with low pressure water.
  • Page 90 COOLING SYSTEM I N S P E CTI O N ( 1 ) 0-RING ( 2 ) WATER P U M P ASSEM BLY Check t h e water pump f o r mechanical seal leakage a n d bear­ ing deterioration.
  • Page 91 COOLI N G SYSTEM COOLANT / R ESERVE TANK G R O M M ET ( 1 I ( 2 1 REMOVAL/INSTALLATION Raise and support the motorcycle rear frame using a hoist or jack u nder the engine. Remove the evaporative emission canister(California model only) .
  • Page 92 EN G I N E REM OVAL/INSTALLAT I O N 2 5 N•m, ( 2 . 5 kg-m, 1 8 ft-lb) 2 7 N•m, ( 2 . 7 kg-m, 20 ft-lb)
  • Page 93 ENG INE REMOVAL/ I NSTALLATION 6 - 5 S ERVI C E I N F O RMAT I O N EN G I N E I N STALLATION E N G I N E R E M OVAL 5 5 N • m ( 5 . 5 kg-m, 40 ft-lb) N·m kg-m,...
  • Page 94 E N G I N E REM OVAL/ I N STALLATION SERVICE I N FO RMATION G E N E RAL • Support the motorcycle using a hoist, a floor jack or other adjustable support. • • • The following parts can be serviced with the engine i nstalled in the frame: •...
  • Page 95 E N G I N E REM OVAL/ I N STALLATION ENG I N E REMOVAL Support the motorcycle using a hoist or a jack. • CAUTION Do not jack up the engine at the oil filter. Drain the engine oil (page 2-4) and the radiator coolant (page 5-3 ) .
  • Page 96 EN G I N E REMOVAL/ I N STALLATIO N Disco n ncet the ignition pulse generator wire connector(4P WH ITE) . Remove t h e lower radiator hose ( radiator-to-water pump) . Disconnect the water hoses (thermostat housing-to-cylinder heads) from the cylinder heads ( page 9-3 ) . Place a floor jack o r other adjustable support under the engi ne.
  • Page 97 E N G I N E R E MO VAL/IN STALLATIO N ENG I N E I N STALLATION Engine insta l l ation is essentially the reverse order o f removal . Use a floor jack or other adjustable support t o carefu lly manuever the engine into place.
  • Page 99 CLUTCH/G EARSH I FT LI N KAG E S ER V I C E I N FO RMAT I O N 7 - 1 7- 1 1 P RI MARY DRIVE G EAR T R O U B L ESHOOTI N G CLUTCH I N STALLATION 7- 1 2 R I G H T C RANKCASE CO V ER R E MOVAL...
  • Page 100 CLUTCH/GEARS H I FT LI N KAGE TROU BLESHOOTI NG Faulty clutch operation can usually b e corrected b y adjusting the clutch lever free play . • Clutch slips when accelerating • No free play • Discs worn Springs weak •...
  • Page 101 CLUTCH/GEARS H I FT L I N KAGE R IGHT CRAN KCASE COVER REMOVAL '88, '89: Drain the engine oil ( page 2 - 4 ) . Remove the clutch cable holder and disconnect the clutch cable from the clutch lifter arm . Loosen the oil pipe holder and remove the oil pipe bolt and seal­...
  • Page 104 CLUTCH/GEA R S H I FT L I N KAGE Remove the drive sprocket and clutch outer guide from the mainshaft. I N SPECT I O N BEARI N G ( 1 1 Check the lifter plate bearing for damage. Turn the bearing inner race with your finger.
  • Page 105 CLUTCH/GEARS H I FT L I N KAGE Check the plate warpage on a su rface plate using a thickness gauge. SERVICE LIMIT: 0 . 30 mm (0.0 1 2 CLUTCH 1 1 1 Check the cl utch center for nicks or indentations made by the C ENTER clutch plates.
  • Page 106 CLUTCH/GEARS H I FT LI N KAGE Check the oil pump drive sprocket for damage. Measure I . D of the d rive sprocket and the O . D . of the outer guide. SERVICE LIMITS: 1 . 0 . Oil pump drive sprocket 32.
  • Page 107 CLUTCH/GEARS H I FT L I N KAGE Remove the following : - gearshift spindle - drum stopper arm bolt, stopper arm, collar and spring - drum stopper plate bolt and stopper plate/drum I N S PECTI O N Check the gearshift spindle for bending o r damage. Check the return spring for fatigue or damage.
  • Page 108 CLUTCH/GEARS H I FT L I N KA G E I N STA L LATI O N I nstall the collar, spring, stopper arm, washer a n d stopper arm bolt and tighten the bolt. I nstall the dowel pins into the holes of the gearshift dru m . Lift up t h e d r u m stopper a r m and install t h e d r u m stopper plate.
  • Page 109 C LUTCH/G EARS H I FT L I N KA G E I nstal l the gearshift pedal mounting bolt and tighten the bolt securely. I nstal l the d rive sprocket cover (page 1 3- 1 7 ) . ( 1 ) 1 FT PEDAL MOUNTING BOLT...
  • Page 110 CLUTCH/GEARS H I FT LI N KAGE Temporarily install the clutch outer and install the gear holder as shown . TOOL: 07724 - 00 1 0 1 00 Gear holder Install the washer and bolt and tighten the bolt. TORQUE: 90 N • m (9.0 kg-m, 65 ft-lbl Remove the gear holder and clutch outer.
  • Page 111 CLUTCH/G EARS H I FT L I N KAGE Align the grooves in the clutch outer with the bosses on the oil pump drive sprocket while turning the sprocket with the chain and pushing the clutch outer onto the shaft. Install the thrust washer onto the m a i nshaft.
  • Page 112 CLUTCH/G EARS H I FT LI N KA G E Hold the clutch center with the clutch center holder, and tight­ en the lock nut to the specified torque . TO RQU E : 1 30 N·m ( 1 3.0 kg-m , 94 ft-l b) TOOLS : Clutch center holder 07923 - K E 1 0000 or...
  • Page 113 CLUTCH/G EARS H I FT LI N KA G E Install the dowel pins and new gasket. '88, '89 : Tighten t h e right c r a n kcase cover mounting bolts in a crisscross pattern in or 3 steps and install the clutch cable holder and oil pipe holder at the same time.
  • Page 114 ALTERNATO R/STARTER CLUTCH...
  • Page 115 ALTERNATOR/STARTE R CLUTCH 8- 5 S E R V I C E I N FORMATI O N 8- 1 F LYW H E E L I N STALLATION L E F T C R A N KCASE C O V E R R E M OVAL LEFT CRANKCASE COVER I N STALLAT I O N F LYW H E E L REMOVAL...
  • Page 116 ALTE RNATO R/S TARTER CLUTCH LEFT CRAN KCASE COVE R REMOVAL Remove the left side cover and disconnect the alternator wire 3P connector (WHITE ) . Remove the drive sprocket cover (page 1 3- 1 4) . Place a container under the left crankcase cover to catch the engine oil .
  • Page 117 ALTERNATO R/STARTER CLUTCH FLYWH EEL REMOVAL Remove the starter d rive and i d l e/reduction gears by removing the s h afts . H o l d the flywheel with the f l y w h e e l h o l d e r and remove the fly­ wheel bolt a n d w a s h e r .
  • Page 118: Starter Clutch

    ALTERNATOR/STARTER CLUTCH STARTER CLUTCH STARTER DRIVEN GEAR D I SA S S E M B LY Reinstall the starter driven gear i nto the flywheel . I nspect the starter clutch by turning the starter driven gear. The gear should turn counterclockwise freely and should not turn clockwise: if it turns i ncorrectly, replace the starter clutch.
  • Page 119 ALTERNATOR/STARTER CLUTCH ASS E M B LY Install the oneway clutch i nto the clutch outer with the flange side facing inside. (3) ON EWA Y CLUTCH Hold the flywheel with the flywheel holder. Apply locking agent to the trox bolt threads and tighten the bolts . TORQUE : 30 N ·...
  • Page 120 ALTERNATO R/STARTER CLUTCH Instal l the flywheel, aligning the woodruff key on the crank­ shaft with the flywheel keyway. Hold the flywheel with the flywheel holder, install the washer and flywheel bolt and tighten the bolt. TORQUE: 1 30 N·m ( 1 3 . 0 kg-m, 94 ft-lbl TOOL: Flywheel holder 07725-0040000...
  • Page 121 M E MO...
  • Page 122 CYLI NDER H EAD/VALV E 1 . 0 7 . 2 N · m ( k g - m , ft- l b l N·m kg-m, ( 2 . 3 1 7 ft- l b) '89 : After � '� � ��...
  • Page 123 CYLI N DE R H EAD/VALVE SERVICE I N FORMATI O N 9 - 1 VALVE SEAT I N S PECT I O N / REFAC I N G 9 - 1 2 TROUBLES H OOTI N G 9 - 2 CYLIN DER H EAD ASSEM BLY 9 - 1 5 9 - 1 6...
  • Page 124 CYL I N D E R H EAD/VALVE TORQU E VALU E S 1 0 N · m ( 1 .0 kg-m, 7 . 2 ft-lb) Cylinder head cover bolt 23 N · m (2.3 kg-m, 1 7 ft-lb) Camshaft holder 8 mm bolt 8 mm nut 23 N ·...
  • Page 125 CYL I N D E R H EAD/VALVE CYLI N DE R H EAD COVE R REMOVAL Remove the following parts: - steering covers - fuel tank ( page 4-3 ) - air cleaner housing (page 4-4) - carburetors (page 4-6 ) Drain t h e coolant (page 5-3 ) .
  • Page 126 C Y L I N D E R H EA D IV ALVE Remove the cylinder head cover bolts, washers and rubber. R U B B E R ( 3 ) Alig n the wire harness with the valve adjusting hole, then re­ ( 1 ) R EA R CYLI N D E R H EA D COVER move the rear cylinder head cover forward .
  • Page 127 CYLI N D E R H EAD IV ALVE Pull wedge A straight up while holding wedge down. Secure wedge A with a m m pin as shown. Remove the camshaft holder on the cam sprocket side by re­ moving the two mounting bolts . Remove the cam sprocket bolt, rotate the crankshaft counter­...
  • Page 129 CYLI N D E R H EAD/VALVE I nstall the camshaft holders and tighten the mounting bolts in '89 : a crisscross pattern i n or 3 steps . NOTE Do not rotate the camshaft when using plastigauge. • TORQUE: 6 mm flange bolt: 1 2 N·m ( 1 .
  • Page 130 CYLI N D E R H EAD/VALVE Remove the rocker arms and wave washers from the shafts . WAVE WASHERS ( 2 ) Inspect the rocker arm shafts and rocker arms for wear or damage. Check the rocker arms for clogged oil holes. Measure the O .
  • Page 131 CYLI N D ER H EAD/VALVE Remove the upper radiator hose and the radiator mounting bolts (page 5-5 ) . Release the radiator from t h e frame grommets a n d suspend it with a piece of rope or something suitable. Remove the front cylinder head .
  • Page 133 CYLI N D ER H EAD/VALVE If the stem-to-guide clearance exceeds the service limits, de­ termine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace any guides as necessary and ream to fit. TOOLS : Valve guide reamer I N :...
  • Page 134 CYLI NDER H EAD/VALVE VALVE GUIDE PROJECTION HEIGHT: IN: 1 9.4- 1 9 .6 mm (0.76 - 0 . 77 in) EX: 1 7 . 9 - 1 8 . 1 mm (0.70 - 0 . 7 1 in) Ream the new valve guides after installation . NOTE Use cutting oil on the reamer during this operation .
  • Page 136 CYLI N DER H EAD IV ALVE Install a 45 degree finish cutter and cut the seat to the proper width . Make sure that all pitting and irregularities are removed . Refinish if necessary . Apply a thin coating of Prussia n Blue to the valve seat. Press the valve through the valve guide and onto the seat to make a ( 1 ) CONTACT TOO H I G H clear pattern.
  • Page 137 CYLINDER H EAD/VALVE CYLI N DE R H EAD ASSEM BLY ( 1 ) VALVE (4) RETAINER I nstall the valve spring seats and new stem seals. Lubricate each valve stem with m olybdenum disulfide oil and SPRING i nsert the valve i nto the valve guide. Turn the valve slowly while i nserting to avoid damaging the seals .
  • Page 138 CYLI N D E R H EAD/VALVE Tap the valve stems gently with a soft hammer to firmly seat the cotters . NOTE Support the cylinder head above the work bench surface to • prevent possible valve damage. Apply locking agent to the threads of the sealing bolts and tighten them, if removed.
  • Page 139 CYLI N D E R H EA D IV ALVE I nstall the carburetor insulator o n the cylinder head, aligning the boss on the cylinder head with the slot in the insulator. ( 1 ) BOSS SLOT ( 2 ) After '9 1 (Cal ifornia model only) : I nstall the insulator bands align i n g the pins o n the insulator bands with the slots o n the insulato rs as shown .
  • Page 140 CYLI N D ER H EAD/VALVE I nstal l the following : - cam chain tensioner with washers and bolts . TORQUE: 1 0 N·m ( 1 . 0 kg-m , 7 . 2 ft-lbl - camshaft ( page 9- 1 8 ) - camshaft holders ( page 9 - 1 9 ) - cylinder head cover (page...
  • Page 141 CYLI N D ER H EAD IV ALVE Align the " FT" mark on the flywheel with the index mark on the timing hol e . N OTE If the front and rear cylinder c a mshafts were removed, do •...
  • Page 142 CYLI NDER H EAD/VALVE '88 , '89: I nstal l the dowel pins into the cylinder head . I nstal l the holders, oil plate, 8 mm bolts, 8 m m nut and 6 mm bolts . After '89: I nsta l l the dowel p ins into the cy linder head . 1 11sta l l the ho lders, o i l pipe 8 m m bo lts, 8 m m nuts and 6 mm bo lts.
  • Page 145 M E M O...
  • Page 146 CYLI N D ER/P IS TO N 1 0-0...
  • Page 147 CYLI N DE R/ P I STO N P IS TO N R I N G I NS TALLATIO N 1 0- 5 S E RVIC E I N FO R M ATIO N 1 0- 1 1 0- 5 TRO U BLES HOO T I N G 1 0- 1 PISTO N I NS TALLATIO N...
  • Page 148 CYLI N D E R/PI STO N CYLI N DER R E M OVAL NOTE To service the rear cylinder/piston , first remove the engine • and then proceed with the common removal steps below. Remove the following : - cylinder head cover (page 9 - 3 ) - cylinder head (page 9-8) - gaskets, dowel pins, and cam chain guides.
  • Page 149 CYLI N D E R/PISTON Inspect the cylinders for transverse warpage across the top. NOTE Measure warpage using a straight edge and feeler gauge as • shown . SERVICE LIMIT: 0 . 1 0 mm (0.004 in) P I STON R E M O V A L Place a shop towel i nto the crankcase and remove the piston pin clips.
  • Page 150 CYLI N D ER/PISTON I nsert the old piston ring into the proper ring groove and clean the groove by rol l i n g the ring around the pistons circumference . Inspect the piston for cracks or other damage. Measure the piston O .
  • Page 151 CYLI N D E R/P ISTON Measure the I . D . of the connectin g rod small end . SERVICE LIMIT: 1 8 .07 mm (0. 7 1 1 in) Calculate the piston pin-to-con n e cting rod clearance . SERVICE LIMIT: 0.060 mm ( 0 .
  • Page 152 CYLI N D E R/PISTON CYLI N DER I NSTALLATION Clean the cylinder gasket surface being careful not t o drop any gasket material into the crankcase . I nstall the dowel pins and new gasket. Coat the cylinders piston rings/grooves and piston with oil . Install the piston assembly into the cylinder from the top of the crankcase while compressing the piston rings with your fin­...
  • Page 153 CYLI N D ER/PISTON I nstal l a new 0-ring into the connecting pipe and install and tighten the connecting pipe mounting bolts, if the connecting pipe was removed . If only the water hose was removed , connect the hose with clamp.
  • Page 154 CRAN KSHAFT/TRANSM ISSION 20 - m 2 5 ft-lb) 2 2 - 3 6ft- 0-5 Okg - m , 30-50N · m (3 .
  • Page 155 1 1 . CRAN KSHAFT/TRANSM I SSION S E RVIC E I N FO R MATIO N 1 1 - 1 C RA N KC A S E 1 1 - 1 3 T RO U BLESHOOT I N G 1 1 -3 TRAN S M I S S IO N ASS EMBLY 1 1 - 1 7...
  • Page 156 C RA N KS HAFT/TRAN S M I S S I O N S P E C I F I CATI O N S mm (in) S E RV I C E LI M IT ITEM STAN DAR D Con nectin g rod big end side clearance 0 .
  • Page 157 CRA N K S HA FT/TRANSMISS I O N TROU BLESHOOTI N G • Excessive noise Crankshaft - Worn main bearing • - Worn crankpin bearing connecting rod - Worn rod small end - Worn crankpin bearing • Hard to shift •...
  • Page 158 CRANKS HAFT/TRANSMISSION CRAN KCASE SEPARATION Remove the engine from the frame ( Sectio n 6). Refer to the service i nformation ( page 1 1 - 1 ) for the parts that must be removed before the separating the crankcase . Remove the oil pipe stay and cam chain tensioner set plate by removing the bolts .
  • Page 159 CRANKS HAFT/TRA N S M I S S I O N Place the left crankcase side down and separate the right crankcase from the left crankcase while prying where indicat­ ed at the point shown and tapping the cases at several loca­ tions w ith a soft hammer.
  • Page 160 CRANKSHAFT/TRA N S M I S S I O N ( 1 ) BEA R I N G CAPS C O N N ECTI N G R O D D I SA S S E M B LY Remove the connecting rod bearing caps noting their loca­ tions .
  • Page 161 CRAN KS HAFT/TRA N S M ISSION Remove the caps and measure the compressed plastigauge at its widest point on each crankpin to determine the oil clear­ ance. SERVICE LIMIT: 0.07 mm (0.003 i n ) I f the rod bearing clearance is beyond tolerance, select re­ placement bearings.
  • Page 162 CRANKS HAFT/TRA N S M ISSION M A I N BEAR I N G I N S PECTI O N Measure the main journal O . D . and record it. Measure the main journal bearing I . D . and record it. Calculate the clearance between the main journal and the main bearing .
  • Page 163 C RAN KSHAFT/TRAN S M ISSION Choss replacement main bearings i n accordance with the table below . M A I N J O U RNAL O . D . CODE 44. 992- 44. 984 - 4 5 . 000 mm 44 .
  • Page 164 CRAN KS HAFT/TRANSMISSION C O N N ECTI N G R O D/ C RA N K S H A FT S E L E CT I O N If a connecting rod requires replacement, y o u should select a rod with the same weight code as the original.
  • Page 165 C RAN KSHAFT/TRAN S M ISSION TRANSM ISSION ( 1 ) MAI N­ SHA FT R EMO V A L ' 8 8 . '89 . ' 9 1 -'9 5 : Remove the mainshaft, cou ntershaft, shift fork shaft and shift drum as a n assembly.
  • Page 166 C RAN KSHAFT/TRA N S M I S S I O N I nspect the shift drum end for scoring, scratches, or evidence of insufficient l ubrication . Check the shift drum grooves for damage. Measure the shift drum shaft O . D . at the left side journal. SERVICE LIMIT: 1 1 .
  • Page 167 CRANKSHAFT/TRANSMISSION Measure the O . D . of the mainshaft following bushings: SERVICE LIMITS : M4 gear bushing : 27 . 94 m m ( 1 . 1 00 in) C3 gear bushing : 2 7 . 94 m m ( 1 . 1 00 in) M 2 gear bushing : 2 7 .
  • Page 169 Check that the studs a re tight. I f any are loose, remove them , clean their threads with c ontact cleaner, then reinstall them using Honda Anaerobic Thread Lock , o r equivalent. (2) 8 mm STU D BOLT HOLE...
  • Page 170 C RAN KS H A FT /TRAN S M ISSI O N After'9 5 : Check that the studs a re tight, any a re loose, remove them , clean their threads with contact cleaner, then reinstall them apply engine oil to the threads . FLAT SI DE ( 1 )
  • Page 172 C RAN KSHAFT/TRANSMISSION I nstall the lock washer and stop washer, aligning bigger tabs of the lock washer with bigger grooves of the stop washer in the countershaft groove . Turn the washers as shown to lock them on the nearest spline. ( 1 ) STOP I nstall the stop washer first, and then the lock washer for the WASHER...
  • Page 173 CRANKSHAFT/TRANSMISSION '88 . '89 . ' 9 1 -' 9 5 : I nstall the right shift fork with the " R " mark o n the fork facing Assemble the mainshaft, countershaft, shift fork shaft and shift drum. I nstall them into the l eft crankcase as an assembly. After'9 5 : Assemble the mainshaft a n d countershaft .
  • Page 174 C RAN KSHAFT/TRANSMISSION Apply oil to all crankcase bolts . Instal l and tighten the right crankcase bolts i n a crisscross pat­ tern in or 3 steps. NOTE Tighten the 8 mm bolts first, then tighten the 6 mm bolts. •...
  • Page 175 C RAN KS HAFT/TRA N S M ISSION I nstal l the front cam chain over the front cam chain d rive sprocket. I nstall the cam chain tensioner set p l ate and tighten the bolt securely. I nstal l the rema1mng parts in the reverse order of removal (page 1 1 - 1 ) .
  • Page 177 1 2. FRONT WH EEL/SUSP ENSION/STEER I NG SERVICE I N F O RMATION 1 2- 1 FRONT W H EEL 1 2-6 TROU BLES H O O T I N G 1 2-2 FORK 1 2- 1 2 HAN D LEBAR 1 2-3 STEERING STEM 1 2- 1 9...
  • Page 178 FRONT WHEEL/S U S P E N S I O N/STE E R I N G T O O LS Special Spoke wrench 07JMA - M R60 1 00 o r equivalent commercially available in U . S . A . 07930- KA50000 N ot available i n U .
  • Page 179 ( 1 ) CEMMENT Remove the grip from the throttle pipe. Apply Honda Bond A or Honda Grip Cemment ( U . S . A . only) to the inside surface of the throttle grip to the clean surface of the throttle pipe.
  • Page 180 FRONT W H EEL/S USPENSION/STEERING BARKE LIGHT SWITCH Disconnect the front brake light switch wires from the switch. WIRE Remove the following : - rear view mirror from the master cylinder - master cylinder holder mounting bolts and holder - right handlebar switch wire bands - right handlebar switch screws and switch Loosen the throttle cable lower adjusting nuts at the carbure­...
  • Page 181 F R O N T WHEEL/SUSPENSIO N/STEERING I N STA LLAT I O N '88 , '89 , '9 1 -'94 : I n stall the rubber seat into the fork bridge . I n stall the washers and handlebar mounting n uts. Tighten the nuts .
  • Page 182 FRONT WH EEL/S U S PE N S I O N/STE E R I N G Install the clutch holder/lever and with the " U P" mark facing Align the end of the holder with the punch mark on the handle­ .
  • Page 183: Front Wheel

    FRONT WHEEL/S U S PE N S I O N /STEERING FRONT WHEEL R E M OVA L Raise and support the motorcycle using a hoist or a jack u nder the engine . Remove the set screw and pull the speedometer cable out of the speedometer gearbox .
  • Page 184 FRONT W H E E L/SUSPEN S I O N/STEE R I N G FRONT AXLE ( 1 ) I N S P E CT I O N AXLE Set the axle in V blocks and measure the runout . Actual ru nout is the tota l i n dicator reading .
  • Page 185 F R O N T W H EEL/S USPENSION/STEERING To balance the wheel, i nstall wheel weights on the highest side of the rim, the side opposite to the chalk marks. Add just enough weight so the wheel will no longer stop i n the same po­ sition when it is spun .
  • Page 186 FRONT WH E E L/S USPENSION/STE E R I N G Drive out the wheel bearings and distance collar. CAUTION • Never reuse old bearings. TOOLS : 07746-005 0 1 0 0 Bearing remover shaft Equivalent commercially available in U .S.A. 07746-0050600 Bearing remover head, 20 mm Equivalent commercially...
  • Page 187 FRONT WH EEL/S U S PEN S I O N /STEERING To replace the wheel; Remove the tire and tube from the rim . Place the rim and hub on the work bench and begin lacing with new spokes from inside the hub. Install the spokes with a space of six holes in between.
  • Page 188 FRONT WHEEL/SUSPENSIO N/STEERING G EAR BOX Apply grease to the speedometer gearbox and gear. ( 1 I I nstall the speedometer gear and washers into the gearbox. I nstall the speedometer gearbox into the wheel hub, aligning the tangs with the slots . Clean the brake discs with a high quality degreasing agent.
  • Page 189 FRONT W H EEL/S U S PENSION/STEERING FORK R E MOVAL Remove the front wheel ( page 1 2 - 7 ) . Remove the brake caliper mounting bolts and brake caliper. Unhook the brake hose from the hook on the fender. Tie the caliper to the handlebar so its weight does not pull on the brake hose .
  • Page 190 FRONT WHEE L/S U SPENSION/STE E R I N G ( 1 ) FORK CAP D I SA S S E M BLY Remove the fork cap bolt . • The cap bolts are under spring pressure. Take care when re­ moving, and wear eye and face protection.
  • Page 191 FRONT W H E EL/S USPENS I O N/ST E E R I N G I n quick successive motions, pull the fork tube out of the slid­ NOTE The slider bushing that is pressed into the slider, and the •...
  • Page 192 FRONT W HE EL/SUSPEN S I O N/STEERING Set the fork tube i n V blocks and read the ru nout. Actual runout is the total indicator reading. 1 /2 SERVICE LIMIT: 0 . 20 mm (0. 008 in) Bushings BACK-UP RING BUSH I N G Visually inspect the slider and fork tube bushings.
  • Page 193 FRONT WHEEL/S U S P E N S I O N /STEERING OIL SEAL I nstall the rebound spring i nto the fork tube. (21 BACK-U P R I N G I nstall a new postion ring i nto the piston groove . Place the oil lock piece on the end of the piston and insert the fork tube i nto the slider.
  • Page 194 FRONT WHEEL/S U S P E N S I O N/STEERING Com press the fork leg and pour Honda Su spensio n F luid SS-8 o r equ iva lent i nto the fork tube. SPECI F I E D L E V E L :...
  • Page 195 FRONT WHEE L/S U S P E N S I O N/STEERING I nstall and tighten the bottom pinch bolt. TORQU E : 50 N · m (5.0 kg-m, 36 ft-lbl Tighten the top pinch bolt. TORQU E : 1 1 N·m ( 1 . 1 kg-m, 8 ft-lb) I nstall the front fender and tighten the mounting bolts secure­...
  • Page 196 FRONT W H EEL/S U S P E N S I O N /STEER I N G STEER I NG STEM (2) SPEEDO­ M ETER R E M OVAL Remove the fork legs and handlebar. Disconnect the speedometer cable from the speedometer, and the 6P black connector (see page 1 - 1 3 ) .
  • Page 197 FRONT WHEEL/S U S P E N S I O N/STEERING ( 1 ) S T E E R I N G Loosen the steering head bearing adjustment nut. S T E M S O C K ET 079 1 6 - 37 1 0 1 00 TOOL: Steering stem socket Hold the steering stem by hand and remove the adjustment nut, dust sea l , upper bearing inner race and upper bearing.
  • Page 198 FRONT WH EEL/S U S P E N S I O N /STEERING ( 2 ) STEM NOTE Always replace the bearing and race as a set. • I nstal l the steering stem nut o n the top end of the steering stem to protect the threads from damage.
  • Page 199 FRONT WH EEL/S USPEN S I O N /STE E R I N G I N STALLAT I O N Pack t h e bearing cavities w i t h grease. I nstall the lower bearing onto the stem. Insert the stem i nto the steering head pipe and i nstall the upper bearing, inner race, dust seal and steering bearing adjustment n ut.
  • Page 200 FRONT WH EEL/S U S PENS I O N /ST E E R I N G I nstall the indicator panel with two screws. I nstall the fork bridge then temporarily i nstal l the fork legs. Tighten the steering stem nut. TORQUE : 1 05 N •...
  • Page 201 MEMO...
  • Page 202 REAR WHEEL/BRAKE/S U S PENSION 1 3-0...
  • Page 203 Support the motorcycle using a hoist or a jack under the engine. CAUTION Do not jack up the motorcycle using the oil filter. • Use only genuine Honda replacement fasteners for the rear suspension. • Note the i nstallation direction of the bolts. •...
  • Page 204 REAR WHEEL/BRAKE/S USPEN S I O N T O O LS Special Driver shaft 07 946 - MJ00 1 00 Attachment, 28 x 30 mm 07746 - 1 870 1 00 Spoke wrench 07JMA - M R60 1 00 or equivalent commercially available i n U .
  • Page 205: Rear Wheel

    R E A R W H EEL/BRAKE/S U S P E N S I O N REAR WHEEL R E M O V A L · Support the motorcycle using a hoist or a jack under the en­ gine. CAUTION Do not jack the oil filter.
  • Page 206 REAR W H EEL/BRAKE/S USPENSION S P R O C K ET/D R I V E N FLAN G E ( 1 1 GOOD ( 2 1 REPLACE D I SA S S E M B LY / I N S PECTI O N Remove the wheel ( page 1 3-31 .
  • Page 207 REAR WH EEL/BRAK E/S U S PENSION First, drive in a new left wheel bearing until it is fully seated, in­ stall the distance collar, then drive in a new right bearing. TOOLS : Driver 07749 - 00 1 0000 Attachment, 42 47 mm 07746 - 00 1 0300...
  • Page 208 REAR WH EEL/BRAKE/S U S P E N S I O N Place the rim and hub on the work bench and begin lacing with a new spoke from the hole of inside i n the hub. Install the spoke with a space of two holes in between . Measure the distance ( B ) , a n d make a calculation.
  • Page 209 REAR WH EEL/BRAKE/S USPENSION I nstal l the axle collar. · --= I N STALLAT I O N I nstall the brake panel on the wheel hub. Position the rear wheel between i n swingarm and install the drive chain over the driven sprocket. Install the left side adjuster collar onto the rear axle and insert the axle (from the left side) through the swingarm, wheel hub and right side collar.
  • Page 210 REAR WHEEL/BRAKE/S USPENSION D I SASS E M B LY Remove the cotter pins and set plate . COTTER PINS ( 2 ) Remove the brake shoes and springs from the brake panel . NOTE Mark the shoes to indicate their original positions before re­ •...
  • Page 211 REAR W H E E L/BRAKE/S USPENSION Apply grease to the brake anchor pins and brake cam. I nstall ( 1 ) BRAKE CAM the brake cam into the brake panel . I nstall the felt seal. Install the indicator plate on the brake cam aligning its tab with cut-out on the brake cam .
  • Page 212: Brake Pedal

    REAR WHE EL/BRAKE/S U S PE N S I O N BRAKE PEDAL R E M OVAL Remove the foot peg bracket mounting bolts and washers . Remove t h e brake pedal b y removing t h e cotter p i n , washer and bolt.
  • Page 213: Rear Shock Absorber

    R EAR W H EEL/BRAK E/S USPEN S I O N REAR SHOCK ABSORBER R E M O V A L • The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Support the motorcycle using a hoist, or a jack under the en­...
  • Page 214 REAR WHEEL/BRA K E/S U S PENSION S P R I N G F R E E L E N G T H Measure the shock absorber spring free length . SERVICE LIMIT: 1 35 . 0 mm ( 5 . 3 1 in) Mark the damper rod at 1 0 mm below the case as show n .
  • Page 215 R EAR W H EEL/BRAKE/S U S PENSION A S S E M B LY ( 1 ) DAMPER ( 2 ) SPRING ( 1 2 ) ADJU STER ADJU STER SEA T (4) SPRING ( 5 1 LOWER SPRING SEAT (3) U PPER SPRING SEAT...
  • Page 216 REAR WH EEL/BRAKE/S U S P E N S I O N SWI NGARM R E M OVAL Remove the rear wheel (page 1 3-3) Remove the gearshift pedal mounting bolt from the foot peg . PEDAL BOLT (i') � Remove the drive sprocket cover.
  • Page 217 REAR W H E E L/BRAKE/S U S PE N S I O N I N S PECT I O N I nspect the swingarm f o r deformation o r cracks. Check the pivot bearings, collars and dust seals for wear or damage.
  • Page 218 REAR WHEEL/ BRAKE/SUSPENSION Drive the left needle bearing out of the swingarm . 07946 - MJ00 1 00 TOOL: Driver shaft Carefully press new bearings into the swingarm pivots . NOTE I nstall the bearings with the marks facing out. •...
  • Page 219 REAR WH EEL/BRAKE/S USPENSION ( 1 ) CHAIN COVER A S S E M B LY / I N STA L LAT I O N I nstall the chain slider a n d chain cover with protector . (2) CHAIN SLIDER I nstall t h e swingarm in t h e frame.
  • Page 220 REAR WHE EL/BRAKE/S U S P E N S I O N SEAT / R EAR FEN DER/SUB-FRAM E R E M OVAL/ I N STA L LAT I O N Remove the seat mounting socket bolts a n d unhook the seat hooks from the frame, then remove the seat.
  • Page 221 M E MO...
  • Page 223 HYDRAU LIC DISC BRAK E After '93 : 1 2 N · m ( 1 .2 Kg-m,9 ft-lb ) � 3 5 N · m ( 3 . 5 Kg-m,2 5 ft -l b ) � 2 2 N · m (2 . 2 Kg-m, 1 6 ft-lb) �...
  • Page 224 H Y D RA U LI C D I S K B R A K E S ERVICE I N FORMATION 1 4- 2 1 4- 5 BRAKE PAD/DISC TROU BLES H O OTI N G 1 4- 3 MASTER CYL I N D E R 1 4- 8 BRAKE F L U I D R EPLACEM ENT/ BRAKE CALIPER...
  • Page 225 H Y D RA U L I C D I S C BRAKE TROUBLESHOOTI N G Brake lever soft o r spongy • A i r bubbles in hydra u l i c syste m . • Low f l u i d leve l . •...
  • Page 226 HYDRAULIC DISC BRAKE BRAKE FLU I D REPLACE M ENT/ AI R BLEEDI NG • CAUTION Be careful not to allo w dust or water to enter the brake system • when filling the reservoir. USE ONL Y D O T BRAKE FL UID Do not mix dif ferent types of fluid since they are not •...
  • Page 227 H Y D RAU LIC D I SC BRAKE 1 ) Squeeze the brake lever, then open the bleed valve 1 /2 turn and close the valve. NOTE Do not release the brake lever (or pedal) u ntil the bleed •...
  • Page 228 HYDRA U L I C D IS C BRAKE Pull the pad pins out of the caliper and remove the brake pads. Position the pad spring in the caliper as show n . I nstall new pads in the caliper. NOTE Always replace the brake pads in pairs to assure even disc •...
  • Page 232 HYDRA U L I C DISC BRAKE I nstal l the snap ring using a snap ring pliers. SNAP RING ( 1 ) Install the boot . • CAUTION Be certain that the snap ring is seated firmly in the groove. TOOL: Snap ring pliers 079 1 4 - 323000 1...
  • Page 233 HYDRAULIC DISC BRAKE BRAKE CALl P E R R E M OVAL Place a clean container under the caliper and disconnect the brake hose from the caliper by removing the oil bolt and sealing washers. • CAUTION A void spilling brake fluid on painted surfaces. Remove the brake pads ( page 1 4- 5 ) .
  • Page 234 HYDRAULIC D I S C BRAKE A S S E M BLY Coat new piston seals and dust seals with clean brake fluid and install them in the caliper. I nstall the pistons anrJ i nstall them with the open ends toward the pads.
  • Page 235 M E M O...
  • Page 236 BATTERY CHARG I N G SYSTEM ( 3 ) ST SWITCH MAIN FUSE 1 5-0...
  • Page 237 1 5. BATTERY /CHARG I NG SYSTEM ' 8 8 - ' 8 9 , ' 9 1 : ( 3 ) MAIN F U S E 30A Y : Yellow ( 1 ) R E G U LATO R/R E CTI F I E R ALTER NATO R 8 1 : Black...
  • Page 238: Troubleshooting

    B ATTERY/ C H A R GING SYSTEM S E RVI C E I N F O R M ATION 1 5 -2 CHARG I N G SYSTEM 1 5- 7 TROUBLESHOOTING 1 5- 3 REGU LATO R/RECT I F I E R 1 5- 8 1 5-4 1 5-·9...
  • Page 239 BATTERY CHARG I N G SYSTEM TROU BLESHOOTI NG ABNORMAL Measure the battery leakage (page Check the regulator/rectifier resistances be- 1 5- 7 ) . tween each regulator/rectifier terminals (page 1 5- 8 ) NORMAL NORMAL Short circuit in wire harness ABNORMAL ----+ •...
  • Page 241 BAlTERY /CHARG I N G SYSTEM VO LTAGE I N S PECTI O N R emove the right a n d left side covers . Remove the battery case cove r . M easu re the battery voltage using a digital multimete r . VO LTAG E : Fully charged : 1 3 .
  • Page 242 2 . Set the battery Amp . H r . Selector Switch for the size of the battery being charged . 3 . Set the Timer to theposition indicated by the Honda Battery Tester ; R E D-3 , R E D-2 or YELLOW- 1 . If you a re BATTERY A M P H R .
  • Page 243 The c h a rger will automatically switch to the Trickle mode • after the set charging time has elapsed . Retest the battery using the Honda Battery Tester a n d rech a rg e i f necessary using t h e above steps . N OTE For accurate test results, let the battery cool for at least ten •...
  • Page 244 BATTERY/ C HA R GING SYSTEM R E G U LATED V O LTAG E I N S P E CT I O N N OTE Be sure the battery is i n good condition before performing • this test . Warm up the engine to normal operating temperature .
  • Page 245 B ATT E R Y/ C HA R GIN G SYST E M ALTERNATOR I N S P ECTI O N NOTE It is not necessary to remove the stator coil to make this • test. Remove the left side cover. Disconnect the alternator 3P (WHITE) connector.
  • Page 247 1 6 . I G N I T I O N SYST EM '88 , '89 R/BI -o ( 4 ) ( 1 ) E N G I N E ( 2 ) S U B I G N I T I O N M A I N S T O P FUSE...
  • Page 248 I G N I TIO N S Y ST E M S E RVIC E I N FO R MATIO N 1 6- 2 I G N I T IO N P U LS E G E N E R ATO R 1 6- 6 S I D E STAND SWITCH 1 6- 7...
  • Page 249 I G N ITI O N SYSTEM TROU BLESHOOTI N G • When performing a spark test, keep open flames or sparks away from the work area. • No spark at one spark plug • Faulty spark plug Faulty spark plug wire No spark at all plugs •...
  • Page 250 I G N ITION SYSTEM I G N ITION CONTROL MODULE I N S P ECTION Remove the left side cover and connector plate . N OTE Check the system components and lines step-by-step ac­ • cording to the troubleshooting chart on page 1 6-3. Disconnect the ignition control module connectors and check them for loose o r corroded termi nals.
  • Page 251 I G N ITION SYSTEM If the resistance is out of range, remove the spark plug wires and measure the resistance between the secondary coil termi­ nals. (20° C/68 ° F) STAN DARD : 1 9 . 8 - 24 . 2 R E PLAC E M E N T Rear ignition coil Remove the right side cover.
  • Page 252 IGN ITIO N S YSTEM I G N ITION P U LS E G E N ERATOR I G N ITI O N P U LS E G E N E RATO R C O N I N S PECT I O N NOTE It is not necessary to remove the ignition pu lse generator to •...
  • Page 253 I G N IT I O N S Y ST E M After '93 : Remove the left side cover. Disconnect the side stand 3 P g reen connector and check for conti n u ity between each terminals as shown below. There should be continuity between the positions on the conti n u ity chart.
  • Page 254 I G N ITION SYSTEM The timing is correct if the " F" mark aligns with the index mark on the right crankcase cover at idle for each cylinder. Raise the engine rpm and the " F " mark should begin to rotate counterclockwise for each cylinder.
  • Page 255 M E M O...
  • Page 256 ELECTRIC S TARTER ( 8 ) CLUTCH SWITCH (7) D I O D E A FT E R '93 ; STARTER RELAY ( 1 2 ) SWITCH B l : Black S I D E STAN D SWITCH ( 1 4 ) M A I N FUSE Y : Yellow ·...
  • Page 257 1 7. ELECTR IC STARTER S ERV I C E I N FO RMATIO N 1 7 - 1 STARTER RELAY SWITCH 1 7 - 6 T RO U B L E S HOOTING 1 7 - 1 C L UTC H D IO D E 1 7 - 7 STARTER MOTO R 1 7 - 3...
  • Page 258 ELECTRIC S TARTER The starter motor can turn i n the neutral position, but should not turn except with the gear selector i n neutral , the side stand up and the cluth lever pulled in. BATTERY VOLT­ AGE M EASURED Measure the Voltage between the Green/White Check the clutch switch ( page 1 8 - 1 1 )
  • Page 259: Starter Motor

    ELECTRIC STARTER STARTER MOTOR R E M OVAL • With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Remove the rubber cap and disconnect the starter motor cable. Remove the motor mounting bolts . Remove the motor from the left side.
  • Page 260 ELECTRIC STARTER I nspect the commutator bars for discoloration . C O M M UTATOR ( 1 l Bars discolored in pairs indicate grounded armature coils. Check for continuity between pairs of commutator bars . There should be continuity . Check for continuity between individual commutator bars and the armature shaft.
  • Page 261 ELECTRIC STARTER A S S E M B LY ( 2 ) CASE BRUSH HOLDER ( 5 ) 0-RING ( 7 ) S H I M S ( 4 ) �,� ( 1 3) S H I M S ( 1 0) 0-RI N G ( 1 2 ) N UTS ( 1 ) FRONT COVER ( 1 0) CABLE TERM I NAL AND BRUSHES...
  • Page 262 ELECTRIC STARTER FRONT ( 2 ) I nstall the front shims in the same location and number when COVER disassembled . Instal l the 0-ring on the case . I nstall the lock washer, aligning its tabs with the slots of the front cover.
  • Page 263 ELECTRIC STARTER C O N T I N U I TY I N S P E C T I O N Remove the starter relay switc h . Connect an ohmmeter t o t h e switch large terminals. Connect a fully charged 1 2 V battery positive wire to the start­ er relay switch Yellow/Red wire terminal, and the battery neg­...
  • Page 264 MEMO...
  • Page 265 1 8. LI GHTS/ M ETER/SWITCH ES S E RVI C E I N FO R MATIO N 1 8- 1 F U E L P U MP RELAY 1 8-9 T RO U BL ES HOO T I N G 1 8-2 F U E L P U MP 1 8- 1 0...
  • Page 266 LIG HTS/METER/S W I TC H ES TROUBLESHOOTI NG N o Lights Come O n When Ignition Switch I s Turned O N : All Lights Come O n , but Dimly, when Ignition Switch I s Bulb at fault or burned out •...
  • Page 267 L I G HTS/M ETER/SWITC H ES H EADLIGHT R E M OVAL/ I N STALLAT I O N Remove the two screws a n d headlight. • Disconnect the headlight connector and remove the rubber protector. Remove the headlight retainer clip and replace the headlight RETAINER CLIP HALOGEN BULB ( 1 )
  • Page 268 LIG HTS/M ETER/SWITC H ES BULB REPLACE M E NT N O T E See page for speedometer bulb replacement. • 1 8- 5 T U R N S I G N A L L I G H T Remove the turn signal lens attaching screws. While pushing i n , turn the bulb counterclockwise to remove .
  • Page 269 LIG HTS/M ETER/SWITC H ES B U L B R E PLAC E M E N T Remove t h e trip-meter knob b y removing the attaching screw . Romove the speedomater cover mounting screws and cover. Replace the meter bulb with new one. ( 5 ) SPEEDOMETER STAY ( 2 ) MOUNTI NG...
  • Page 270 LIG HTS/M ETER/SWITC H ES I N D I CATO R PAN E L B U L B R E PLAC E M E N T Remove the indicator bulbs from the indicator panel, b y first pulling out each bulb and socket together. Replace the bulb, if desired .
  • Page 271 LIGHTS / M ETER/S WITC H ES HAN DLEBAR SWITCHES ) LEFT HANDLEBAR SWITCH The handlebar switches (dimmer, turn signals, horn, starter, engine stop, etc . ) must be replaced as assemblies. Remove the steering covers. L E FT H A N D L E B A R SWITCH Disconnect the left handlebar switch connector (9P White) .
  • Page 272 LIG HTS/ M ET ER/SWITC H ES THERMOSTATIC SWITCH I N S P E CT I O N T h e the rmostati c switch senses t h e temperature o f t h e r a d i a ­ tor coolant a n d s i g n a l s t h e f a n moto r .
  • Page 273 L I G HTS/ M ETER/SWITC H ES T H E R M O M ET E R ( 1 ) T H E R M O S E N S O R I N S P E C T I O N D r a i n the coo l a nt from t h e t h e r m ostat housing by removing the d r a i n bolt i n t h e h o u s i n g .
  • Page 274 L I G H TS / M ETER/SWITC H ES FU EL PUM P S Y S T E M I N S P ECTI O N Turn the ignition switch a n d remove the seat and discon­ O F F nect the fuel pump wire connectors and temporarily connect the balck and black/blue wire teminals at the main harness connector with a jumper wire.
  • Page 275 LIGHTS/METER/SWITC H ES N EUTRAL SWITCH I N S P E CT I O N Remove t h e left side cover a n d disconnect the 2P ( Black) con­ nector. Check the neutral switch for continuity between the light green/red connector and body gro u n d .
  • Page 276 LIG HTS/ M ET E R/SWITC H ES TU RN SIG NAL RELAY Remove the seat, then remove the turn signal relay from the rubber bracket . Check the turn signal circuit for proper connections before making this test. Connect each terminal as indicated below : ( + ) White/G ree n : D .
  • Page 277 1 9. WI R I N G DIAG RAM ·as. ·as: ..� i H H n · :::& ..dl "' • • � ; 9 ; • � � �- � ! ... �- _ ..! uo 1!:.
  • Page 278 W I R ING D I AGRAM > • � � - � � 1 9- 2...
  • Page 279 W I RING D I A G R A M '92 , '93 ; :;; !:! � � � � � � 1 9 - 3...
  • Page 280 W I R IN G DIAGRAM After '93 : 1 9-4...
  • Page 281 20. TROUBLESHOOTI NG E N G I N E DO ES NOT START O R I S POO R PERFO R MANCE AT H I G H H A R D TO START 20- 1 SPEED 20-4 E N G I N E LACKS PO W E R 20-2 POO R H A N D L I N G 20-4...
  • Page 282 TROUBLESHOOTING E N G I N E LACKS POWER POSSIBLE CAUSE Raise wheels off ground and spin WHEELS DO NOT SPIN FREE LY --- · Brake dragging • Worn or damaged wheel bearings by hand • Wheel bearing needs lubrication WHEELS SPIN FREELY •...
  • Page 283 TROUBLESH OOTI N G POSSIBLE CAUSE Remove cylinder head cover and VALVE TRAIN NOT LUBRICATED --•• Clogged oil passage inspect lubrication • Clogged oil control orifice PROPERLY • Contaminated oil VALVE TRAI N LUBRICATED • Faulty oil pump PROPERLY • 1 2 .
  • Page 284 TRO U BLESH OOTI N G POOR PE RFORMANCE AT H IGH SPEED POSSIBLE CAUSE . Check i g n ition t i m i n g a n d v a l v e I N C O R R E C T ---- -- -- -_ _,� . I m p roper v a l v e c l e a r a n c e c l e a r a n c e I m p roper i g n it i o n t i m i n g...
  • Page 285 2 1 . I N DEX Air Cleaner ........... . . Engine Oil Level .
  • Page 286 I N D EX Right Crankcase Cover Installation 7 - 1 4 Valve Clearance ..........

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