10258826-Honda Fourtrax 350 Service Manual Repair 1986-1987 Trx350

...
BS-B7
TRX35D
FOURTRAX s
4X4
B7-B9
TRX35DO
FOREMANTM
4X4
. - - - - - - - - - IMPORTANT SAFETY NOTICE - - - - - - - - ,
Indicates a strong possibility oj severe persona/Injury or death 1/ irutructloru an not fol/owed.
CAUTION : Indicates a possibility of personal injury or equipment damage if instructions are not folfowed.
NOTE: Gives helpful information .
Detailed descriptions of standard workshop procedures, safety principles and service operations ere not included . It is
important to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAllNJURV to service personnel or could damage 8 vehicle or render it unsafe . Please understand
that those warnings CQuid not cover all conceivable ways in which service, whether or not recommended by 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
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.
HOW TO USE THIS MANUAL CONTENTS
Sections 1 through 3 apply to the complete
FOURTRAX and FOREMAN , while sections 4 GENERAL INFORMATION
through 21 describe parts of the FOURTRAX
and FOREMAN , grouped according to loca- LUBRICATION
tion .
MAINTENANCE
Find the section you want on this page, then
turn to the table of contents on page 1 of that FUEL SYSTEM
section .
ENGINE REMOVAL/INSTALLATION
Most sections start with an assembly or
system illustration, service information and
COOLING SYSTEM
troubleshooting for the sectio n. Th e subse-
quent pages 9ive detailed procedures.
W CYLINDER HEADIVALVES
If you are not familiar with this vehicle, read ~ :==============
z
the Technical Features in section 22. W CYLINDER/PISTON
If you don't know the sou rce of the trouble.

F=================
CLUTCH/OIL PUMP/KICK STARTER
go to section 23. Troubleshooting.
FRONT WHEEL/SUSPENSION/STEERING
BRAKES
'""'~« ~============
REAR WHEEL/SUSPENSION
"' :=============
u
FRONT DIFFERENTIAL/FINAL DRIVE
BUMPERS, FENDERS, CARRIERS
IGNITION SYSTEM
-' BATTERY/ CHARGING SYSTEM

5:==============
... STARTER SYSTEM
0:
~ :===================
-' LIGHTS/SWITCHES
w ~============
WIRING DIAGRAMS
TECHNICAL FEATURES
TROUBLESHOOTING
INDEX
1. GENERAL INFORMATION
GEN ERAL SA FETY 1-1 TORQUE VALUES 1-5
SERVICE RUL ES 1- 1 TOOLS 1-7
M OOEL IOENTIFI CA nON 1-2 CABLE & HARN ESS ROUTING 1-9
SPECIFICATIONS 1-3
GENERAL SAFETY
Ii ~Ii
If the engine must In running to do some work, make sure the Inhaled asbestos fibers have been found to cause respiratory
area Lr well-ventilated. Never run the engine in a closed area. disease and cancer. Ne~'er use an air hose or dry brush to clean
The exhaust contains poisonous carbon monoxide gru that brake or clutch assemblies. In the United Stales, use OSHA-
may cause loss of consciousness and lead 10 death. approved vacuum cleaner or alternate method approved by
OSHA designed 10 minimize the hazard caused by airborne
asbestos fibers.
r.',e battery generates hydrogen gas which can be highly
explosive. Do not smoke or allow flames or sparks near the CAUTION:
battery, especially while charging it. Used engine oil may cause skin cancer if repealedly left in con-
tact with the skin jor prolonged periods, Although this is
Unlikely unless you handle used oil on a daily basis, it is still
adviseable to thoroughly wash your hands with soop and
Gasoline is extremely flammable and;s explosive under certain water as soon as possible after handling used oil.
conditions. Do not smoke or allow flames or sparks in your
work area.
i
The battery electrolyte contains sulfuric acid. Protect your
eyes, skin and clothing. In case of contact, /lush thoroughly
with water and call a doctor 1/ electro/yle gets in your eyes.
SERVICE RULES
1 . Use genuine HONDA or HONDA·recommended parts and lubricants or their equivalents. Parts that don't meet HONDA 's
design specifications may cause damage to the vehicle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger-diameter or inner bolt first. Then tighten to the specified torque
diagonally in ' ·5 steps, unless a particular sequence is specified.
6 . Clean parts in non-flammable or high flash point solvent upon disassembly.
7. Lubricate any sliding surfaces before reassembly.
8. After reassembly, check all parts for proper installation and operation.
1-1
GENERAL INFORMATION
MODEL IDENTIFICATION
FOREMAN f' S7 Shown; After '87 similarl FOURTRAX raG Shown; '87 similar)
~(21
(3) The frame serial number is stamped on the front bum- (4) The engine serial number is stamped on the upper side
per. of the right crankcase.
(5) The carburetor identification number is on the left side

of the carburetor body.
1-2
GENERAL INFORMATION
SPECIFICATIONS
< >:FOREMAN
DIMENSIONS Overall length 1,850 mm (12.8 in) <1,975 mm (77.B in»
Overall width 1,040 mm (40.9 in)
Overall height 1,080 mm (42 .5 inr
Wheelbase 1,210 mm (47 .6 in)
Seat height 770 mm (30.3 in) <After '87:785 mm (30.9 in I>
Foot peg height 305 mm (12.0 in)
Ground clearance 160 mm (6.3 in)
Dry weight 259 kg (571 Ibl <268 kg (591 Ibl>
FRAME Type Double cradle
Rim size Front 7.5)( 11 DC
Atter '88: 11 x7.SAT
Rear 7.5xl1DC
After '88: 11x7.SAT
Suspension travel Front Axle. travel 110 mm (4.33 in)
Rear Axle. travel 110 mm (4.33 in)
Front tire size, pressure 24 x 9.00-11,2.2 psi ( 15 kPa, 0.15 kg /cm 2)
Rear tire size, pressure 24 x 9.00-1 1, 2.2 psi (15 kPa, 0.15 kg/cm2)
Front brake Hydraulic operated two leading shoe
Rear brake Cable operated leading/ trailing shoe
Fuel tank capacity 10.5 liters (2.8 US gal, 2.3 Imp gal)
Fuel reserve capacity '86, '87: 2.6 litars (0.7 US gal, 0.6 Imp gal)
After '87: 2.0 liters (0.5 US gal, 0.4 Imp gall
Toe-in Omm (0 in)
Caster angle 3·
Camber angle O·
Trail length 14.0 mm (0.55 inl
Tread Front 800 mm 131.50 in)
Rear 800 mm (31.50 in)
ENGINE Type Gasoline, air-cooled 4 ·stroke
Cylinder arrangement Single cylinder inclined 20 0 from vertical
Bore x stroke 81 x S8 mm (3.19 x 2.S8 in)
Displacement 350.4 cc 121.4 cu·i n)
Compression ratio 8.5:1
Valve train Overhead camshaft, chain driven
Maximum horsepower 24.5 HP/S,OOO rpm (SAE)
Maximum torque 2.9 kg·m (21.0 ft·lb)/5,500 rpm (SAE)
Oil capacity 2.8 lit 13.0 US qt, 2.5 Imp qt) at disassembly
2.3 lit (2.4 US qt, 2.0 Imp qtl after draining
Lubrication system Forced pressure and wet sump with oil cooler
Cylinder compression 125 -1 45 kPa (12.5 - 14.5 kg/cm 1 , 178-206 psi)
Intake valve Opens 50 BTDC
Closes 35 0 ABDC
at 1 mm lift
Exhaust valve Opens 35 0 BBDC
Closes 50 ATOC
Valve clearance Intake 0.08 mm 10.003 in)
(Cold) Exhaust 0.08 mm (0.003 in)
CARBURETOR Type Dual valve
Identification mark QA03A
Venturi diameter 31 mm (1.22 in)
Main jet #142
Slow jet #35
Starter jet #100
Pilot screw opening 1· 1/2 turns out
Jet needle 3rd grOov8 from the top
Float level 18.5 mm (0.73 in)
Idle speed 1,400 ::t 100 rpm
1-3
GENERAL INFORMATION
DRIVE TRAIN Clutch Wet multi-plate, semi-automatic

Transmission 5-speed constant mesh with reverse
Primary reduction 2.103 (29/6 1)
Gear ratio Sil 4.083 (12/ 49 )
I 2.389 (18/43)
II 1.609 (23/37)
III 1.179 (28/33)
IV 0.906 (32/29)
Reverse 4.781
Final reduction Middle 1.172 x 1.461 (29/34 x , 3'1 9) Final 3.889 (9/35)
Gearshift pattern Left foot operated return system,
Forward: N-S/l - l -2-3-4
Reverse: N-R
Differential oil capacity '86: 135 cc (4.6 oz) at disassembly
100-110 cc 13.4 - 3.7 oz) after draining
After '86: 225 cc (7.6 oz) at disassembly
200- 210 cc (6.8- 7.1 ozl after draining
Final drive oil capacity 135 cc 14.6 oz) at disassembly
100-' 10 cc (3.4-3.7 oz) after draining
ELECTRICAL Ignition COl
Ignition timing Initial 10° BTDC at idle
Full advance 30° BTDC at 3,500 rpm
Alternator Capacity 240 W /5,000 rpm <3 10 W/5,000 rpm>
Battery 12V-12AH
NGK DRBES-L (OABES, DR7ES)
NO X24ESA-U (X27ESA-U, X22ESR-U)
Spark plug gap 0.S-0.7 mm (0.024-0.028 in)
Headlight 12V SO/55W
Taillight 12V 5W X2
Neutral indicator 12V 3W
Reverse indicator 12V 3W
Oil temperature indicator 12V 3W
Accessory light 12V 5W X2<12 V 25 W x 2>
1-4
GENERAL INFORMATION
TORQUE VALUES
ENGINE
a'ty Torque
Thread Oia.
Item After
(mm) N'm kg-m ft-lb
'87
Engine oil drain bolt '86, '87: 1 12 15 - 25 1.5-2.5 11-18
After '87: 1 12 20 - 30 2.0-3.0 14 - 22
Oil filter cover 3 6 8 - 12 0.8-1.2 6- 9
Clutch adjusting screw lock nut 1 8 19 - 25 1.9-2.5 14 - 18
Valve adjusting lock nut 4 6 , 5-18 1.5-1.8 11 - 13
Spark plug 1 12 15 - 20 1 .5- 2.0 11 - 14
Insulator band screw 3 5 3- 5 0.3 - 0.5 2- 4
Oil hose set piece bolt 2 6 10 - 14 1.0- 1.4 7 - 10
Cylinder head cap nut 4 10 35-45 3.5- 4 .5 25-33
Cylinder head flange bolt 2 10 35 - 45 3.5- 4 .5 25 - 33
Cam sprocket bolt (NOTE 1) 2 7 17 - 23 1.7 - 2.3 12 - 17
Cylinder head cover (7 mm flange boltl 4 7 13 - 17 1.3-1.7 9 - 12
(6 mm SH bolt) 7 (6) 6 8 - 12 0.8 - 1.2 8- 9
(6 mm flange bolt)) 3 (4) 6 10-14 1.0-1.4 7-10
Oil path pipe bolt tOil control bolt Bf 2 8 12 - 16 1.2-1.6 9 - 12
Cylinder mounting bolt 2 6 8 - 12 0.8 - 1.2 6- 9
Oil pipe bolt '86, '87 : 1 7 8 - 12 0.8-1.2 6-9
After '87: 1 7 10-14 1.0- 1.4 7 - 10
Mainshaft bearing stopper plate 2 6 10- 14 1.0 - 1.4 7 - 10
Change dutch lock nut 1 18 100 - 120 10.0 - 12.0 72 - 87
Centrifugal clutch lock nut INOTE 1 and 2) 1 20 110 - 130 t 1.0- 13.0 80-94
Clutch spring bolt 4 6 10 - 14 1.0-1.4 7 - 10
Relief vallie nut (Atter '87 only) (NOTE 1) 1 8 13 - 18 1.3 - 1.8 10 - 13
Flvwheel bolt 1 12 100 - 120 10.0- 12.0 72 - 87
Starter clutch torx bolt 6 8 20 - 25 2.0-2.5 14-18
Drille shaft holder bolt 2 8 20-25 2.0-2.5 14 - 18
Crankcase bolt 12 6 8 - 12 0.8-1.2 6- 9
Output gear case mounting bolt 4 8 30 - 34 3.0 - 3.4 22 - 25
Output gear bearing lock nut 10uter ) 2 64 90 - 110 9.0-11.0 65-80
(Inner) 2 30 70 - 80 7.0 - 8 .0 51 - 58
Output gear bearing holder socket bolt 4 8 20 - 25 2.0 - 2.5 14 - 18
Cam chain tensioner lifter bolt 3 6 8 - 12 0.8-1.2 6- 9
Kick starter plate socket bolt 2 6 10 - 14 1.0 - 1.4 7 - 10
Neutral switch 1 10 11 - 1 5 1.1 - 1.5 8 - 11
Oil temperature sensor 1 12 15 - 20 1.5 - 2.0 11 - 15
Gear shift return spring pin 1 8 18 - 25 1.8- 2. 5 13 - 18
Decompressor cable nut ('86, '87 only) 1 6 5- 7 0.5-0.7 4 -5
NOTE . 1, Apply locking agent to the threads .
2, left·hand threads.
FRAME
Torque
Thread Dia.
Item Q'ty
(mm) N'm kg·m ft-tb
Handlebar upper holder bolt 4 8 18 - 30 1.8- 3.0 13 - 22
Handlebar lower holder nut 2 10 40 - 48 4 .0- 4 .8 29 - 35
Front wheel nut 8 10 60 - 70 6.0-7 .0 43 -51
Tie rod end nut '86, '87 : 6 10 65 - 75 6.5-7. 5 50-54
-.tr After '87: 6 10 35 - 4 5 3.5 - 4.5 25 - 33
Tie rod lock nut 6 10 35- 45 3.5-4.5 25 - 33
Pillot arm nut 1 14 60 - 70 6.0- 7.0 43-51
Knuckle holder nut '86 , '87: 8 10 60 - 80 6.0 - 8.0 43 - 58
-.tr After ' 87 : 8 10 35-45 3.5 - 4.5 25 - 33
lower kingpin bolt 2 20 50 - 70 5.0-7.0 37 - 51
Upper kingpin bolt 2 20 5 - 10 0.5 - 1.0 4- 7
Kingpin lock nut 2 20 50 - 70 5.0-7.0 37 - 51
Front brake panel bolt (NOTE 3) 8 8 27 - 33 2.7 - 3.3 20 - 24
1-5
GENERAL INFORMATION
Torque
Thread Dia.
Item a'ty
(mm) N·m kg -m ft-Ib
Front shock absorber
lower mount bolt (Ieftl 1 14 60-80 6.0-8.0 43 - 58
upperllower (right) mount nut '86, '87: 3 10 60-80 6.0-8.0 43-58
-.'r After '87: 3 10 35-45 3.5-4.5 25-33
Swingarm left pivot bolt 2 30 100 - 130 10.0 - 13.0 72-94
Swingarm right pillot bolt 2 30 16 - 20 1.6 - 2.0 12 - 14
lock nut 2 30 100 - 130 10.0-13.0 72 - 94
Differential gear case nut '86, '87: 12 10 60- 80 6.0 - 8.0 43 - 58
* After '87: 12 10 35-45 3.5 - 4 .5 25 - 33
Front axle nut 2 16 80-100 8.0-10.0 58 - 72
Swingarm joint nut '86, '87: 6 10 80 - 90 8.0 - 9.0 58 - 65
"fl After '87: 6 10 35 - 45 3.5 - 4.5 25 - 33
Steering stem nut 1 14 100- 120 10,0-12.0 72 - 87
Steering lower stay lock nut 1 46 50-70 5.0-7.0 37 - 51
Front skid plate bolt 3 8 18 - 25 1.8-2.5 13- 18
Front guard plate/ pipe bolt 5 8 18 - 25 1.8- 2.5 13 - 18
Rear wheel nut 8 10 60- 70 6.0 - 7.0 43 - 51
Rear axle nut 2 18 120- 160 12.0 - 16.0 87 - 116
Master cylinder hose bolt 2 10 25 - 35 2.5-3.5 18- 25
Wheel cylinder hose bolt 2 10 25 - 35 2.5 - 3 . 5 18 - 25
Rear brake panel nut 'S6, '87: 4 10 50 - 60 5.0 - 6.0 36 - 43
-(( After '87: 4 10 35 - 45 3.5 - 4.5 25 - 33
Reservoir cover screw 2 4 1-2 0.1-0.2 0.7-1.4
Foot peg bolt 4 10 40-50 4.0 - 5.0 29-36
Brake pipe joint 5 10 12-15 1.2 - 1.5 9 - 11
Rear shock absorber
upper mount nut '86, '87: 2 10 40 - 50 4.0 - 5.0 29-36
-(( After '87: 2 10 35 - 45 3.5 - 4 .5 25 - 33
lower mount bolt/nut '86, '87: 2 10 60 - 80 6.0 - 8,0 43 - 58
* After '87: 2 10 35-45 3.5 - 4 .5 25-33
Trailer hitch 4 10 70 - 80 7.0 - 8.0 51 - 58
Final gear case (cover) joint nut '86, '87: 12 10 60 - 80 6.0 - 8.0 43 - 58
* After '87: 12 10 35 - 45 3,5 - 4 .5 25 - 33
Differential assembly
case rear cap torx bolt 6 8 30 - 35 3.0 - 3.5 22 - 25
case cap torx bolt 6 8 30 - 35 3.0 - 3.5 22 - 25
Ring gear bolt 6 8 45 - 55 4,5 - 5,5 33- 40
Pinion bearing lock nut 1 60 90-110 9 ,0- 11.0 65 - 80
Differential gear cover 10 mm bolt 2 10 45 - 50 4.5 - 5.0 33 - 36
8 mm bolt 6 8 23 - 28 2.3 - 2.8 17 - 20
Differential gear pinion joint nut 1 16 100 - 120 10,0- 12,0 72 - 87
Final drive gear lock nut 1 60 90 - 110 9.0 - 1 1 ,0 65 - 80
Final drive gear cover 10 mm bolt 2 10 45 - 50 4.5-5.0 33-36
8 mm bolt 6 8 23 - 28 2.3 - 2.8 17-20
Final drive gear pinion joint nut 1 16 100- 120 10.0- 12.0 72 - 87
Differential/linal drive oil filler cap 2 30 10 - 14 1.0- 1.4 7 - 10
Top engine hanger nut 1 10 70 - 80 7.0 - 8.0 51 - 58
Top engine hanger plate bolt 4 8 34-40 304 - 4.0 25 - 29
Front engine mounting bolt (upper/lower) 2 10 70-80 7.0-8 .0 5 1- 58
Engine hanger bracket nut 4 10 70 - 80 7.0 - 8.0 51 - 58
Rear engine mounting nut lupper!lower) 2 10 70 - 80 7 .0 - 8.0 51 - 58
Muffler band bolt 2 8 18 - 28 1.8- 2.8 13 - 20
Exhaust pipe joint nut 4 8 24 - 30 ZA-3.0 17-22
Muffler mounting bolt 3 50 - 60 5.0 - 6.0 36 - 43
.
NOTE 3: (After 87 Only) USing again strictly prohibited.
10
CAUTION
~@
-tl : Nut fo r A/ter '87 is a self·locking nut with the nUI·head peened; nUl for '86 and '87 is a
self·locking nul (U·lot:king nul). Tighten each nut to each specified torque, or the nut is
broken or loosened. ('86, '87) (After '871
1-6
GENERAL INFORMATION
Torque specifications listed on the previous pages are for the most important tightening points. If a torque specification is not
listed, follow the standards given below.
STANDARD TORQUE VALUES
Item Torque N·m (kg-rn, h-Ib) Item Torque N·m (kg-m. ft -Ib)
5 mm bolt, nut 4.5 - 6 (0.45-0.6, 3-4) 5 mm screw 3 .5-5 (0.35 - 0.5, 2 - 41

6 mm screw, 6 mm
6 mm bolt, nut 8 - 1210.8-1.2,6-9) 7 - 1110.7 - 1.1,5 - 8)
flange bolt with 8 mm head
8 mm bolt, nut 18 - 2511.8-2.5,13-18) 6 mm flange bolt, nut 10-14 (1.0 -1.4,7 - 10)
10 mm bolt, nut 30 - 40 (3.0- 4.0, 22-291 8 mm flange bolt, nut 24-30 {2. 4-3 .0, 17 - 221
12 mm bolt, nut 50- 60 (5.0-6.0. 36-43) 10 mm flange bolt, nut 35-45 (3.5- 4 .5, 25 - 33)
TOOLS
SPECIAL
DESCRIPTION TOOL NUMBER ALTERNATE TOOL REF. SEC.

Camber/ caster gauge attachment 07910-MJ30100 (Not available in U.S.A.) 3
Valve guide reamer, 5 .5 mm 07984-2000000 or 07984 - 200000A (U .S.A. only ) 7
Remover handle 07936 - 3710100 9, 11 , 14, 15
Remover weight 07741 - 0010201 or 07936 - 3710200 9 , 10, 11 , 14,
'5
8earing remover, 1 7 mm 07936-3710300 9, 11
Clutch center holder 07923-KE10000 or Plate holder 07HG8 - oo1010A 9
and clutch center coltar " A"
07HGB - ool020A (U.S.A . only)
Clutch holder 07G MB - HA 70100 9
8earing remover set, 10 mm 07936 - GEOOOOO 10
Shaft holder 07923 - 6890101 11
Lock nut wrench, 30 x 64 mm 07916-M800001 11
Lock nut wrench attachment 07GMA-HA70110 or 07916 - HA0020A 11
Attachment, 61.5 mm 07946-3600000 11
8earing remover, 20 mm 07936 - 3710600 11
Lock nut wrench, 34 x 44 mm 07916 - ME50001 1" 15
Lock nut wrench attachment 07916-9690100 11
Universal bearing puller 07931 - 4630000 or 07631 - 0010000 or equivalent 11, 15
commercially available in U.S.A.
Crank assembly tool set 07931-KFOOOOO (Not available in U.S.A.) 11
- Crankshaft assembly collar 07931 - KF00100 11
- Shaft puller 07931-ME40000 or 07931 - ME4oo0A (U.S.A. only) 1" 1 5
- Threaded adapter 07931 - KFOO200 11
Attachment, 28 x 30 mm 07946 - 1870100 11
Attachment 07946 - HAOOOOO 11
Spring compressor adaptor 07967 - KC10000 (Not available in U.S.A .) 12
Lock nut wrench 07908 - 4690001 or KS - H8A - 08 - 469 (U .S.A. 12
only)
Bearing remover set 07936-8890101 (Not available in U.S.A.) 12, 14
- Remover head 07936-8890200 (Not available in U.S.A.! 12, 14
- Bearing remover, 30 mm 07936 - 8890300 12, 14
- Remover weight 07741 - 0010201 or 07936 - 3710200 12
- Remover handle 07936 - 3710100 12
Wrench adaptor 07GMA-HA702oo 12
Attechment 07965-SA00600 13
Shock absorber compressor base 07959-MB10000 12, 14
Spring compressor adaptor 07967-KC10000 (Not available in U.S.A.) 12, 14
Pivot lock nut wrench 07908-4690001 or KS - HBA - OB - 469 (U.S.A. 14
only)
Ball race driver 07945-3330300 14
Driver 07949 - 3710001 14
Differencial inspection attachement 07GMK - HA70100 15
1-7
GENERAL INFORMATION
SPECIAL (Cont'd)
Pinion holder 07924-HAOODOO Must be modified pinion holder (4) 15

hole
Bearing remover. 1 2 mm 07936 - 1 6601 00 15
Pinion gear driver 07945- HAOaDOn (Not available in U.S.A.) or 15
Driver 40 mm 1.0. 07746-0030100
Attachment 07960 - 1870100 15
COMMON
Valve adjusting wrench, lax 12 mm 07708 - 0030200 or equivalent commercailly available 3

in U.S.A.
Valve adjusting w rench 8 07708 - 0030400 or valve adjusting wrench 3
089201-200-000
Float level gauge 07401 - 0010000 4
Valve guide remover, 5.5 mm 07742 - 0010100 7
Valve spring compressor 07757 - 0010000 7
Driver 07749 - 0010000 9,10,11,12,
14 , 15
Attachment, 24 x 26 mm 07746 - 0010700 9, 10
Attachment, 42 x 47 mm 07746 - 0010300 9, 11 , 12,15
Pilot, 17 mm 07746 - 0040400 9, 11
Pilot, 20 mm 07746-0040500 9,11,12
Puller 07933- HB3000A (U.S.A. only I 9
Flywheel holder 07725 - 0040000 or strap wrench , commercially avail- 10
able in U.S.A.
Rater puller 07733 - 0020001 10
Torx driver bit/T401 07703-0010100 or equivalent commercially available 10
in U.S.A.
Socket bit, 17 mm 07703 - 0020500 or equivalent commercially available 12, 14
in U.S.A.
Attachment, 72 x 75 mm 07746-0010600 11
Attachment. 37 x 40 mm 07746 - 0010200 11 ,1 2,14
Pilot, 40 mm 07746 - 0040900 11
Attachment, 52 x 55 mm 07746-00 10400 11,12, 14,15
Pilot, 22 mm 07746-0041000 11,12,15
Inner driver 07746-0030100 1" 15
Attachment, 30 mm J.D. 07746-0030300 11
Attachment, 32 x 35 mm 07746 - 0010100 11, 12,14, 15
Pilot, 28 mm 07746-0041100 12, 14, 15
Pilot, 30 mm 07746-0040700 12
Attachment, 62 x 68 mm 07746-0010500 14, 15
Shock absorber compressor 07959 - 3290001 12, 14
Tire bead breaker set
Breaker arm
07772 - 0050001
07772-0050200
1- 0' Un;v",,,' b"d b,,,k,, GN-
AH - 958 - BB1 (U.S.A. only)
14
14
Breaker arm compressor 07772 -0050100 14
Pilot, 35 mm 07746 - 0040800 15
Pilot, 12 mm 07746 - 0040200 15
Attachment, 35 mm 1.0. 07746 -0030400 15
Inner driver 07746 - 0020 100 15
Inspection adaptor 07508 - 0012500 Not available in U.S.A. 17
Digital multitester 07411 - 0020000 or KS - AHH - 32 - 003 {U .S.A. 17, , 8
only!
Circuit tester (SANWA) 07308 - 0020000 or TH -5H (KOWAl 17, 18
1-8
GENERAL INFORMATION
CABLE & HARNESS ROUTING

Note the following when routing cables and wire harnesses:
• A loose wire, harness or cable can be a safety hazard. After

o X
clamping, check each wire to be sure it is secure.
Q
• Do not squeeze a wire against a welds or clamps.
• Secure wires and wire harnesses to the frame with their

respective wire bands at the designated locations. Tighten
the bands so that only the insulated surfaces contact the
wires or wire harnesses.
• Route harnesses so they afe neither pulled taut nor have

excessive slack.
• Protect wires and harnesses with electrical tape or tubing if

o
~
x
~
they contact a sharp edge or corner. Clean the attaching
o
surface thoroughly before applying tape .
• Do not use a wire or harness with a broken insulation.

Repair by wrapping them with protective tape or replace
them.
X X
4~£=
• Route wire harnesses to avoid sharp edges or corners . Also
avoid the projected ends of bolts and screws.
• Keep wire harnesses away from the exhaust pipes and

other hot parts.
• Be sure grommets are seated in their grooves properly.
• After clamping, check each harness to be certain that it

dose not interfere with any moving of sliding parts.
• After routing, check that the wire harnesses are not twisted
or kinked.
x x x
• Wire harnesses routed along the handlebars should not be
pulled taut, have excessive slack, be pinched by or interfere
with adjacent or surrounding parts in all steering positions.
• Do not bend or twist control cables.

Damaged control cables will not operate smoothly and may
stick or bind.
0: CORRECT
X: INCORRECT
1-9
GENERAL INFORMATION
j 1) FRONT BRI'~E HOSE BRAKE CABLE
~~~~~~~~~~i~~~!
::c-'-""-'''''---:, ,,~H"-"'7''----- ''=----", REVERSE CABLE
(4) FAN MOTOR AIR VENT
TUBE
(17) FUEL PUMP
TUBE
(14) IGNITION '"",TCH-

CONNECTOR
(13) lIGHTINGI
STARTER
SWITCH (16) REAR BRAKE BREATHER TUBE
) fAN MOTOR CONTROL UNIT
(12) "''''0'''
REVERSE
INDICATOR . ~=~~~~'61 BRAKE pev
CONNECTOR ~~F~::::::;;~-;;'t~~f- (PRESSURE CONTROL VALVE)
(11) COl
I ~lvn!---(7:) BRAKE HOSE
(101 BRAKE HOSE

IBI PIPES
Aft er ' 87 :
(9) FRONT
BRAKE 8) IGNIT ION SWITCH
BREATHER TUBE
(22) IGNITION COIL AFTER '86 :
(21) FAN MOTOR CONTROL UNIT
~~~S~~~=
L __ 1191 AIR CLEANER
CASE DRAIN
TUBE
(20) DIFFERENTIAL
BREATHER TUBE
1-10
GENERAL INFORMATION
AFTER ' 86 :
(3) BREATHER TUBES
(4 ) REVERSE
(5) REAR BRAKE

CABLE
(13) BRAKE
CABLE
(12) REAR BRAKE

BREATHER
Tuse COl UNIT
'86, '87: After ' S7: (8 ) IGNITION SWITCH

1111 AEAR BRAKE
CABLE WIRE
(9) OECOMPRESSOR
CABLE: '86, 'S7 only
t 10) AE"EA',E
CABLE
1-11
GENERAL INFORMATION
(1) ALTERNATOR WIRE
(3) CABLE CLlP
(4) STARTER
MOTOR
{51 DECOMPRESSQA
CABLE: '86, '87
114) CABLE ONLY
CUP
(6) ALTERNATOA
WIRES
(7) FUEL
PUMP
(131 CABLE GROUND

CLIP CABLE
(12) BRAKE PEI)AL

1101 NEI"TAIAU (91 CABLE
CABLE
REVERSE BAND
1111 RE'''AS'
~
CABLE
SWITCH/ OIL TARTER. )
TEMPERATURE ALTERNATOR,
SENSOR WIRE GROUND
(16) STARTER MOTOR

CABLE
111) cor'NECn)R BOX
REGULATORI
RECTIF I ER . TO~
ALTERNATOR
(21) BATTERY--__________-1~~~~~ CONNECTOR
AFTER '86:
(19) FUEL
CUT
RELAY
(2Q) REGULA TORI

RECTIFIER
1-12
GENERAL INFORMATION
(1) FUEL CAP

THER TUBE
141 CAIRBUIRE1rOR/
OVERFLOW TUBE
13) CRA.NKC:ASE
BREATHER HOSE A
(6) CARBURETOR BRIEA'rHER TUBE

17) RR,,'r",'" TANK (FOURTRAX ONLY)
(8) BREATHER
TUBE
(9) CRANKCASE
BREATHER
DRAIN TUBE
(13) CRANKCASE
BREATHER
HOSE A
(12) CR,'NK:CASE (11) CA"BU 'RETOF no) DRIVE

BREATHER HOSE B OVERFLOW TUBE BREATHER TUBE
(FOURTAAX ONLY)
1-13
GENERAL INFORMATION
FOREMAN
(2) REAR BRAKE

( 1) DECQMPRESSOR TUBE
CABLE: '86: 87 ONLY (3) COOLING FAN
TUBE
. COl UNIT
171 BRAKE
BREATHER TUBE (5) FUEL
~~====::1:7) AEAR BRAKE BREATHER TUBE

tJ. COLLING FAN BREATHER TUBE
FUEL PUMP BREATHER TUBE
1-14
GENERAL INFORMATION
FOREMAN
FUEL UNIT WIRE
(1) COOLING FAN

BREATHER
(6) Aher '87:

fRONT DRIVE BREATHER TUBE
BRAKE 151 D!FI'ERIENrIAl
BREATHER BREATHER TUBE
TUBE
lS) FUSE CASE

fUEL UN IT
17) FUSE CASE
(9) FUEL UNIT WIRE
(12) STARTER RELAY

SWITCH
11 0) "i"m"T' CABLE
111) CHOKE CABLE
1-15
LUBRICATION
LUBRICATION DIAGRAM
(3) Oil COOLER
Oil FILTER
AFTER 'B6 :
(10) Oil RELIEF VALVE
,.t _____ ,
I '
(1) OIL FILTER SCREEN

,,,-------,'
(8) MAINSHAFT
(9) COUNTEASHAFT
2-0
2. LUBRICATION
SERVICE INFORMATION 2-1 ENGINE OIL & FILTER CHANGE 2 -2
TROUBLESHOOTING 2-1 OIFFERENTIAL/FINAL DRIVE OIL 2-3
ENGINE OIL LEVEL 2-2 LUBRICATION POINTS 2-4
~--------------------------~ II
SERVICE INFORMATION
GENERAL
• Refer to section 6 for oil cooter and cooling fan services .

• Section 9 shows how to service the oil pump.
ENGINE OIL VISCOSITIES
SPECIFICATIONS
Engine oil capacity 2.8 lit (3.0 US qt, 2.5 Imp qtl at disassembly
2 .3 lit (2.4 US qt, 2.0 Imp qU after draining
Engine oil recommendation Use Honda 4-stroke oil or equivalent.

API Service Classification: SE or SF
Viscosi t y: SAE 10W- 40
Other viscosities shown in the chart may be

used when the average temperature in your
riding area is within the indicated range .
-20 -Kl 0 I() 2030 <lO °C
Differential
Oil capacity '86: , 35 cc 14.6 azl at disassembly
100- 110 cc (3 .4 - 3 .7 azl after draining
After '86: 225 cc {7.6 azl at disassembly
200 - 210 cc (6.8 - 7.1 azl after draining
Oil recommendation Hypoid gear oil, SAE #80
Final Drive
Oil capacity '35 cc (4,6 ozl at disassembly
1 OO~, 10 cc (3 . 4 ~ 3. 7 ozl aher draining
Oil recommendation Hypoid gear oil, SAE #80
TORQUE VALUES
Engine oil drain bolt '86, '87: 15 ~ 25Nom(1.5 ~ 2 . 5kg-m, 11 ~ 18ft-lbl

After '87: 20 ~ 30 Nom (2,0 - 3 .0 kg -m , 14 - 22 ft -Ibl
Differential/final drive oll filler cap 10 - 1 4 Nom 11.0 - 1.4 kg -m , 7 - '0 ft -Ibl
Oil filter cover 8 - 12 N·m (0.8 - 1.2 kg -m , 6 - 9 ft-Ibl
TROUBLESHOOTING
Oil level too low - high oU consumption
External oil leaks
Worn piston rings
Oil not changed often enough
Faulty head gasket
Oil contamination
Oil or filter not changed often enough
Head gasket faulty
Worn piston rings
2-1
LUBRICATION
ENGINE OIL LEVEL

(2) UPPER
Place the vehicle on level ground.
LEVEL
Check the oil level using the oil filler capfdipstick by inserting it
into the filler hole without screwing it in.
tf the oil level is below or near the lower level line on the dip-
stick, add the recommended oil (page 2-1) up to the upper
level line.
ENGINE OIL & FILTER CHANGE

NOTE
Change engine oil with the engine warm and the vehicle on
level ground to assure complete draining.
Remove the oil filler cap and drain bolt.
Remove the three bolts attaching the oil filter cover, oil fitter
and spring. Discard the oil filter.
Check that the sealing washer on the drain bolt is in good con-
dition and install the drain bolt.
TORQUE:
'86, '81: 15 - 25 N·m (1.5 -2 .5 kg-m, 11 - 18 ft-Ibl
After '87: 20-30 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-Ibl
Make sure that the oil filter cover O-ring and the other O-ring in
the crankcase are is in good condition. Install the oil filter
spring, filter and cover, and tighten the three bolts.
(1) OIL FILTER
TORQUE : 8 - 12 N·m (0.8-1.2 kg·m, 6 - 9 ft·lbl
Fill the crankcase with re commended oil (page 2-')'
OIL CAPACITY;
2.8 lit (3 .0 US qt, 2.5 Imp qtl at disassemblv
2.3 lit (2.4 US qt, 2.0 Imp qt) attar draining
Install the oil filler cap/dipstick.

Start the engine and let it idle for 2 or 3 minutes.
Stop the engine and check that the oil level is at the upper level (S) SPRING (4 ) OIL FIL TEA COVER
line on the dipstick. Make sure there are no oil leaks.
2-2
LUBRICATION
DIFFERENTIAL/ FINAL DRIVE OIL

CHECK
Place the vehicle on level surface.

Front differential only: Remove the front guard plate by remov -
ing the mounting bolts.
Remove the oil filler cap.
Check that the oil level is within the indicated range
(illustration: tower rightJ .
Fill with the recommended oil if the oille\lel is below the stan-
dard level (The bottom of the threaded section).
Install the oil fi ller cap .
Front differential only: Install the front guard plate.
CHANGE
Front differential only: Remove the front gua rd plate by remov -

ing the mounting bolts.
Remove the oil filler cap and the drain bolt to drain all oil from
the gear case.
Install the drain bolt securely.
fill with the recommended oil to the standard level (The
bottom of the threaded section) .
Oil CAPACITY:
DIFFERENTIAL: 135 cc (4.6 oz) at disassembly
100 - 110 cc (3.4-3.7 ozl after draining.
After '86 : 225 cc 17.6 ozl at disassembly
200 - 210 cc 16.8-7. 1 ozl after draining
FINAL DRIVE : 135 cc 14.6 ozl at disassembly
100 - 110 cc (3.4-3.7 ozl after draining m DlllEVEl RAN GE
RECOMMENDED Oil: Hypoid gear oil SAE #80
Install the filler cap.

(2) Maximum level
TORQUE : 10 - 14 N·m 11.0 - 1 .4 kg -m, 7 - 10 ft -Ibl
Front differential only: Install the front guard plate. (3(
(4) Standard oil level
2-3
LUBRICATION
LUBRICATION POINTS
Use general purpose grease when no other specification is
given. ApplV oil or grease to any 2 sliding surfaces and cables
not shown here.
• Apply silicone grease.
(2) ICABlE LUBRICANT I (3) BRAKE LEVER

THROTTLE CABlEI PIVOTSI
CABLE LEVER PIVOT
,--
(1) BRAKE CAM /ANCHOR PIN
I
.~
(4) STEERING UPPER BUSH ING!
STEERING SHAFT SPLINEI
,
STEERING PIVOT BUSH ING
(5) KN(JeKLE!
(9) SWING ARM KNUCKLE
PIVOT BEARINGSI HOLDER
DUST SEALS (FRONT! PIVOT BEARINGSI
REAR) DUST SEALS
(10) WHEEL HUB/BRAKE DRUM (6) WHEEL HUB (DUST SEAL)
COVER (DUST SEAl)
REAR AXLE SHAFT (S) BRAKE PEDAL I FRONT BRAKE DRUM SEAL (After'S7)
"BRAKE SHOE-lO-BRAKE BACKING PLATE
.~
SPLINE PIVQT/DUST "BRAKE ADJUSTERS
SEALS
171 DRIVE SHAFT
SPLINE
2-4
3. MAl NTENANCE
SERVICE INFORMAnON 3· 1 BRAKE SHOES 3· 8
MAINTENANCE SCHEDULE 3·2 BRAKE SYSTEM 3· 8
FUEL LINE 3· 3 REVERSE LOCK SYSTEM 3·10
FUEL FILTER 3·3 CLUTCH SYSTEM 3· 10
THROTTLE OPERATION
CARBURETOR CHOKE
AIR CLEANER ELEMENT
SPARK PLUG
3·3
3·4
3·4
3·5
SUSPENSION
SPARK ARRESTER CLEANING
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
3·11
3· 11
3· 11
3·12
•
BREATHER TUBE 3·5 STEERING SHAFT HOLDER BEARING 3· 12
VALVE CLEARANCE 3· 5 STEERING SYSTEM 3·12
CARBURETOR IDLE SPEED 3·7 SKID PLATE, GUARD PLATE
(AFTER '86:) 3· 13
CYLINDER COMPRESSION 3·7
BRAKE FLUID 3·7
SERVICE INFORMATION
SPECIFICATIONS
Spark plug gap: 0.6 - 0.7 mm (0.024-0.02B inl
Recommended spark plugs: NGK: DRBES-L (DRBES. DA7ESI
NO: X24ESA-U (X27ESA-U, X22ESR-UI
Valve clearance: Intake: 0.08 mm (0.003 inl
Exhaust: 0.08 mm (0.003 inl
Decompressor free play 1-3 mm (1/32 - 1/8 inl
Idle speed: 1 .400 ± 100 rpm
Cylinder compression 125 - 145 kPa (12.5- 1 4.5 kg/cm 2, 178 - 206 psi)
Thronle lever free play: 3 - 8 mm (1/8 - 5116 inl
Front brake lever free play: 25 - 30 mm (1 - 1-1/4 inl
Rear (parking) brake lever free play: 15 - 20 mm (5/8-3/4 in)
Rear brake pedal free play: 15 - 20 mm (5/8 - 3/4 inl
Reverse selector lever free play: 2 - 4 mm (1 / 16 - 1/8 in)
Front tire size: 24 x 9.00-11
Rear tire size: 24 x 9.00-11
Recommended tire pressure: Front: 2.2 psi 11 5 kPa, 0.15 kg /cm2)
Rear: 2.2 psi (15 kPa, 0.15 kg /cm 2 )
Front tire toe-in Omm(Oin)
camber: 00
caster: 30
TORQUE VALUES
Clutch adjusting screw lock nut 19 - 25 N·m n .9 - 2.5 kg-m, 14 - 18 tt-Jb)
Valve adjusting lock nut 15- 1 8 N·m (1.5-1.B kg-m, 11-13 ft-Ib)
Spark plug 15 - 20 N·m (1.5-2.0 kg-m, 11-14 ft-Ib)
Tap engine hanger nut 70 - 80 N'm (7 .0 - a.0 kg-m, 51 - 58 ft -Ib)
Top engine hanger plate bolt 34 - 40 N·m (3.4- 4.0 kg-m. 25 - 29 ft -tb)
TOOLS
Special
Camber/caster gauge attachment 07910 - MJ30100 (Not available in U.S.A.)
Common
Valve adjusting wrench, 10 x 12 mm 07708 - 0030200 or equivalent commercially available in U.S.A.
Valve adjusting w rench B 07708 - 0030400 or valve adjusting wrench 089201 - 200 - 000
3-1
MAINTENANCE
MAINTENANCE SCHEDULE
The maintenance intervals shown in the following schedule are based upon average riding conditions . The vehicle's subjected
to severe use, or ridden in unusually wet or dusty areas, require more frequent servicing.
Perform the Pre-ride Inspection in the Owner's Manual at each scheduled maintenance period.
INITIAL REGULAR
Inspect and Clean, Adjust, Lubricate or Replace ,
"
SERVICE SERVICE
if necessary Refer to
PERIOD PERIOD
C, Clean R; Replace page
{First week of (Every 30
k Adjust
operation) operating days )
• FUEL LINE (EVERY YEAR) 3-3

"
• FUEL fiLTER R: (EVERY 6 MONTHS) 3-3
• THROTTLE OPERATION , , 3-3
· CARBURETOR CHOKE , 3-4
3-4
AIR CLEANER NOTE 2
,
C
3-5
·
SPARK PLUG
VALVE CLEARANCE , , 3-5
ENGINE OIL R R 2-2
2-2
·
ENGINE OIL FILTER
CARBURETOR IDLE SPEED ,
R R
, 3-7
FINAL DRIVEl (EVERY YEARI
" (EVERY 2 YEARS)
2-3
FRONT DIFFERENTIAL OIL R:
BRAKE FLUID ' B6, '87 R: (EVERY 2 YEARS)
,
After ' S7
After 'ss
.. R: (EVERY 2 YEARS)
NOTE 5 , 3-7
· BRAKE SHOE WEAR NOTE 3

, "
(EVERY YEAR)
, 3-8
3-8
·•
BRAKE SYSTEM
, , 3- 10
REVERSE LOCK SYSTEM
, ,
·
CLUTCH SYSTEM
SUSPENSION , 3- 10
3-11
·• SPARK ARRESTER
NUTS , BOLTS, FASTENERS
NOTE 1
, ,
C 3- 11
3- 11
•• WHEELSITIRES , , 3- 12
·. STEERING SHAFT HOLDER
BEARINGS
(EVERY YEAR) 3- 12
"
·. STEERING SYSTEM
"
(EVERY YEAR)
,
3 - 12
SKID PLATE, GUARD PLATE NOTE 4 I 3-13
• Should be serviced by an authOrized Honda dealer, unless the owner has proper tools and service data and mechanically
qualified .
... In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES: 1. U.S.A. only.
2. Service more frequently when riding in dusty areas, sand or snow.
3. Service more frequently after riding in very wet Of muddy conditions .
4 . After ' 86 models.
5 . Replace every 2 years. Replacement reguires mechanical skill.
3-2
MAINTENANCE
FUEL LINE
Check the fuel lines.
Replace any which show signs of deterioration, damage Of
leaks.
FUEL FILTER
Turn the fuel valve OFF.
Pull the fuel filter f rom its clamp.
Clamp the fuel line between the fuel filter and the fuel pump.
\
Disconnect the fuel lines from the filter.
Replace the fuel filter with a new one as indicated by the
maintenance schedule. (See page 3-21.
Gasoline is flammable and is explosive under certain

conditions. Do not smoke or allo w flames or sparks in )'our
working area.
Secure the new filter in the frame clamp.

After installing. turn the fuel valve ON and check for fuel leaks.
THROTTLE OPERATION
Check for smooth throttle lever operation with complete
opening and automatic closing in all steering positions . Make
sure there is no deterioration, damage or kinking in the throttle
cable. Replace any damaged parts.
Disconnect the throttle cable at the upper end.

Thoroughly lubricate the cable and pivot point with a
commercially available cable lubricant.
Install the throttle cable in the reverse order of rem oval.
Measure the throttle lever free play at the tip of the throttle
lever. (2) LOCK NUT
FREE PLAY : 3 - 8 mm (1 18 - 5116 in)
Adjust as follows:
Slide the rubber boot off the cable adjuster.
Loosen the lock nut and adjust the throttle lever free play by
t urning the cable adjuster.
Tighten the lock nut and install the rubber boot securely.
3-3
MAINTENANCE
CARBURETOR CHOKE
The choke system uses a fuel enrichment circuit controlled by
a starter valve. The starter valve opens the enrichment circuit
via a cable when the choke lever on the handlebar is moved to
the left.
Check for smooth choke lever operation and lubricate the

choke cable if required .
AIR CLEANER ELEMENT

Remove the seat by pulling the seat latch lever.
Remove the air cleaner cover by removing the wing bolt.
Release the retaining clips from the air cleaner case cover, and
remove the cover.
Loosen the air cleaner element band screw.

Remove the element holder attaching screw and remove the
air cleaner element assembly from the case.
Remove the element holder by turning it counterclockwise.

Remove the element band and separate the element from the
element core.
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 - 901 and squeeze out
the excess.
Place the element onto the core and replace the element band
N
~ ~.";j _ ~'3)
, _ @ ~
and holder . DRY _ .~ _ ,
Install the element in the air cleaner case. (2) (4) (5)
Install the air cleaner case cover and clips. (lIWASHIN SQUEEZE OUT GEAR OIL SQUEEZE OUT
Install the air cleaner cover and the seat. SOLVENT SOLVENT (SAE "80 - 90l EXCESS OIL
THOROUGHLY
3-4
MAINTENANCE
SPARK PLUG 1. (1) CENTER ELECTRODE

Disconnect the spark plug cap and remove the spark plug.
Visually inspect the spark plug electrodes for wear.
The center electrode should have square edges and the side
0 .6 - 0 .7 mm
m.024 - 0 .028 in ) I l""
1 - - ( 2 ) CHECK : GAP
DEPOSIT WEAR
electrode should have a constant thickness. (3) SIDE ELECTRODE

Discard the spark plug if there is apparent wear or if the insula-
tor is cracked or chipped. (5) CHECK : SEALING
Measure the gap with a wire-type feeler gauge and adjust if OAMAGE
necessary by carefully bending the side electrode. ...
SPARK PLUG GAP;
~CHECK: CRACKS
0.6 - 0 .7 mm 10.024 - 0 .028 inl
RECOMMENDED REPLACEMENT PLUG : 'Lr
NGK : DRBES-l (DRSES , DR7ES)
NO : X24ESA-U (X27ESR-U, X22ESR-UI
Check the sealing washer and replace with a new one if dam-
...
aged.
With the sealing washer attached, thread the spark plug in by
hand to prevent crossthreading. Tighten the spark plug to the
specified torque.
TORQUE: 15 - 20 N·m 11.5 - 2.0 kg -m , 11 - 14 ft-Ibl
BREATHER TUBE
Remove the plug from the drain tube to empty any deposits.
Install the drain plug.
NOTE
Service more frequently when riding in rain, at full throttle,
or if deposit level can be seen in t he transparent section of
the drain tube.
VALVE CLEARANCE
NOTE
Inspect and adjust the valve clearance while the engine is
cold (below 35°C/ 95°FL
Remove the air cleaner case (page 4-5).

Remove the engine hanger plates by removing the mounting
bolts.
Remove the intake and exhaust valve adjusting hole covers.
Remove t he timing hole and flywheel hole caps .

Rotate the crankshaft clockwise and align the "T" mark on the
rotor with the index mark. The piston must be at TDC on the
compression stroke.
3-5
MAINTENANCE
Inspect the intake and exhaust valve clearances by inserting a

feeler gauge between the adjusting screw and valve stem.
VALVE CLEARANCES:
Intake: 0 .08 mm (0 .003 in)
Exhaust : 0 .08 mm (0 .003 in)
Adjust by loosening the lock nut and turning the adjusting

screw until there is a slight drag on the feeler gauge.
TOOLS:
Valve adjusting wrench, 10 )( 12 mm 07708 - 0030200
or equivalent commercially available in U.S .A .
Valve adjust ing wrench B 07708 - 0030400
or v alva adjust ing wrenc h 0 89201 - 200 - 000
Hold the adjusting screw and tighten the lock nut.
TORQUE: 15 - 18 N·m (1 .5 - 1 .8 kg-m , l' - 13 ft-Ibl
Recheck t he valve clearance.
Install the valve adjusting hole covers.

Install the engine hanger plates and tighten the hanger bolt s
and nuts to the specified torque values.
TORQUE VALUES ;
10 mm nut: 70 - S0 N' m 17 .0 - S.0 kg -m . 51 - 5S ft-Ibl
S mm bolt : 34 - 40 N·m 13.4 - 4 .0 kg -m . 25 - 29 ft-Ib)
Install the air cleaner case.
STARTER DE CD MPRESSOR FREE PLAY

ADJUSTMENT 1'86, '87 onlyl
NOTE
Always adjust the decompressor linkage aft er adjust ing the
valve clearance.
Remove t he timing hole cap and flyw heel hole cap.

Rotate the crankshaft clockwise to align t he " T " mark w ith
the index mark. Make sure the piston is at T DC (Top Dead Cen-
ter) on the compression stroke.
Measure the free play at the tip of the decompressor valve lift-
".
FREE PLAY: 1 - 3 mm 11/32- 1/S inl
Adjust by loosening the lock nut and turning the adjust ing nut.
CAUTION
Excessive free play causes hard starring. Insufficient free play
may cause erratic Mgine idfing and valve damage.
Tighten the lock nut. Operate the kick st art er and check the
operation of the decompressor mechanism .
Recheck free play.
3-6
MAINTENANCE
CARBURETOR IDLE SPEED

NOTE
Inspect and adjust the idle speed after all other engine m ain-
tenance items have been performed and are within specifi-
cations.
The engine must be warm for accurate idle speed inspec-
tion and adjustment .
7
Warm up the engine for about ten minutes.
Turn the throttle stop screw as requ ired to obtain the spec if ied
idle speed.
IDLE SPEED: 1,400 j: 100 rpm
CYLINDER COMPRESSION
Warm up the engine.
Stop the engine and remove the spark plug.
Install a compression gauge.
Open the throttle all the way and crank the engine with the
starter motor until the gauge reading stops riSing.
NOTE
The maximum reading is usually reached within 4 - 7
seconds.
COMPRESSION PRESSURE:
125 - 145 kPa (12.5 - 14.5 kg/c m l , 178 -206 psi)
Low compression can be caused by :

- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder
High compression can be caused by :

- carbon deposits in combustion chamber or on piston head
BRAKE FLUID
Check that the brake fluid reservoir is full. If the level is near
the lower level mark, fill the reservoi r up to the upper level
mark.
Check the entire system for leaks if the level is low .
CAUTION
When adding brake fluid, be sure the resen:oir is hori::,onta/
IN/ore the cap is remo ved, or brake fluid may spill out.
Use only DOT J or " broke fluid from a sealed container.
A void spiffing fluid on pain/ed, plastiC, or rubber parts. Place a
rag over these pariS whenever (he system is serviced.
Never aflow contaminalion (dirt , waler, etc.) 10 enler Ihe brake
fluid reservoir.
3-7
MAINTENANCE
BRAKE SHOES
FRONT BRAKE
Remove the brake shoe lining inspection hole cap and inspect
the lining thickness.
lining thickness:
STANDARD: 4 .0 mm 10. 16 in)
SERVICE LIMIT: 1.0 mm (0.04 in)
NOTE
If either lining is worn beyond the limit, both brake shoes
must be replaced.
After checking, install the inspection hole cap securely to the

drum while pushing the cap with screwdriver as shown.
REAR BRAKE
Replace the brake shoes if the indicator plate aligns with the
brake panel index mark when the rear brake lever or pedal is
applied.
BRAKE SYSTEM 25 - 30 mm (1 -1 ·1/4 in)
FRONT BRAKE
Measure the distance the brake lever moves before the brake
starts to take hold.
Measure at the tip of the front brake lever, should be within the
standard.
FREE PLAY : 25-30 mm 11 - 1-1 /4 in)
If the brake lever free play is excessive and the brake linings
are not worn beyond the recommended limit, adjust the brake
shoe lining-to-drum clearance .
Turn the brake shoe adjuster up with a screwdriver until the

shoes lock, then back off three stops.
Recheck the brake lever free play. If free play is still excessive
after adjusting the brake lining clearance, there is probably air
in the brake system and it must be bled out (section 13).
After checking, inst all the inspection hole cap securely to the
drum while pushing the cap with a screwdriver as shown.
3-8
MAINTENANCE
REAR BRAKE 15 - 20 mm (5 f8 - 3/4 in)
Check the cable, brake lever and brake pedal for loose connec-
tions, excessive play or other damage. Replace or repair if nec-
essary.
Disconnect the brake cables at the brake lever or pedal ends.
Thoroughly lubricate the cables and their pivot points with a

commercially available cable lubricant.
Install the cables.
Measure the rear (parldng) brake lever free play at the end of
the brake lever.
REAR BRAKE LEVER FREE PLAY: 15-20 mm (5/8 -3/4 in)
Minor adjustments can be made with the upper adjuster _Slide

the rubber cover off the adjuster, loosen the lock nut and ad·
just.
Major adjustments should be made with the lower adjusting

nut 8t the tear brake arm.
Measure the brake pedal free play at the end of the brake pedal
and adjust as described below .
BRAKE PEOAl FREE PLAY: 15-20 mm 15/8-3/4 inl
Adjust the rear brake lever and pedal free play by turning the
adjusting nuts at the lower end of the cables.
NOTE
Make sure the cut·out of each adjusting nut is seated on the
brake arm pin.
3-9
MAINTENANCE
REAR BRAKE PEDAL HEIGHT
loosen the lock nut and adjust the pedal height by turning the
stopper bolt.
Tighten the lock nut securely.
After adjustment, check the rear brake pedal free play and
adjust if necessary.
REVERSE LOCK SYSTEM

Check the reverse selector cable and lever for a loose connec -
tion, excessive play or other damage.
Replace or repair if necessary.
Measure the reverse selector lever free play at the lever end
near the cable.
FREE PLAY: 2-4 mm (1 116 - 118 in)

~
~f-
2 - 4 mm (l f 16 - 1/B in)
Adjust by loosening the lock nut and turning the adjusting nut.
Tighten the lock nut securely .
CLUTCH SYSTEM
Remove the rubber cap and loosen the dutch adjusting screw
lock nut.
Slowly turn the adjusting screw counterclockwise until resis -

tance is felt . Then turn the adjusting screw clockwise 1 f4 turn,
and tighten the lock nut.
TORQUE: 19 - 25 N·m 11.9-2.5 kg·m, 14 - 18 h -Ib)
Install the rubber cap.

After adjustment, start the engine and check for proper clutch
operation.
3-10
MAINTENANCE
•• SUSPENSION
Do not r;d~ a ~'ehic1e with faulty susptmsion.

t
I Loose, klorn or damaged suspension parts impair vehicle
stability and comrol.
Check the action of the front/rear shock absorber by pushing

down them several times.
Check the entire shock absorber assembly for leaks or

damage. Replace damaged components which cannot be
repaired .
Tighten all nuts and bolts .
SPARK ARRESTER CLEANING
Do not touch the exhaust components while the exhaust system

Is hot.
Perform this operation in a H'ell·ventlfated aua, free from fiu
hazard.
Use adequau eye prOlection.
Remove the muffler lid .

Start the engine with the transmission in neutral , and purge
accumulated carbon from the spark arrester system by
momentarily revving up the engine several times .
Stop the engine and allow the exhaust system cool. Install the
muffler lid.
NUTS, BOLTS, FASTENERS

Tighten bolts, nuts and fasteners at the regular intervals
shown in the Maintenance Schedule (page 3-2).
Check. that all chassis nuts and bolts are tightened to their cor·
rect torque values (pages 1· 5 through 7). Check. that all cotter
pins and safety clips are in place.
3-11
MAINTENANCE
WHEELS/ TIRES
Check the tires for cuts, embedded nails, or other damage.
Check the tire pressure .
Recommended pressure:
Front : 2.2 psi (15 kPa, 0 . 15 kg/cm 21
Rear: 2.2 psi (15 kPa, 0 .15 kg/cm l )
NOTE
• Tire pressure should be checked when the tires are COLD.
STEERING SHAFT HOLDER BEARING

NOTE
Make sure the cables do not interf ere with the rotation of
the handlebar.
Raise the front w heels off the ground and make sure that the
handlebar rotates freelv .
If the handlebar moves unevenly, binds or has vertical move-
ment, check the steering tower stay bearing (page 12-26).
STEERING SYSTEM
TOE-IN
Place the vehicle on level ground with the front wheels facing \
straight ahead .
Mark the centers of the tires with chalk to indicate the axle
I
center height.
11) TOE-IN GAUGE
Align the toe-in gauge with the marks on the tires as shown.
Check the readings on the gauges scales.
Slowly move the vehicle back until the wheels have turned
180 0 so the marks on the tires are aligned with the gauge
height on the rear side .
3-12
MAINTENANCE
..
Measure the toe-in on the rear part of the tires at the same
points_ A .J
TOE-IN : 0 mm (0 in)
..l-
I
Il) FRONT
+I
When the toe-in is out of specification, adjust it by changing
r---:=
h~
the length of the tie-rods equally w hile measuring the toe-in
{page 12-141.
(q I
r I
B
CASTER
Remove the wheel cap, cotter pin and front axle nut (page 12-
14).
Install a attachment onto the front axle.
Set the camber and caster gauge to the attachment.
Measure the camber

CAMBER: 0 0
TOOLS:
Adapter 07410 - 0010100
Camber/ caster gauge attachment 07910 - MJ30100
(Not available in U .S. A .'
Set the turn gauge under the front wheels.

Measure the caster .
CASTER: 3 0
Caster is not adjustable. If it is out of specification, check the

suspension and frame for damage and replace any parts neces-
sary, then recheck alignment.
SKID PLATE, GUARD PLATE

(AFTER '86:)
The engine guard and skid plates protect the engine, differen-
tial and final drive from rocks.
Check the guard and plates for cracks, damage or looseness at
intervals shown in the Maintenance Schedule.
Replace the guard and plates if they are cracked or damaged .
If the guard and plate bolts are loose, tighten them to 18 ~25
N.m(1.8-2.5kg-m, 13~18ft- lbl
3-13
FUEL SYSTEM
3 - 5 N·m
(0.3 - 0 . 5
4-0
4. FUEL SYSTEM
SERVICE INFORMATION 4-1 CARBURETOR DISASSEMBLY 4 -9
TROUBLESHOOTING 4-2 CARBURETOR ASSEMBLY 4- 12
FUEL TANK 4-3 CARBURETOR INSTALLATION 4 - 14
FUEL PUMP 4-4 PILOT SCREW ADJUSTMENT 4 - 16
AIR CLEANER CASE 4-5 HIGH ALTITUDE ADJUSTMENT 4-16
CARBURETOR REMOVAL 4-8
III
SERVICE INFORMATION
GENERAL
'[ [
Gasoline is extremely flammable and is explosive undercerlajn conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or a/low /lames or sparks in the work area.
CAUTION
Do no/ bend or [wist control cables. Damaged con frO' cables will nor operate smoothly and may slick or bind.
• When disassembling fuel system parts, note the locations of the O-rings. Replace them with new O-rings during re-
assembly _
• The carburetor float chamber has a drain screw that can be loosened to drain gasoline.
• Refer to Section 20 for fuel pump inspection.
SPECIFICATIONS
Fuel tank capacity 10.5 lit (2.8 US gal , 2.3 Imp. gal)
Fuel reserve capacity ' 86, ' 87: 2 .6 lit (0 .7 US gal , 0 .6 Imp . gal)
After '87 : 2.0 lit 10. 5 US gal , 0.4 Imp. gal)
Carburetor
Identification mark QA 03A
Type Dual valve

Venturi diameter 31 mm (1 .22 in )
Float level 18. 5 mm (0.73 in)
Pilot sc rew opening 1-1/2 turns out
Idle speed 1400 ± 100 rpm
Main jet #142
Slow jet #35
Starter jet #100
Throttle lever free play 3-8 mm 11/8-5/ 16 in)
Jet needle 3rd groove from the top
TORQUE VALUE
Insulator band screw 3 - 5 N·m (0.3 - 0.5 kg-m. 2 - 4 ft -Ib)
TOOL
Common
Float level gauge 07401 - 0010000
4-1
FUEL SYSTEM
TROUBLESHOOTI NG
Engine cranks but won 't Itart
No fuel in tank
No fuel to carburetor
Too much fuel getting to cylinder
No spark at plug (ignition malfunction)
Air cleaner clogged
Engine idles roughly. stells, or tun s poorly

Idle speed incorrect
Ignition malfunction
Rich mixture
Lean mixture
Air cleaner dirty
Insulator leaks
Lean mlltture
Carburetor fuel jet clogged
Fuel filler cap vent hole blocked
Fuel filter clogged
Fuel line kinked or restricted
Float valve faulty
Float level t oo low
Intake air leak
Rich mixture
Starter \/8lv e stuck open or damage
Float valve faulty
Float level too high
Carburetor air jet clogged
Air cleaner dirty
4-2
FUEL SYSTEM
FUEL TANK
REMOVAL
Remove the fuel tank guard under the fuel tank.
Remove the seat.

Turn the fue l valve OFF and remove the rear fender (page
1 6-4).
Disconnect the fuel tank breather tube at the fuel cap.
Disconnect the fuel line at the fuel valve and remove the valve
from the fuel tank.
FOREMAN: Disconnect the fuel unit wires
Remove the fear pipe carriers by removing four mounting

bolts.
Remove the fuel tank mounting bolt and pull the tank out of
the frame.
Remove the tank band by removing the nuts.

Check the air vent hole in the filler cap for blockage .
Keep gasoline away from flames or sparks.

Wi/U up spilled gasoline at once.
4-3
FUEL SYSTEM
INSTALLATION
o
Make sure the O-rings are in good condition and install the fuel
tank in the reverse order of removal.
Check for fuel leaks after installing the tank.
(11 FUEL TANK CAP

•
.. !
(3) TANK BAND
FOREMAN
-/
-, -
,,
,
,,,
", \ '
'- "\
(6) FUEL UNIT
(7) FUEL TANK GUARD
FUEL PUMP
Refer to Section 20 for fuel pump inspection.
REMOVA L
Turn the fuel valve OFF.

Remove the seat and the right side cover.
Remove the front fender mounting bolts and screws (right rear
side of fended .
Disconnect the fuel pump wire connectors.
Keep gasoline away from flames or sparks.

Wipe up spilled gasoline at once.
(1) FUEL FtL TEA
~~ ~
Disconnect the fuel tubes and the air vent tube.
Remove the fuel pump mounting bolt and remove the fuel
pump with its band.
INSTALLATI ON ~~r4,.' "-f' /;;fo

Install the fuel pump in the reverse order of removal. / ~~:rER '88
Check for fuel leaks after installing the pump.
(2) FUEL PUMP
4-4
FUELSVSTEM
AIR CLEANER CASE

REM OVAL
Remove the seat and the right and left side covers.
Remove the air cleaner cover by removing the wing bolt.
Remove the frame cross brace by removing the mounting

bolts.
Loosen the tube bands and remove the carburetor connecting
tube.
Remove the air cleaner case mounting bolts.
Remove the fender upper cover (page 16-1).
loosen the air deaner connecting tube bands.
I
TUBE BANDS
Remove the tube clips from the breather tube.
Free the breather tube from the clamp on the frame and then
remove the air cleaner case.
Check the air cleaner case for deterioration and replace if nec·
essary.
Check the breather tube for any restriction.
4-5
FUEL SYSTEM
Remove the inner fenders and front fenders (page 16-2).

Remove the air duct bV removing the mounting bolts.
(2) CASE COVER
(4 ) CRANKCASE
BREATHER
(3) CONNECTING FQURTRAX
TUBe
(1) AIR CASE
FOREFi
MAN L~J
m INNER BOOT
(6) AIR CLEANER
ELEMENT
4-6
FUEL SYSTEM
INSTALLATION
Install the air duct on the duct stays.

Instell the front fender ~p8ge 16-3).
Seat the inner boot groove in the air intake cover 8S shown .
Install the inner fenders !page 16· 3).
AIR INTAKE
COVER
Install the air cleaner case in the frame .

Route the breather tube and clamp it securely (page 1- 13),
Tighten the air cleaner connecting tube bands securely.
(3) AIR CLEANER
-
CONNECTING TUBES
Install the carburetor connecting tube to the air cleaner case

and carburetor. Tighten the tube bands securely.
Install the cross brace and tighten the botts.
Install the air cleaner cover, side covers and seat.
4-7
FUEL SYSTEM
CARBURETOR REMOVAL
Remove the seat, side covers, air cleaner cover and frame
cross brace (page 4-5).
Remove four front fender mounting bolts.

Remove the carburetor connecting tube by loosening the tube
band screws.
Loosen the choke valve nut and remove the choke valve from
the carburetor.
Disconnect the fuel tube at the carburetor.

loosen the carburetor intake pipe bend screw.
Remove the carburetor out of the frame.
Remove the two carburetor cover screws end the cover .
4-8
FUEL SYSTEM
Disconnect the throttle cable end from the throttle drum. (1) THROTTLE
Remove the throttle cable from the carburetor body by loosen-

ing the lock nut.
CAUTION
Do not kink or twisl the thrOflle coble. It will not operate
smoothly and may stick if it is kinked or twisted.
Free the four-way joint f rom the clamp. (21 FOUR-WAY JOINT
Disconnect the air vent and overflow tubes with the four-way
alld three-way joints from the carburetor.
~EE-WAY JOINT
CARBURETOR DISASSEMBLY
CHOKE VA LVE
Disconnect the choke cable end from the choke valve and
remove the valve spring.
Check the valve and spring fo r nicks , grooves or other dam-
age.
Check the valva seat for wear.
PISTON THR OTILE VA LVE
NOTE
The butterfly throttle valve attaching screws are staked and
the valve cannot be removed .
Remove the carburetor top cover bv removing the three

screws.
4-9
FUEL SYSTEM
Remove the throttle arm set screw.

Pull the shaft out and remove the throttle valve with the arm
end washer.
Remove the two screws attaching the arm to the piston end (1) THROTTLE
separate the piston and jet needle from the arm.
(31 THROTTLE
VALVE ARM
Check the parts for wear or damage. {11 VALVE ARM
I I
(31 JET NEEDLE
FLOAT ANO JETS
Remove the four screws and the fl08t chamber.
4-10
FUELSVSTEM
RemOlle the float pin, baffle, float and float lIallie.
Inspect the float lIallie for groolles and nicks, and replace if
necessary.
Inspect the operation of the float lIal\le.
RemOlle the main jet. needle jet holder and needle jet. 111 PILOT 121 SLOW (3) MAIN JET
RemOlle the slow jet. SCREW
Remolle the starter jet. / ./'(4) NEEDLE
Turn the pilot screw in and record the number of turns before it / JET
seats lightly. Use this as a reference for reinstallation. HOLDER
CAUTION
Damage to the pilor screw sellt will occur if the pilot screw is
tightened against/he seat.
Remolle the pilot screw.
Inspect the pilot screw and each jet and replace them if they 111 SLOW JET
are worn or damaged .
Remolle the plug.
Blow all jets open with compressed air.
t7I NEEDLE
JET
(6) NEEDLE
JET
HOLDER ~ .....,....
(5) MAIN JET .,.,
'-0..
0' :----...
o (4) PILOT SCREW
4-11
FUEL SYSTEM
Blow all carburetor body openings open with compressed air.
CARBURETOR ASSEMBLY
•
til
A
o
Install the starter jet, slow jet, needle jet, needle jet holder and (3) MAIN JET (4) NEEDLE
main jet.
CAUTION
I
' /
JET
HOLDER
I
Handle off jets with care. They can easily be scored or
scratched.
Install the pilot screw and return it to its original position 8S

noted during removal.
Perform pilot screw adjustment if a new pilot screw is installed
(page 4 -16).
Install the plug and baffle.
-
4-12
FUEL SYSTEM
FLOAT LEVEL INSPECTION
With the float valve seated and the float arm just touching the
valve, measure the float level with the float level gauge as
shown.
SPECIFICATION : 18.5 mm (0 .73 In)
TOOL:
Float level gauge 07401 - 0010000
The float cannot be adjusted.

Replace the float assembly if it is out of specificstion.
Install a new O-ring in the f loat chamber. (1) OVERFLOW TUBE

Install the f loat chamber, aligning the overflow tube with the
hole in the baffte 8S shown.
Ir,stall the four float chamber screw s.
Install the needle clip on the jet needle.

,-
11) JET NEEDLE
-~
STANDARD SETTING : 3rd groove from the top
Install the piston throttle valve in the reverse order of remo val. (21 3rd GROOVE
from the top
(1) BUTTERFLY THROTTLE

THROTILE VA LVE SYNCHRONIZATION
Close the butterfly throttle valve fully_
4-13
FUEL SYSTEM
Make sure that the piston throttle valve is closed fully. and
there is no clearance between the throttle link and the valve
shaft arm.
Adjust synchronization by opening or closing the slot in the

throttle link.
Install a new O-ring onto the choke valve.

Install the spring over the choke cable and connect the cable
end to the choke valve.
Move the choke lever all the way to the right and left and make
sure the choke valve operates properly.
CARBURETOR INSTALLATION (1) OVERFLOW TUBE
Connect the air vent and overflow tubes to the four -way joint
and three-way joint , then connec t the tubes to the carburetor
as shown.
Clamp the four-way joint securely,
/~
(4) THREE-WAY JOINT
Install the throttle cable round joint to the carburetor body.

Connect the throttle cable end to the throttle drum.
CAUTION
Do not kink or twisl the throltle coble. II wiff not operate
smoolhly and may stick if il is kinked or twisted.
NOTE
• ApplV grease to the throttle cable end.
Tighten the round joint lock nut.
4-14
FUEL SYSTEM
Install t he carburetor cover.

Install the carburetor by aligning its intake pipe boss with the
insulater groove.
Tighten the insulator band screw securely.
Install the choke valve and tighten the valve nut.
Install the carburetor connecting tube and tighten the tube

bands.
TORQUE : 3 - 5 N·m (0 .3- 0 .5 kg-m. 2- 4 ft- Ibl
Route the following cables and tubes (page 1 -10 through 15):
- throttle cable
- choke cable
- air bent tube
- overflow tube
- f uel tube
Install the frame cross brace, side covers, air cleaner cover and
seat.
4-15
FUEL SYSTEM
PILOT SCREW ADJUSTMENT

NOTE
The pilot screw is factory pre-set . Adjustment is not neces-
sary unless the carburetor is overhauled , a new pilot screw
is installed or adjustment is necessary for high altitude rid -
ing.
CAUTION
Damage to the pi/ol screw seal will occur if the pilol screw is
lightened against the seal.
Turn the pilot screw clockwise until it seats lightly and back it
out '- 1/2 turns.
This is an initial setting prior to the fina l pilot screw adjust-
ment.
Warm the engine up to operating temperature .
Stop the engine and connect a tachometer.
Start the engine and adjust the idle speed with the throttle
stop scraw.
IDLE SPEEO; 1.400 :j: '00 rpm
Turn the pilot screw clockwise slowly until the engine stops,
and t hen back it out 2 turns. St art the engine and readjust the
idle speed with the throWe stop screw, if necessary.
HIGH ALTITUDE ADJUSTMENT

SPE CIFICATION S
Between
Below
3 ,000-8 .000 ft
5,000 h 11,500 ml
0 ,000 - 2,500 m)
Main jet #142 #132
Pilot screw
Factory preset , /4 screws in
opening
The carburetor must be adjusted for high altitude riding Ibe-
tween 3 ,000 - 8 ,000 ft / 1,000- 2 ,500 mi .
STANDARD SETTING: 5,000 ft 11 .500 m l max.

HIGH ALTITUDE SETTING : 3.000 ft (1.000 m) min.
The high altitude carburetor adjustment is performed as fol -

lows:
Remove the carburetor Ipage 4-8) and float chamber.
Replace the standard main jet with the high altitude type
1# 132). Assemble and install the carburetor.
Turn-in the pilot screw 1/4 turns from the initial setting.
Start the engine and adjust the idle speed at high altitude to
ensure proper high altitude operation.
CAU TION
Sustained operation below 5,OOO/eet (1.500 m) with the high al-
titude settings may cause engine overheating and engine dam-
age. Instafl the #142 main jet and screw out the pilot screw 114
turns. when riding below 5,000 jeet (1,500 m).
4-16
MEMO
ENGINE REMOVAL/ INSTALLATION
34 - 40 N·m (3. 4 - 4 .0 kg-m , 25 - 29 ft -Ib)

70 - 80 N·m
17.0-8.0 kg -m, 51 - 58 ft-Ib)
50 - 60 N·m
(5.0-6.0 kg-m,
~~ _ _ _ _, 36 -~ 3 ft -Ibl
70 - 80 N'm
17 .0 - 8.0
51 - 58
70 -- S0 N·m
(7.0 - 8 .0 kg-m.
51 - 58 ft -Ib)
18 - 28 N' m
11,8 - 2.B kg-m, 13-20 ft-Ib)
5-0
5. ENGINE REMOVAL/INSTALLATION
70 - 80 N·m
(7 .0 - 8 .0 kg-m ,
S1 - 58fHbl
70 - 80 N·m (7.0 - 8 .0 kg -m . 51 - 5& ft-Ib)
40 - 50 N·m
(4.0 - 5.0 kg-m, 29 - 36 ft ·lbl
• 5-1
SERVICE INFORMA nON 5-2 ENGINE INSTALLATION 5 -7

ENGINE REMOVAL 5-3
SERVICE INFORMATION
GENERAL
• A floor jack or other adjustable support is required to support the engine .

• The following parts or components can be serviced with the engine inst alled in the frame :
Carburetor Kick starter

Oil pump Gearshift linkage
Alternator Cylinder head
Starter motor Cylinder and piston
Clutch
SPECIFICATIONS
Engine oil capacity 2.8 lit (3.0 US qt, 2.5 Imp qtl at disassembly
2 .3 lit (2.4 US qt. 2.0 Imp qtl after d raining
Engine weight (At dry) 56.1 kg 11 24 Ibl
TORQUE VALUES
Top engine hanger nut 70-80 N·m (7.0-8.0 kg-m, 51 -58 ft- Ib)
Tcp engine hanger plate bolt 34 - 40 N·m (3.4-4.0 kg-m, 25 - 29 ft-tb)
Front engine mounting nut (upperllower) 70-80 N·m (7.0-8.0 kg-m, 51 - 58 ft -Ib)
Engine hanger bracket nut 70-80 N·m 17.0-8.0 kg·m, 51 - 58 ft-Ib)
Rear engine mounting nut (upper/ lower) 70-80 N'm (7.0-8.0 kg-m , 51 - 58 ft -Ib)
Foot peg bolt 40 - 50 N'm !4.0-5.0 kg-m, 29-36 tt-Ib)
Muffler band bolt 18 - 28 N·m (1.8-2.8 kg-m, 13-20-ft-lb)
Exhaust pipe joint nut 24-30 N·m (2.4 - 3 .0 kg-m, 17-22 ft -tbl
Muffler mounting bolt 50 - 60 N·m (5.0 - 6.0 kg-m, 36 - 43 ft -Ib)
5-2
ENGINE REMOVAL
Remove the fuel tank (page 4-3).
Remove the front/ rear fenders and carriers (section 16).
Remove the skid plate .
Disconnect the battery negative cable from the battery.

Shift the transmission into neutral.
Drain the engine oil (page 2-2\.
Remove the carburetor (page 4-8).

Remove the fuel pump .
Remove the breather tank (FQURTRAX only)
Disconnect the engine ground and starter motor cables .
Remove the exhaust pipe protector.
loosen the muffler band bolts.
5-3
Remove the front muffler mounting bolt .
Remove the rear and upper muffler mounting bolts.
Remove the rear muffler protector bolt.
Remove the front and upper protector bolts.
Remove the muffler and muffler protector from the rear.
Remove the exhaust pipe joint nuts, then the exhaust pipe .
Remove the bolts attaching the oil hose cover and the cover.
Remo ve the oil hose setting piece, then the oil hoses.
5-4
Remove the right foot peg .
Remove the bolts attaching reverse stopper lever cover and

the cover.
Disconnect the neutral and reverse switch connectors.
Disconnect the oil temperature sensor wire connectors (A her

'87: connector) .
Remove the reverse stopper cable from the reverse stopper

lever.
Remove the kick starter pedal.
Disconnect the decompression cable from the follower lever

and free it from the clamps 1'86, ' 87 only:).
Loosen the crankcase breather hose band and then pull the
breather hose out of the crankcase.
Remove the shift pedal and left foot peg.
5-5
Remove the front drive shaft cover bolts and the cover.
Remove the front driv9shaft (page 10·4).

Loosen the left crankcase breather hose band (FOU RTRAX
ONl VI and pull the breather hose out of the left crankcase
cover.
(2, FRCiNT ORIVESHAFT COVER
Disconnect the alternator and pulse generator connectors.
Place a floor jack or other adjustable support under the engine.
loosen the rear driveshaft boot band.
NOTE
The jack height must be continuously adjusted 50 that the
mounting bolts can be removed, and so stress is relieved
from other bolts until they are removed .
Aemove the top engine hanger bolts and the plates.
5-6
Remove the front upper engine mounting bott.
Remove the engine hanger bracket bolts and the bracket .
Remove the front lower engine mounting bolt.
Remove the rear lower and upper engine mounting bolt.
Carefully separate the engine from the rear driveshah univer-

sal joint, and remove the engine from the frame.
ENGINE INSTALLATION
Engine installation is essentially the reverse of removal.
Apply molybdenum disulfide grease to the output gear shah

splines.
Use a floor jack or other adjustable support to carefully

manuever the engine into place.
CAUTION
Carefully align mounting points with the jack 10 prevent
damage to mounting bolllhreads and wire harness and cables.
Be careful not ta damage Ihe ai/temperature sensor.
5-7
Tighten all the fasteners to the specified torque.
TORQUES:
Top engine hanger nut
70 - 80 N·m 17 .0 - 8 .0 leg-rn, 51 - 58 ft ·lb)
Top engine hanger plate bolt
34 - 40 N'm 13.4 - 4 .0 kg-m. 25 - 29 ft·lb)
Front engine mounting nut (upper/lower)
70 - 80 N·m 17.0-8.0 kg-m. 51 - 58 ft-Ibl
Engine hanger bracket nut
70 - 80 N·m 17 .0 - 8 .0 kg·m, 51 - 58 ft-tb)
Ra8r engine mounting nut (upperllower)
70 - 80 N·m 17.0 - 8 .0 kg -rn , 51 - 58 ft-tb)
Foot peg bolt
40 - 50 N·m (4 .0 - 5.0 kg-m, 29 - 36 ft· lbl
Muffler band bolt
18 - 28 N·m 11 .8 - 2 .B kg·m, 13 - 20 'I-tb)
Exhaust pipe Joint nut
24 - 30 N·m 12.4 - 3 .0 kg·m, 17 - 22 ft -Ib)
Muffler mounting bolt
50-60 N·m 15.0 - 6 .0 kg.m. 36 - 43 ft-Ib)
NOTE
Route the wires and cables property (page '-'0 through
'51.
FiU the crankcase to the proper level with the recommended
oil Ipage 2-2).
Perform the following inspections and adjustments:
- throttle operation Ipage 3-31
- reverse selector cable (page 3- 10)
:m.
Connect the neutral and rel'erse switch wires properly.
If these wire connections are interchanged, the neutral indica-
tor will come on K'ilh the transmission in rtl'erse and the vehicle
will reverse suddenly,
5-8
MEMO
COOLING SYSTEM
10- N·m
(1.0-1.4 kg-m, 7 - , 0 ft -Ibf
6-0
6. COOLI NG SYSTEM
•, SERVICE INFORMATION 6-1 COOLING FAN 6-3
OIL COOLER/OIL HOSES 6-2
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of oil cooler and cooling fan. These parts can be serviced with the engine in the
frame .
• Refer to section 20 for oil temperature sensor and fan motor control unit troubleshoot ing/inspections.
SPECIFICA TIONS
Engine oil capacity 2.8 lit (3 .0 US qt , 2. 5 Imp qU at disassembly

2 .3 lit (2 .4 US qt, 2 .0 Imp qtl after draining
Engine oil recommendation Use Honda 4-stroke o il or equivalent .
API Service Classification : SE or SF
Viscosity: SAE 10W - 40
TORQUE VA LUE
Oil hose set piece bolt 10 - 14 N·m (1.0 - 1.4 kg-m. 7 - 10 ft -Ibl
6-1
COOLING SYSTEM
OIL COOLER/ OIL HOSES

INSPECTI ON
Remove the f ront fende r (page 16 -1\,

Inspect t he oil cooler soldered joints and seams for leaks .
Blow dirt out of core fins with compressed air. If insects, etc"
are clogging the oil cooler, remove them with low pressure
water.
Carefully straighten any bent f ins.
REMO VAL
Drain the engine oil {page 2-21,

Remove the oil hoses f rom the oil cooler by removing the
mounting bolts.
Remove the oil cooler. oil hose guard . clamp and set piece.
Disconnect the oil hoses from the crankcase cover .
INSTALLA TION
Install new D-rings and the oil hoses to the crankcase cover.
Install the set piece and tighten the socket bolts to t he speci-
fied torQue.
TORQUE : 10 - 14 N·m 11.0 - 1.4 kg-m, 7 - 10 ft-Ibl
Install the oil cooler to the f rame and tighten the bolt s secure-
I,.
Connect the oil hoses to the cooler wit h new D-rings .
Tighten the bolts securely.
Route the oil hoses according to the illustration on page 1-11 .
6-2
COOLING SYSTEM
Install the oil hose clamp and guard .

T ighten the bolts securel y .
Fill the crankcase with the re c ommended oil (page 2-2 ),

Start the engine and make sure there are no oil leaks.
COOLING FAN
REMO VAL
Remove the front fender (page 16- 1).

Disconnect the cooling fan wire connec tors.
Remove the oil cooler mounting bolts and move the oil cooler
upward.
Remove the mounting bolts, and lift the fan upward and out of
the frame.
(1) FAN (3) AIR V ENT TUBE

DI SASSEMBLY
Remove the lock nut and pull the fan off the motor shaft.
Disconnect t he cooling fan motor air vent tube.

Remove the three motor attaching screws and separate the
motor from the shroud.
if
6-3
COOLING SYSTEM
ASSEMBLY
Install the fan motor in the shroud and tighten the three screws
securely.
Install the fan onto the motor shaft by aligning their fl ats.
Apply locking agent to the fan motor shaft threads.
Install and tighten the special lock nut .
Connect the breather tube to the f an motor .
INSTALLATION
Install the cooling fan to the frame and tighten t he mounting

bolts.
Aoute the cooling fan motor air ven t t ube correctly (page
'- '0).
Connect the fan motor wire connectors.
Install the oil cooler to the frame and t ighten the mount ing
bolts.
6-4
MEMO
CYLINDER HEADtv ALVES
8 12 N·m
10 .8 - ' .2 kg-m,
6 - 9 ft -Ib) 3 1 7 kg-m ,
~="7 13 17N.m~1. 12h_l b)
12 - 16 N·m
n. 2 - 1 .6 kg-m , ' ________~_:;~
9 - 1 2 ft -)bi
(Aft., '87, -, 10 - 14 N'm ~l":"0lOft_lbl

- 1 .4 kg-rn ,
~1l'J'" ~
, ' 8 ~ . " ~_I1"':h.,~ ~ 1 4 ' - . ri="",,. 8- 12 N'm
~~- ~~ ~ : : , , , , -
(0 .8 - 1. 2 kg-m,
6 - 9 ft-Ib )
L
I
_ - f) Q
'
o;/'"
(1
~~
17 - 23' \ '~/
N'm
7 - 2 .3 kg-m ,
". "
' 2- '7f1-lb) _ _ n
"
- 10 - 14 N·m
(1.0
7 - 1.4 kg-m.
- 10h-lb)
(35 - 4 .5
35 - 45 N·m 25 - 35 I I
" " ' - - - - 35 - 4 5 N·m (35

25 - -334 .ft-l
5 kg-m
b) ,
7-0
7. CYLINDER HEAD/VALVES
SERVICE INFORMATION 7- 1 VALVE SEAT INSPECTIONfREFACING 7-9
TROU BLESHOOTING 7-2 CYLINDER HEAD ASSEMBLY 7- 11
CYLINDER HEAD COVER CYLINDER HEAD INSTALLATION 7-12
REMDVALfDI SA SSEMBLY 7-3
CAMSHAFT INSTALLATlDN 7-13
CAMSHAFT REMOVA L 7-5
CYLINDER HEAD COVER
CYLINDER HEAD REM OVAL 7-6 ASSEMBLY flNSTALLATION 7- 15
VALVE GUIDE REPLA CEM ENT 7-8
SERVICE INFORMATION
GENERAL
• This section covers cylinder head, valves, camshaft, rocker arm and c am chain tensioner lifter services.
These services can be performed with the engine installed in the frame.
• Camshaft lubrication oil is fed to the cylinder head through an oil pipe. Be sure this pipe is not clogged before installation .
• Before assembly, apply molybdenum disulfide grease to the camshaft bearings to provide initial lubrication.
• Pour clean engine oil into the oil pockets in the cylinder head during assembly to lubricate the camshaft lobes.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Cylinder compression 125-145 kPa (12.5-14. 5 kg/ cm l , 178- 206 psi ) --
Cam- C,m IN '86 36.134 - 36.144 mm (1.4226- 1 .4230 in) 35.964 mm (1.4159 in)
shah lobe After '86 35.391 - 35.401 mm 11.3 933 - 1.3937 in) 35.201 mm (1.3859 in)
height
EX '86 35 .926 - 35.936 mm 11.4144 - 1.4148 in) 35.756 m m It .4077 in)
After '86 35.391 - 35.401 mm 11.3933 - 1.3 937 in) 35.20 1 mm (1.3859 in)
Journal R 23.954 - 23.975 mm (0. 9431 - 0.9439 in) 23 .90 mm (0 .941 irt)
0.0 . 23.934 - 23 .955 mm /0. 9423 - 0.9431 in)
C 23 .88 mm (0.940 in)
L 19.954 - 19.975 mm (0.7856 - 0.7864 in) 19.90 mm (0.783 in)
Bearing R,C 24.000 - 24.02 1 mm /0.9 449 - 0.9457 in) 2 4 .05 mm (0.947 in)
LO.
L 20.000 - 20.021 mm (0.7874 -0. 7882 in) 20 .05 mm (0.789 in)
Oil R, L 0.025 - 0 .067 mm (0.00 10 - 0.0026 in) 0 . 10 mm (O.004 in)
clearance C 0.045 - 0.087 mm (0.0018-0.0034 in) 0.'2 mm 10.005 inl
Cylinder head warpage -- 0 . 10 mm (0.004 in)
Rocke r J.D. 11 .988 - 12.006 mm {OA720 - 0A727 in) 12 .04 mm (OA 74 in)
"m Shaft 0.0. 11.966 - 11.984 mm {O A71 1 - 0A718 in) 11 .92 mm {O.469 in)
Arm-to·shaft clearance 0.016 - 0.052 mm (0.0006 - 0.0020 in) 0.08 mm (0 .003 in)
Valve Free Inner 35.15 mm ( 1.384 in) 32 .2 mm ( 1.2 7 in)
spring length
Outer 45.75 mm (1.80 1 in) 42 . 7 mm (1.68 in)
Preload Inner 6.3:t: 0.6 kg /26.8 mm (13.8 9 ± 1.32 Ib/ l .0S in) --
Outer 16 ± 1.6 kg/30.8 mm (35.28 ± 3 .53Ibl 1.21 in) --
7-1
CYLINDER HEAD/VALVES
ITEM STANDARD SERVICE LIM IT
Valve, valve Stem 0.0 . IN 5 . 4BO ~ 5 . 490 mm (0.2157-0.2 161 in) 5.45 mm (0.215 in)
guide
EX 5.460 - 5 .470 mm (0:2150 - 0.2154 in) 5.43 mm (0.214 in)
Guide 1.0. IN 5.500 - 5.512 mm (0.2165-0.2170 in) 5.525 mm (0.2175 in)
EX 5.500 - 5.512 mm (0.2 165 - 0.2170 in) 5.525 mm (0.2175 in)
Stem-ta-guide IN 0.010 - 0.032 mm (0.0004-0.0015 in) 0.12 mm (0.005 in)
clearance EX 0 .030 - 0.052 mm (0.0012-0.0022 in) 0.14 mm (0.006 in)
Valve seat width ' .2 mm (0.05 in) 1. 5 mm (0.06 in)
TORQUE VA LUES
Cylinder head cap nut 35 - 45 N·m (3.5-4.5 kg -m, 25 - 33 ft-Ib)

Cylinder head flange bolt 35 - 45 N·m (3. 5 - 4 . 5 kg -m, 25 - 33 ft-Ib)
Cam sprocket bolt 17 - 23 N'm n .7 - 2 .3 kg -m , 12 - 17 ft-Ib) Apply locking agent
Cylinder head cover {7 mm flange bolt I 13 - 17 N'm (1.3 - 1.7 kg-m, 9 - 12 ft-lb)
(6 mm SH bolt I 8- 12 N·m 10.8 - 1.2 kg -m, 6 - 9 ft-Ib)
(6 mm flange bolt I 10- 14 N·m 11.0 - 1.4 kg-m, 7 - 10 ft·lb)
Oil path pipe bolt (Oil control bolt B) 12 - 16 N·m 11 .2-1.6 kg. m, 9 - 12 ft-Ib)
TOOLS
Special
Valve guide reamer, 5 .5 mm 07984 - 2000000 or 07984 - 200000A (U.S.A . only)
Common
Valve guide rem over, 5.5 mm 07742 - 0010100
Valve spring compressor 07757 - 0010000
Velve seet cutter, 29 mm (EX 45 °~ 07780 - 0010300
Valve seat cutter, 33 mm (IN 45 °) 07780 - 0010800
Valve seat cutter, 30 mm (EX 32 °) 07780 - 0012200
Valve seat cutter, 35 mm (IN 32 °) 07780 - 0012300
Valve seat cutter, 30 mm (EX, IN 60°) 07780 - 0014000
Cutter holder 0778 1- 0010101
NOTE : Valve seat cutters are commercially available in U.S.A.
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by
tracing engine noises to the top·end with a sounding rod or stethoscope.
low compression Eltcesslve noise

Valves: Incorrect valve adjustment
- Incorrect valve adjustment Sticking valve or broken valve spring
- Burned or bent valve Damaged or worn rocker arm or camshaft
- Incorrect valve timing Worn or damaged cam chain
- Weak valve spring Worn or damaged cam chain tensioner
Cylinder head: Worn cam sprocket teeth
- leaking or damaged head gasket
- Warped or cracked cylinder head Poor idling
Cylinder and piston (Section 8) • Compression too low
High compression
Excessive carbon built-up on piston crown or on com-
bustion chamber
7-2
CYLINDER HEAD COVER REMDVALI

DISASSEMBLY
REMOVAL
Remove the following parts:

- front fender {page 16-1 1.
- air cleaner case Ipage 4 -5J.
- carburetor (page 4-81.
- 6 mm bolt, oil path pipe bolts and oil path pipe .
Disconnect the decompression cable from the valve lifter lever

1'86, '87 only) .
After '87:
In ? T" PIPE BO~TS ::O=
(2) Oil PATH PIPE
Remove the top engine hanger bolts and plates.
Remove the valve adjusting hole covers and loosen the valve
adjusting screw lock nuts and screws .
Loosen the cylinder head cover bolts in 2 or 3 steps in a
c risscross pattarn, starting with the centor bolt, and remove
the bolts and cylinder head cover.
DI SASSEMBLY 111 DOW':L PIN _____ (2 ) LIFTER

, ____ LEVER
Remove the valve lifter lever dowel pin .
•
7-3
Groove the rocker arm shaft dowel pins with a grinder and
drive the dowel pins out using 8 screwdriver.
Pull the rocker arm shafts out of the cover and remove the
rocker arms.
13i1)'OWIEL
PINS
IN SPECTION
Inspect the rocker arms and shafts for wear or damage .
NOTE
If the rocker arms require servicing or replacement, inspect
the cam lobes for scoring , chipping or flat spots .
Measure the LO. of each rocker arm.
SERVICE LIMIT: 12.04 mm 10.474 lnl
Measure the 0 .0. of each rocker arm shaft.
SERVICE LIMIT : l ' .92 rnm 10.4 69 in)
Calculate the rocker arm-te-shaft clearance.
SERVICE LIMIT: 0 .08 mm (O.a03 Inl
'86, '87 :
Inspect the valve lifter lever, re turn spring and oil seal f or wear
or damage .
' 7.<.~~~~~~~
13) VALVE LIFTER LE V ER
After' S7 : After 'S7 :

Inspect t he valve lifter lever, return springs, decompression
0) OIL SEA L
lever and oil seal fo r wear or damage.
14 ) RE T URN
SPRI NG
7-4
CYLINDER HEAD/V ALVES
CAMSHAFT REMOVAL
REM OVAL
Remove the two cam chain tensioner attaching bolts and the
tensioner.
Remove the timing and flvwheel hole caps.
Turn the flywheel clockwise and remove the cam sprocket 121 CAM SPI'OC:KEir1
bolts and cam sprocket. T
Remove the camshaft.
Suspend the cam chain with a piece of wire to prevent it from

falling into the crankcase.
Remove the camshaft side cap.
INSPECTION
Using a micrometer, measure the height of each cam lobe and

inspect it for wear or damage.
'86 After '86
-------
IN
35.964 mm
(1.4159 in) 35.201 mm
35.756 mm (1.3859 in)
EX (1.4077 in)
7-5
Measure t he camshaft journal 0.0. (1) LEFT
SERVICE LIMITS :
Left: 19.90 mm 10.783 in)
121 0 FNTI' R
Right: 23 .90 mm (0.941 in)
Center: 23 .88 mm (0 .940 in)
(3) RIG HT
Install the cylinder head cover and tighten the cover bolts in a
crisscross pattern in 2 or 3 steps.
TORQUE:
6 mm small head bolt : 8 - 12 N·m (0 .8 - 1.2 kg-m, 6 - 9 ft-Ibl
6 mm flange bolt : 10 - 14 N·m 11.0 - 1.4 kg-m . 7 - 10 ft-tbl
7 mm flang e bolt : 13 - 17 N·m 11.3 - 1.7 kg-m , 9 - 12 ft-tbl
M easure the camshaft journal bearing I.D.
SERVICE LIMITS :
left : 20 .05 mm (0.789 in)
Right and center: 24.05 mm (0.941 in)
Calculate the camshaft-ta-bearing clearance.
SERVICE LIMITS :
left and right: 0 . '0 mm (0.004 in)
Center: 0 . 12 mm (0.005 in )
CYLINDER HEAD REMOVAL

REMO VAL
Remove the following parts:

- cylinder head cover (page 7-3)
- exhaust pipe !page 5~3)
Remove the cylinder head cap nut s end flange bolts in a

crisscross pattern in 2 - 3 steps.
Remove the cylinder head.
Remove the carburetor insulator from t he cylinder head.
Remove the heed gasket, dowel pins end cam chain guide.
7-6
DISASSEMBLY
Remove the valve spring cotters, retainers, springs and valves

with the Valve Spring Compressor.
TOOL :
Valve spring compressor 07757 - 0010000
CAUTION
To prevent loss of tension, do nOf compress Ihe valve springs
more than necessary /0 remove the cotlers.
NOTE
Mark all parts during disassembly so they can be placed
back in their original locations.
Remove the va lve stem seals and valve spring seats.
INSPECTION
• CYLINDER HEAD
Remove carbon deposits from the combustion chamber.
Clean any gasket material off the cylinder head surface .
Check the spark plug hole and valve areBS for cracks.
Check the cylinder head for warpage with a straight edge and
feeler gauge.
SERVICE LIMIT: 0.10 mm 10.004 Inl
• VALVE SPRING FREE LENGTH

Measure the free length of the inner and outer valve springs .
SERVICE LIMITS :
Inner : 32.2 mm 11 .27 in)
Outer: 42.7 mm 11 .68 in)
Replace the springs if they are shorter than the service limits .
• VALVE STEM ·TO·GUIDE CLEARANCE

Inspect each valve for bending , burning or abnormal stem
wear.
Check valve movement in the guide.
Measure and record each valve stem 0 .0 .
SERVICE LIMITS: IN : 5.45 mm 10.215 in)

EX: 5.43 mm 10.214 in)
7-7
NOTE \11 VALVE G'{ID \.~~~!l:,

Ream the guides to remove any carbon deposits before
checking clearances. •
TOOL:
Valve guide reamer, 5.5 mm 07984 - 2000000 or
07984 -200000A (U.S. A .
only)
Measure and record each valve guide 1.0.
SERVICE LIMIT: 5.525 mm 10.2175 inl
Subtract each valve stem 0.0 . from the corresponding guide

I.D. to obtain the stem-la-guide clearance .
SERVICE LIMITS: IN : 0 . 12 mm (0.005 in)

EX: 0.14 mm 10.006 in)
If the stem-lo-guide clearance exceeds the service limits, de-
termine jf a new guide with standard dimensions would bring
the clearance within tolerance. If so, replace any guides as
necessary and ream to fit .
If the stem-la-guide clearance exceeds the sreviee limits with
new guides also, replace the valves.
NOTE
Reface the valve seats whenever the valve guides are re t
placed .
VALVE GUIDE REPLACEMENT (1)VALVE GUIDE
Heat the cylinder head to tOO - 1 50°C (212-300° F) with a

hot plate or oven .
. .11 .
To avoid burns, wear heavy gloves when handling Ihe heated
cylinder head.
CAUTION
Do nOf use a lorch 10 heal the cylinder head: it may cause
warping.
Support the cylinder head and drive the old guides out of the
combustion chamber side of the cylinder head. ( 1 ) VALVE GUIDE
REMOVER
TOOL:
Valve guide remover, 5.5 mm 07742 - 0010100
CAUTION
• A void damaging /0 Ihe cylinder head.
Install a new O-ring onto a new valve guide. Drive in the guide
from the top of the head.
TOOl;
Valve guide remov er, 5 .5 mm 07742 - 0010100
7-8
CYLINDER HEAD/vALVES
Inspect the valve guide for damage. (1) VALVE GUIDE REAMER
Ream the new valve guide after installation.
TOOL:
Velva guide reamer, 5.5 mm 07984-2000000 or
07984 - 200000A (U.S. A.
only)
NOTE
Use cutting oil on the reamer during this operation.
• Always rotate the reamer in the same direction .
Clean the cylinder head thoroughly to remove any metal parti-

cles .
Rafsee the valve seat.
VALVE SEAT INSPECTION/REFACING

Clean the intake and exhaust valves thoroughly to remove
carbon deposits.
Apply a light coating of Prussian Blue to the valve seats. Lap
the valves and seats using a rubber hose or other hand-lapping
tool.
Remove and inspect the valves.
CAUTION
The valves cannot lw ground. 1/ a valve face is burned or badly
worn or if if cOn/acls the seat unevenly, replace the va/I'e.
Inspect the width of each valve seat.
STANDARD : 1.2 m m !0.05 in)

SERV ICE LIMIT : 1.5 mm (0.06 in)
If the seat is too wide, too narrow or has low spots, the seat
must be ground.
I (11 SEAT WIDTH
VA LVE SEAT CUTTERS
Honda Valve Seat Cutters, a grinder or equivalent valve seat

ref acing equipment are recommended to correct a worn valve
seat .
NOTE
• Follow the retacer manufacturer's operating instructions.
I
"""
7-9
VALVE SEAT RE FAC ING

111 ROUGHNESS
/
Use a 45 degree cutter to remove any roughness or irregulari-
ties from the seat.
NOTE
Rafsee the seat with 8 45 degree cutter whenever a valve
guide is replaced.
Use a 32 degree cutter to remove the top 1/4 of the existing

valve s8at materiel.
Use a 60 degree cutter to remove the bottom 1/4 of the old

seat. Remove the cutter and inspect the area you have
refaced. i 1I OLD SEAT W IDTH
InSlali a 45 degree finish cutter and cut the seat to the the
proper width. Make sure that all pitting and irregularities are re-
moved . 1.2 mm iO.05 in)
Refinish if necessary.
7-10
,
r
,.
CYLINDER HEADIV ALVES
Apply a thin coating of Prussian Blue to the valve seat. Insert

the valve through the valve guide until it seats to make 8 clear I ' 1 CONTACT TOO HIGH
pattern ,
NOTE
The location of the valve seat in relation to the valve face is
-- / "
(2) OLD SEAT WIDTH
very important for good seating.
I If the contact area is too high on the valve, the seal must be
lowered using a 32 degree flat cutter. 32'L_ -'"
If the contact area is 100 low on the valve, the seat must be
III CONTACT TOO LOW
raised using a 60 degree inner cutter.
~\~ ,
/21 OLD SEAT WIDTH
---6;:;;;06
Refinish the seat to specifications, using a 45 degree finish
cutter.
After cutting the seat, apply lapping compound to the valve
face. and lap the valve using hand lapping tool.
After lapping, wash all residual compound off the cylinder

head and valve.
NOTE
• Do not allow lapping compound to enter the guides.
CYLINDER HEAD ASSEMBLY (1 ) VALVE
Install the valve spring seat and a new stem seal.
lubricate the valve stems with molybdenum disulfide grease

and insert the valve into the valve guide.
l
/21 SPRING SEAT
(3) STEM SEAL
,4, ~~~,~~S
To avoid damage to the stem seal, turn the valve slowly when
inserting.
0.(2
Install the valve springs with the t ightly wound coils facing the
cylinder head . (6fRET AtNEA
15) COTTERS
-_-,S::o.~8 .. ..
7-11
CYLINDER HEAD/VAlVES
Install the valve spring relainers and the valve cotters.
TOOL:
Valve spring compressor 07757 - 00 10000
CAUTION
To prevent loss oj tension, do nor compress the valve spring
more than necessary.
Tap the valve stems gently with a plastic hammer to f irm seat
the cotters.
CAUTION
Support/he cylinder head oOOn'the work bench sur/ace to pre-
vent possible valve damage.
Install a new O-ring in the carburetor insulator groove and in-

stall the intake pipe with two bolts.
CYLINDER HEAD INSTALLATION

Install the bottom end of the cam chain guide into the groove
in the right crankcase, and its bosses in the grooves in the cyl-
inder upper surf ace.
Install t he dowel pins and a new cylinder head gasket.
InSlali the cylinder head, and tighten the cylinder head cap
nuts and flange bolts in a crisscross pattern in 2 or 3 steps.
TORQUE:
Cap nut: 35 - 45 N-m
(3 .5 - 4 .5 kg-m, 25 - 33 ft-Ibl
Flange bolt: 35 - 45 N'm

13.5 - 4 .5 kg-m , 25 - 33 h -Ibl
Install the exhaust pipe.
7-12
CAMSHAFT INSTALLATION
Align the "T" mark on the flywheel with the index mark on the
alternator cover by turning the flywheel clockwise.
Apply molybdenum disulfide grease to the camshaft journals.
Install the cam sprocket, camshaft and camshaft side cap.
NOTE
• Install the cam sprocket with its timing marks facing to left.
Position the cam lobes down and align the timing marks on the
cam sprocket with the cylinder head upper surface.
Rail the cam chain over the cam sprocket and insta ll the cam
sprocket onto the shoulder of the camshaft.
Apply locking agent to the threads of the cam sprocket bolt. (1) CAM SPROCKE~T""-"""'"
Tighten the cam sprocket bolt on the punch mark side first, BOLT
then turn the c rankshaft clockwise one turn and tighten the
other sprocket bolt to the same torque.
TORQUE: 17 - 2 3 N·m 11.7 - 2 .3 kg-m , 12 - 17 ft -Ibl
7-13
Realign the " T " mark with index mark and recheck the cam ";';';"'TiMiNi': MARKS
sprocket timing marks.
Fill the oil pocket in the cylinder head with fresh oil.
Remove the cam chain tensioner sealing bolt and washer from
the tensioner .
Turn the tensioner shaft clockwise with a small screwdriver to
retract the tensioner. and hold it in the fully retracted position .
NOTE
The tensioner will be forced out by the spring when it is re -
leased.
Wedge the tensioner shaft with a piece of hard wire as shown

to hold the tensioner .
7-14
Install a new cam chain tensioner gasket.
Install the cam chain t ensioner and tighten the attaching bolts
securely.
Remove a piece of hard wire from the cam chain tensioner.
HARD WIRE
Install the washer and bolt, and tighten the bolt securely.
CYLINDER HEAD COVER ASSEMBLY /

INSTALLATION
ASSEMBLY
Oil the rocker arm shaft s and arms.
Install new O-rings in the grooves of the rocker arm shafts.
.
Install the rocker arms and shafts, aligning the cut-out in the
shafts with the cover mounting hole and insert the dowel pins. •
"---
(21 a-RINGS
' 86, '87 :

Install the oil seal, valve lifter lever and return spring. and
insert the dowel pin. -
'86 : ' 87:
lOlL
SEAL
111 LEVER
~L
(3) SPRING
{4~1o"OneW"""'L"P"'IN
------
7-15
After ' 87 : After '87 :

Install the oil seal, return spring and valve lifter lever, and
(1) I SEAL (31
insert the dowel pin.
Instatl the return spring and decompression lever. DECOM -
PRESSION
LEVER
INSTALLA TION
POSition the camshaft so that both cam lobes face down by ro -

tating the crankshaft.
Apply liquid sealant to the mating surfaces of the cylinder head

cover.
NOTE
• Do not apply sealant to the camsha ft journal surfaces.
Install the two dowel pins into the cylinder head and install the
cylinder head cover .
Tighten the cylinder head cover bolts in a criss cross pattern in (2) 6 mm FLANGE 11) 6 mm SH
2 or 3 steps, staning with the center bolt.
TORQUE :
6 mm small head ISH) boh :
8 - 12 N·m (0 .8 - 1.2 kg-m . 6 - 9 ft -Ibl
6 mm flange bott:
10- 14 N·m 11 .0 - 1.4 kg-m , 7 - 10 ft-Ibl
7 mm flange bolt :
13 - 17 N·m (1.3 - 1 .7 kg-m, 9 - 12 ft-Ibl
) 6 mm SH
(Af ter ' 87 :
InstaU the valve adjusting hole covers _
(4)7 mm 6 mm FLANGE)
BOLTS BOLT
NOTE
Three cylinder head cover bolts have copper washers _

Note their locations. ~________,C(1"'BB~O~LT
~SS
Make sure that the oil path pipe and oil path pipe bolts are not
clogged, and that the sealing washers are in good condition .
Y
7-(3"" O" ,'""
L
L"P;-';
A'TH PIPE
(2) WASHERS
SZ
7-16
Install the oil path pipe with the oi l path pipe bolts. sealing '86 , •
washers and 6 mm bolt. (1) OIL
Tighten the oil path pipe bolts and the 6 mm bolt .
TORQUE :
Oil path pipe bolt : 12 - 16 N·m 11 .2- 1 .6 kg -m , 9 - 12 ft-Ib)
Adjust the valve clearance (page 3 -5 \ and test the cylinder

compression (page 3-7).
Install the decompression cable and adjust the decompression

cable free play (page 3-6) 1'86, '87).
Install the carburetor and fuel tank (section 4).

Install the top engine hanger plates (page 5 -8).
Install the air cleaner case and the front fender . After ' 87 :
(1) OIL PATH PIPE BOLTS
?~ ,
~o~
1(2) Bmm
BOLT
(3) OIL PATH PIPE
7-17
CYLINDER/PISTON
8 - 12N·m
10 .8 - 1.2 kg.m,
6 - 9 ft-Ib)
8-0
8. CYLINDER/PISTON
SERVICE INFORMATION B-' PISTON 8-3
TROUBLESHOOTING B-' PISTON/CYLINOER INSTALLATION 8 -4
CYLINOER 8-2
SERVICE INFORMATION
SPECIFICATIONS

Cylinder 1.0 . el .000- 81.010 mm (3 .1890 - 3 . 1894 inl 81.10 mm 13. ' 93 in)
Taper -- 0.10 mm 10.004 in)
Out of round -- 0.10 mm !O.004 in)
Warpage across top -- 0.10 mm 10. 004 in )
Piston,
piston pin,
piston rings
Piston 0 .0 .
Piston pin bore
Piston pin 0.0 .
80 .965 - 80.985 mm (3 .1876 - 3.1884 in )
21 .002 - 21 .008 mm (0 .8269 - 0 .8271 in)
20 .000 - 20.994 mm 10.7874-0.8265 in)
80.90mm 13. 185 in)
2 t .04 mm m .828 in )
20.96 mm 10.825 in)
IE
Piston-ta-pin clearance 0 .002 - 0.014 mm (O .OOOt -0.0006 in) 0.02 mm 10.001 in)
Piston ring -ta-ring TOP 0 .015 - 0 .045 mm (0 .0006 - 0 .0018 in ) 0.09 mm 10 .004 in )
groove clearance SECOND 0 .015 - 0 .045 mm 10.0006 - 0 .0018 in ) 0 .09 mm 10.004 in)
Piston ring TOP/ SECOND 0 .20 - 0 .35 mm (0 .008-0.0 14 in) 0 .55 mm (0 .022 in)
end gap --
OIL 0.20 - 0.70 mm [0 .008 - 0.028 in)
Cylinder-to-piston clearance 0.015 - 0.045 mm {0.0006 - 0.001S in) 0 . 10 mm (0.004 inJ
Connecting rod small end 1.0. 21 .020 - 21.041 mm {0.8276 - 0.8284 in) 21 . 10mm (O.831 in )
TORQUE VALUE
Cylinder mounting bolt 8-12 N,m {O.8 - 1.2 kg -m , 6 - 9 ft -Ib)
TROUBLESHOOTING
Low or unstable compression Overheating
Worn cylinder or piston rings Exces sive carbon built-up on the piston head or com-
• Cylinder head and valves (Section 7) bust ion chamber wall
E)lcessiva smoke Knocking or abnormal noise

Worn cylinder, piston or piston rings Worn piston and cylinder
Improper inst allation of piston rings • Excessive carbon built-up
Scored or scratched piston or cylinder wall
8-1
CYLINDER/PISTON
CYLINDER
REMOVAL
Remove the cylinder head {page 7-61
Remove the cylinder mounting bolts and cylinder.
Remove the cylinder gasket and dowel pins.
Clean any gasket material off t he cylinder base surf ace . (1 I BASE SUAF/ICE
NOTE
• Be careful not to damage the gasket surf ace.
INSPE CTION
Inspect t he cylinder bore for wear or damage.

Measure the cylinder I.D. in X and Y axis 8t three levels.
Take the maximum reading to determine t he cylinder wear.
SERVICE LIMIT : 81.10 mm (3 .193 In)
Calculate the piston-to -cylinder clearance. Take the rn811imum

reading to determine the clearance.
Re f er to page 8-4 f or m easurement of the piston 0. 0 .
SERVICE LIMIT: 0 .10 mm 10.004 In)
l
Calculate the taper and out of round at three levels in X and Y
8xis. Take the maximum reading to determine t hem .
!ii~i(11
,'
(3) BOTTOM
TOP
(2 ) MIDDLE
SERVICE LIMITS :
Taper: 0 .10 mm (0.004 In) EB> X
Out of round: 0 .10 mm (0 .004In) Y
8-2
CYLINDER/PI STON
Inspect the top of the cylinder for warpage.
SERVICE LIMIT : 0 . 10 mm (0 .004 in l
PISTON
REMO VAL
Remove the piston pin clip with pliers.
NOTE
• Do not let the clips fall into the crankcase.
Press the piston pin OUI of the piston and remove the piston .
PISTON RING INSPECTION
Remove the piSton rings.
NOTE
• 00 not damage the piston rings during removal.
Measure the piston ring-lo-gro ove clearance.
SERVICE LIMITS :
Top: 0 .09 mm (0 .004 inl
Second: 0 .09 mm {Q.004 inl
Inspect the piston for wear or damage.
Insert each piston ring squarely into the cylinder and measure
the ring end gap .
NOTE
Push the rings into lhe cylinder with the top of the piston to
be sure they are squarely in the cylinder.
SERVICE LIMIT:
Top /Second: 0 .55 mm (0 .022 inl
8 -3
CYLINDER/PISTON
Measure the diameter of the piston at 10 rnm (004 in) from the
bottom and 90 " to the piston pin hole.
SERVice LIMIT: 80.90 mm (3. 185 in)
Compare this measurement with the service limit and calculate

piston-la-cylinder clearance.
Refer to page 8-2 for cylinder bore inspection.
SERVice LIMIT: 0 . 10 mm (0 .00 4 In)
Measure the piston pin bore.
SERVICE LIMIT; 2 1.04 mm (0 .828 Inl ,

~
Measure the 0.0. of the piston pin . •

SERVICE LIMIT: 2 0. 96 mm (0 .825 in )
Calculate the piston-la-piston pin clearance.
SERVICE LIMIT : 0.02 mm (0 .001 In)
Measure the connecting rod small end 1.0.
SERVICE LIMIT: 2 1. 10 mm (0. 8 3 1 in)
PISTON/CYLINDER INSTALLATION
Clean the piston ring grooves thoroughly and install the piston
rings.
8-4
CYLINDER/PISTON
NOTE
Avoid piston and piston ring damage during installation.
Install the piston rings with the markings (T or RJ facing up.
Do not mix the top and second rings.
Space the piston ring end gaps 120 degrees apart. (11 "T" OR "R"'
Do not align the gaps in the oil rings (side rails) .
After installation, the rings should rotate freely in the ring

grooves.
(2) TOP RING
1-._-- (3) SECOND RING
(4) SIDE RAIL

(5) SPACER
I (6 (
OIL RING
(4 ) SIDE RAIL
(2) TOP RING
(7) 20 mm in)
OR MORE
_ (3) SECOND RING
Clean any gasket material off the crankcase surface.
NOTE
• Be careful nOI to damage the gasket surface.
8-5
CYLINDER/PISTON
Install the piston and piston pin, using new piston pin clips.
NOTE
Face the piston "IN" mark toward the intake valve side.
Do not align the piston pin clip end gap with the piston cut-
out.
Do not let the clip fall into the crankcase.
Install a new gasket and dowel pins.
Coat the cylinder bore and piston rings with engine oil and in-
stall the cylinder.
NOTE
Avoid piston ring damage during installation.
• Do not let the cam chain fall into the crankcase.
Install the cam chain guide.
Install the cylinder mounting bolts but not tighten them.
Install the cylinder head (page 7-12!.
Tighten the cylinder mounting bolts.
TORQUE: 8 - 12 N·m 10.8 - 1.2 kg-m , 6 - 9 ft -lbl
-
Install the following:
I
- camshaft (page 7·13)
- cylinder head cover (page 7- 16)
8-6
MEMO
100 - 120 N·m

(10.0-120 . k g-m
72 - 87 ft -lb) •
~®~
~ ~••~";JI.. (0.8- 1 . 2 kg-m

6 - 9 ft -Ib) ,
After '87
10 - 14N·m
(71.0 - 14k
. g-m
- 10 ft-lbl .
SEE PAG:~~~OWN
'86 MOO
FOR AFTER '86:

10- 4 N·m
.
(1.0- 14kg-m , 7 - 10 h -Ibl
9-0
9. CLUTCH/OIL PUMP/KICK STARTER
SERVICE INFORMATION 9· 1 REVERSE LOCK MECHANISM 9 · 16
TROUBLESHOOTING 9· 2 OIL PUMP/PRIMARY DRIVE GEAR 9 · 16
RIGHT CRANKCASE COVER REMOVAL 9·3 KICK STARTER 9·20
CENTRIFUGAL CLUTCH 9·4 OIL FILTER SCREEN 9· 24
CHANGE CLUTCH 9·B RIGHT CRANKCASE COVER
INSTALLATION 9· 24
CHANGE CLUTCH LIFTER MECHANISM 9· 12
RIGHT CRANKCASE COVER BEARING/
OIL SEAl/FOLLOWER CAM 9· 14
SERVICE INFORMATION
GENERAL
, his section covers removal and installation of the centrifugal clutch, change clutch, oil pump and kick starter , These parts
can be serviced with the engine installed in the frame.
SPECIFICATIONS

Change Spring free length 32 . 1 mm 11 .26 in) 31.0 mrn (1.22 in )
clutch
Disc thickness 2.62 - 2 . 78 mm (0.103 - 0 . 109 in) 2 .3 mm (0.09 in)
Plate warpage -- 0 .20 mm (0.008 in)
Clutch outer guide 0.0. 27.959 - 27.980 mm 0.1007 - 1.1016 in) 27.92 mm (1,099 in)
1.0 . 22.000-22.021 mm (0.8661-0.8670 in) 22 .05 mm (0 .868 in)
Mainshaft 0.0. (outer guide ) 21.959 - 21.980 mm (0.8645-0.8654 in) 21.92 mm (0 ,863 in)
Outer guide-lo-mainshaft
0.020 - 0.062 mm (0.0008-0.0024 in ) 0.1 mm (0.004 in )
Clearance
Centrifugal Drum 1.0 . 140.0 - 140.2 mm (5. 51 - 5.52 in) 140.4 mm (5.53 in)
clutch
Weight lining thickness 2.95-3.05 mm (0.116 - 0.120 inl 2.0 mm (0 .08 in)
Clutch spring free height 3 .7 mm (0.15 in) 3 . 55 mm (0.140 in)
Clutch weight spring free length 21 .6 mm (0.85 in) 22.5 mm (0.89 in)
Kic k starter Shaft 0 .0. 21.959 - 21.980 mm (0.8645 - 0.8654 in ) 21.90 mm (0 .862 in)
Pinion gear 1.0. 22.020-22.041 mm (0.8669-0.8678 in) 22 . 10 mm 10.870 in)
2nd idle gear 1.0. 18.01 4 - 18.034 mm (0.7092 - 0.7100 in) 18.06 mm 10.711 in)
2nd idle gear bushing 0.0. 17.966 - 17.984 mm (0.7073-0.7080 in) 17 .93 mm 10.706 in)
2nd idle shaft 0 . 0. 13.973 - 13.984 mm (0.5501 -0.5506 in ) 13.95 mm 10.549 in)
2nd idle gear bushing 1.0. 14.000 - 14.021 mm (0.55 12 - 0 .5520 in) 14.05 mm (0.553 in)
1 st idle shaft 0.0 . 14.966 - 14.984 mm (0.5892-0.5899 in) 14.93 mm 10.588 in)
1 st idle gear 1.0 . 15.016 - 15.034 mm (0.59 12-0.5919 in) 15.06 mm (0 .593 in)
Primary Crankshaft 0 .0 . 26.959 - 26.980 mm (1.06 14-1.0622 in) 26.93 mm (1.060 in)
drive gear Gear 1.0 . 27.000 - 27 .021 mm /1.0630-1 .0638 in) 27 .05 mm (1.065 in )
Oil pump Pump end clearance 0.02 - 0.08 mm (0.001 - 0.003 in ) 0.10 mm (0.004 in)
Rotor tip clearance 0.15 mm (0.006 in) 0.20 mm (0.008 in)
Rotor-to·body clearance 0.15-0.21 mm 10.006 0 .008 in) 0.25 mm (0.010 in)
9-1
TORQUE VALUES
Oil pipe bolt '86, '87: 8 - 12 N-m 10.8 - 1.2 kg-m, 6 - 9 ft-Ibl
After '87: 10 - 14 N'm 11.0 - '.4 kg -m, 7 - 10 ft-Ib)
Oil path pipe bolt (Oil control bolt BI , 2 - 16 N·m (1.2-1.6 kg-m, 9 - 12 ft-Ib\
Oil hose set piece bolt , 0 - 14 N·m (1.0-1.4 kg-m, 7 - 10 ft-Ibl
Mainshaft bearing stopper plate a
10-14 N·m (1.0 - 1.4 kg -m , 7 - 1 ft-Ib)
Change clutch lock nut 100 - 120 N·m /10.0 - 12.0 kg-m, 72-87 ft-Ib)
Centrifugal clutch lock nut 110- 130 N·m 111.0 - 1 3.0 kg-m. 80- 94 ft-Ib) Apply locking agent l
Left hand threads
Clutch lifter plate bolt 10 - 14 N'm (1.0 - 1.4 kg-m, 7 -10 ft·lb)
After'B6:
Oil pump relief valve nut 13-18 N'm (1.3 - 1.8 kg -m. 10 - 13 ft-Ib) Apply locking agent
TOOLS
Special
Remover handle 07936 - 3710100
Remover weight 07741 - 0010201 or 07936 - 3710200
Bearing remover, 1 7 mm 07936 - 3710300
Clutch center holder 07923 - KE1 0000 or 07HGB - 00 101 OA and 07HGB-001 020A (U.S.A. only)
Clutch holder 07GMB - HA70100
Common
Driver 07749-0010000
Attachment, 24 )( 26 mm 07746 - 0010700
Attachment, 42 )( 47 mm 07746 - 0010300
Pilot, 17 mm 07746 - 0040400
Pilot, 20 mm 07746 - 0040500
Puller 07933 - HB3000A U.S.A. only
TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the clutch.
Clutch slips when accelerating

Faulty clutch lifter
Discs/plates worn
Weak springs
Clutch will not disengage

Faulty clutch lifter
• Plates warped
The vehicle creeps With clutch disengaged

Faulty centrifugal clutch
• Plates warped
Clutch operation feels rough

• Outer drum slots rough
Hard to shift
Incorrect clutch adjustment
• Faulty clutch lifter
Low oil pressure

Faulty oil pump
• Oil pump drive gear broken
9-2
CLUTCH/OIL PUMP/ KICK STARTER
RIGHT CRANKCASE COVER REMOVAL (11 DECOMPRESSION CAllLE'

(,B6, '87 ONLY)
Shift the transmission into neutral and drain the oil from the
engine.
Remove the kick starter pedal and right foot peg.
Disconnect the decompression cable from the follower lever

('86, '87 only).
Remove the oil path pipe bolt from the crankcase cover.
Remove the oil hose guard and set piece, and then remove the
oil hoses (Section 61.
Remove the stopper lever cover bolts and the cover. iii"~~~~~SE STOPPER LEVER
Disconnect the neutral and reverse switch connectors.
Disconnect the oil temperature sensor wires (After '87: wire).
Remove the reverse stopper cable from the stopper lever.

Remove the reverse stopper lever bolt and the revers e stopper
lever.
9-3
Remove the right crankcase cover bolts and the cover.
Remove the gasket and dowel pins.
CENTRIFUGAL CLUTCH
REMOVAL
Remove the right c rankcase cover.
Unstake the centrifugal clutch lock nut.
Hold the centrifugal clutch weight assembly with a clutch

holder and remove the lock nut by turning it clockwise.
TOOL:
NOTE
• The lock nut has left hand threads.
Remove the lock washer.
9-4
Remove the centrifugal clutch weight assembly and drum with

a clamping two jaw puller.
NOTE
• Jaws must be a clamping type to ensure fit on clutch drum.
TOOL:
Puller 07933 - HB3000A
(U.S.A. only)
INSPECTION (1) LINING
• Weight lining
Measure the weight lining thickness as shown.
SERVICE LIMIT: 2 .0 mm (0.08 in)
• Weight Spring/Clutch Spring

Remove the E-dips, washer, clutch spring and washer.
Check the weight springs for wear or damage, and replace if

necessary .
Measure the clutch weight spring free length.
SERVICE LIMIT; 22.5 mm (0.89 in)
9-5
CLUTCH/Oil PUMP/ KICK STARTER
Measure the height of the clutch spring. I

SERVICE LIMIT : 3 .55 mm (0. 140 in )
Replace the spring if it is short er than t he service lim it.
Install the washer and clutch spring. 111
NOTE
• Install the spring with t he dished face towards t he inside .
Install the outside washer with the locating pins facing out .
Install the E-ctips, aligning their gaps with the locating pins on
the washer.
14 , W,'SI<ER (3) LOCATI NG PINS
• Clutc h Drum/One-W ay Clutch

Check the inside of t he centrifugal clutch drum for scratches
or excessive wear. Replace if necessary .
Measure the 1.0 . of the clutch drum .
SERVICE LIMIT: 140.4 mm (5 .53 In)
Inspect t he one-way clutch fo r smooth operat ion and c heck (1) CLUTCH DRUM (2) ONE-WAY
t he rollers for excessive wear. CLUTCH
9-6
CLUTCH/OIL PUMP/K ICK STARTER
Install the one-way clutch into the cl utch drum with its "OUT-
SIDE" mark facing out.
INSTALLATION
Install the centrifugal clutch drum with the one-way clutch

onto the crankshaft.
Install the centrifugal clutch weight assembly onto the clutch

drum and crankshaft .
Install and tighten the lock nut to press in the weight assemb-
ly, and remove the nut.
Install the lock washer with the "OUT-SIDE" mark facing out.
Apply a locking agent to the lock nut threads.

Hold the centrifugal dutch weight assembly with the clutch
holder and tighten the lock nut by turning it counterclockwise .
TORQUE: 110 - 130 N·m ,1 1 .0 - 1 3 .0 kg-m, 80 - 94 ft -Ib)
TOOL :
NOTE
• The lock nut has left hand threads.
Stake the lock nut and install the right cran kcase cover (page
(1) CLUTCH HOLDER
9-24).
9-7
CHANGE CLUTCH
REMOVAL
Remove the following:

- right crank case cover ipage 9·3)
- centrifu gal clutch (page 9-4)
- clutch lever
Remove the clutch bolts, loosening them in a criss-cross pat-

tern in 2 or 3 steps.
Remove the lifter plate and clutch springs.
Turn the lifter bearing inner race with your finger. The bearing
should turn smoothly and quietly_ Also check that the bearing
outer race fits tightly in the clutch lifter plate.
Unstake the clutch center lock nut.
Install the clutch center holder as shown, and remove the

clutch lock nut.
TOOL;
Clutch center holder 07923 - KE10000 or
07HGB - 001010A and
07HGB - 001020A
(U .S.A. only)
Remove the washer, clutch center, discs, plates and the pres-
sure plate as an assembly.
9-8
Remove the thrust washer and clutch outer.
Remove the clutch outer guide from the mainshaft.
... - ......
INSPECTION
Check the slots of the dutch outer for damage or wear caused
by the clutch discs. Replace if necessary.
Measure the 0.0. and 1.0. of the clutch outer guide.

~,
SERVICE LIMITS:
0.0.: 27 .92 mm 11 ,099 in)
I.D. : 22.05 mm (0. 868 in)
\
Measure the 0 .0 . of the mainshaft.
SERVICE LIMIT : 21.92 mm (0.863 in)
Calculate the clutch outer guide-to -mainshaft clearance.
9-9
Measure the spring free length.
SERVICE LIMIT; 31 .0 mm 11 .221nl
Replace the clutch discs if they show signs of scoring or dis-

coloration.
...
Measure the disc thickness.
Check for plate and disc warpage on a surface plate using a

feeler gauge.
SERVICE LIMIT : 0 .20 mm 10.008 in)
INSTALLATION
Install the clutch outer guide, clutch outer and thrust washer.
9-10
CLUTCH /OIL PUMP/KICK STARTER
Assemble the clutch pressure plate, discs, plates and clutch (1) CLUTCH PRESSURE PLATE
center.
NOTE (4( eLl)TC:H CENTER
Stack the discs and plates alternately.

• Coat new clutch discs with engine oit.
"" .,"rH PLATE i5 pcs)
CLUTCH DISC i6 pcs)
Install the washer onto the mainshaft.
Hold the clutch center and tighten the lock nut.
TORQUE : 100 - 120 N-m ( 10.0 - 12.0 kg-m . 72-87 ft·lb)
TOOL:
Clutch center holder 07923 - KE10000 or
07HGB - OD1010A and
07HGB - 001020A
(U .S.A. onlyl
Stake the clutch center lock nut.
Install the clutch springs, lifter plate and bolts.

Tighten the bolts in a criss-cross paUern in 2 or 3 steps .
TORQUE: 10 - 14 N·m 11.0 - 1.4 kg-m, 7 - 1 0 ft - Ib ~
Install the bearing and lifter piece in the lifter plate.
Align the index mark on the crankcase with the punch mark on
the clutch lever and install the clutch lever.
Install the centrifugal clutch (page 9-7).
9-11
CHANGE CLUTCH LIFTER MECHANISM 111 ADJUSTING SCRIEW
DISASSEMBLY
Remove the clutch adjuster rubber cap, adjusting screw lock

nut and washer.
•
Remove the clutch lifter lever stay mounting bolts, the lifter
lever and the spring.
Remove the washers, bearing and clutch lifter cam.
Remove the ball retainer and clutch lifter with adjusting screw .
Check the disassembled parts for damage or wear, and replace

the parts if necessary.
9- 12
ASS EMBLY

- adjusting screw into the clutch tifter
- 0·rin9 onto the adjusting screw
- clutch lifter, by aligning its groove with the stop pin on the
right crankcase cover.
Install the ball retainer onto the clutch lifter .
Install the dutch lifter cam by facing its groove toward the
clutch lever bearing hole in the right crankcase cover.
9-13
Install the washer, bearing and thrust washer onto the clutch
lifter cam.
Install the lifter lever in the reverse order of removal. (1) LIFTER LEVER
~#
/1
•
RIGHT CRANKCASE COVER BEARING/ (1) KICK S"'AFTElE;i"",~.".......~i2TCt:UrCH---
OIL SEAL/FOLLOWER CAM

IN SPECTI ON
Check the kick shaft, clutch lever and crankshaft bearings in

the right crankcase cover for wear or damage.
Check the oil seals for wear or damage. ('BS, '87 ONLY)
Replace them if necessary.
9-14
BEARING REPLACEMENT ..L!~~IO\:ER WEIGHT
Remove the crankshaft bearings from the right crankcase

cover with the following tools.
TOOLS :
Crankshaft bearing
Remover handle 07936-3710100
Remover weight 07741-0010201 or
07936 -3 710200
Bearing remover, 17 mm 07936 -3 710300
Drive new crankshaft and kick starter shaft bearings into the
cover using the following tools.
TOOLS:
Crankshaft bearing
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 17 mm 07746 - 0040400
Kick shaft bearing
Driver 07749 - 0010000
Attachment, 24 x 26 mm 07746 - 0010700
Pilot, 20 mm 07746-0040500
FOLLOWER CAM 1'86, '87 only I (1) SNAP RING
Remove the snap ring, follower cam, spring and follower lever.
Inspect the follower cam, follower lever and spring for damage ( 1) FOLLOWER CAM (2) SPRING
\ ~.~
or wear and replace if necessary.
(3) FOLLOWER LEVER
9-15
REVERSE LOCK MECHANISM

REMOVAL

- washer and clutch lever
- reverse shaft arm
- rotor bolt, reverse lock plate and reverse rotor
Remove the washer and spring from the reverse shaft arm .
Check all parts for excessive wear or damage . and replace if

necessary.
INSTALLATION
Install the reverse lock plate by aligning the pins on the shift
drum with the holes in the reverse lock plate.
Align the neutral and reverse rotor holes with the pins on the
shift drum and install the neutral and reverse rotor using the
bolt .
Rotate the neutral and reverse rotor and check for smooth op-
eration.
Install the reverse shaft arm with the washer and spring .
Align the index mark on the crankcase w ith the punch mark on
Install the thrust washer.
OIL PUMP/ PRIMARY DRIVE GEAR

REMOVAL
Remove the following :

- centrifugal clutch (page 9 -4)
- change clutch (page 9-8 )
Remove the O-ring. oil pipe mounting bolts, oil pipe bolt and
pipe .
9-16
Remove the oil pump mounting bolts.
Remove the oil pump, primary drive gear and thrust washer.
Remove the a -ring and two dowel pins.
•
,,
~
PRIMARY DRIVE GEAR IN SPECTION
Inspect the primary drive gear fo r damage or excessive weal.

Measure the primary drive gear I.D.
SERVICE LIMIT: 27 .05 mm 11 .065 in)
Measure the crankshaft a .D.
SERVICE LIMIT: 26.93 mm 11.060 in)
9-17
OIL PUM P DISASSEMBLY
Remove the snap ring, washer and three screws.
Oisassemble the oil pump.
After '86
Remove the oil relief valve by removing the nut.
Disassemble the oil relief valve by removing the cotter pin.
(5) RELIEF VALVE (AFTER '86) (4) SCREWS
Check the relief valve parts for wear or damage and replace if (1) SPRING (2) RELIEF VALVE (3) NUT
necessary.
Replace the relief valve assembly if necessary.
~~ (51 WASHER (4) RELIEF VALVE BODY
OIL PUMP INSPECTION
Install the outer and inner rotors into the body and insert the oil
pump driven gear shaft.
Measure the pump rotor -ta-body clearance.
SERVICE LIMIT: 0 .25 mm (0.0 10 In)
Measure the pump rotor tip clearance.
SERVICE LIMIT: 0 .20 mm (0.008 in)

CLEARANCE
Remove the oil pump driven gear shalt from the oil pump body III END CLEARANCE
and measure the pump end clearance.
SERVICE LIMIT : 0 . 10 mm 10.004 inl
9-18
OIL PUMP ASSEMBLY/ IN STALLATION (11 BODY (3) INNER ROTOR

121 OUTER ROTOR-:''' /
Assemble the oil pump cover with the driven gear and the oil
pump body with the outer and inner rotors. ---- ~-.,/
,~
(5) DRI'VEN (4) COVER
Install the washer, snap ring and oil pump body screws as (3) SNAP RING
shown. (2) WASHER
(1) NUT
After 'S6 : (AFTER 'B6:)
Install the oil relief valve and tighten t he nut.
Apply locking agent to the threads.
TORQUE: 13 - 18 N·m 11.3 - 1.8 kg·m . 10 - 13 ft·lbl
(5) RELIEF VALVE (AFTER '86:) (4) SCREWS
Inst all the t hrust washer and primary drive gear onto the crank·
shaft.
Install the O-ring and dowel pins in the right crankcase.
Install the oil pump and tighten the pump bolt s.
Inst all the oil pipe with the oil pipe bolt, mounting bolt and O·
ring.
Tighten t he oil pipe bolt to the specified torque.
TORQUE:
' S6, ' 87 : 8 - 12 N·m (0 .8 - 1.2 kg-m , 6 - 9 ft-Ibl
After ' 87 : 10 - 14 N·m 11 .0 - 1.4 kg.m. 7 - 10 ft ·lbl
Install the remain ing removed parts in t he reverse order of re -

moval.
9-19
KICK STARTER
REMOVAL

- right crankcase cover (page 9-3)
- centrifugal clutch (page 9 -4 1
- change clutch (page 9 -8)
Remove the socket bolt. bearing stopper plate , 2nd kick idle
gear and bushing .
Remove the 1SI kick idle gear shaft, thrust washer and 151 kick I
idle gear. SHAFT
1
' 86. ' 8 7:
Remove the thrust washer, decompressor cam, spring and
spring seat from the kick starter shaft.
Temporarily install the kick starter arm onto the starter shaft
and remove the shaft assembly by turning the kick starter arm
clockwise to hee the ratchet from the ratchet guide .
9-20
CLUTCH /Oil PUMP/ KICK STARTER
DI SASSEMBLY II I RATCHET 121 RATe fjET SPRING
Remove the thrust washer, collar, return spring, spring seat,

ratchet spring and ratchet.
~ - (3 ) COLLAR
151 SPIRING SEAT 14) RETURN SPRING
Remove t he snap rings, thrust washers and starter pinion gear n) PIN ION GEAR
from the starter shalt.
(' 86 , ' 87 _
ONLY )
'·c )(
/ >1. l
(2) KICK STARTER SHAFT
INSPECTION
Measure the kick starter shaft 0.0.
SERVICE LIMIT : 21 .90 mm (0 .862 in)
Inspect the pinion fo r damaged f atch et teeth .
Measure the kick starter pinion 1.0.
SERVCIE LIMIT : 22 . 10 mm 10.870 in )
Measure the 2nd idle gear 1.0.
SERVICE LIMIT : 18.06 mm (0 .711 Inl
Measure the 2nd idle gear bushing 1.0.
SERVICE LIMIT: 14.05 mm 10 .553 in )
Measure the 2nd idle gear bushing 0 .0 .

.ra, - J
SERVICE LIMIT : 17 .93 mm (0 .706 in )
9-21
Measure the kick starter 1st idle gear 1.0.
Measure the 1 st idle gear shaft 0.0.
- -
Check the kick starter shaft and 1 st idle gear shaft holes in the
right crankcase for wear or damage.
Measure the 2nd idle gear shaft 0.0.
SERVICE LIMIT: 13.95 mm (0.549 inl
To replace the 2nd idle g8rar shaft, the crankcase must be sep-
arated (Section ,,).
ASSEMBLY \11 SNAP RING ('86, '87 GEAR

ONLY)
Install the one snap ring in the groove in the shaft. ('86, '87
onlv)
Install the thrust washer, pinion gear, thrust washer and other
\
snap ring onto the shaft.
/
(4) KICK STARTER SHAFT
\
(3) SNAP RING
Align the punch marks and install the ratchet onto the shah.
9-22
Install the ratchet spring and spring seat. SPRING SEAT

Install the return spring and insert its end into the hole in the
shaft.
Install the coliar. aligning its groove with the end of the return
spring.
Install the thrust washer.
{4 1 RETURN SPR:lNG _ 131 COLLAR
INSTALLATION
Temporarily install the kick starter arm onto the shalt .
Hook the return spring to the crankcase .
Install the kick starter assembly by turning it clockwise and

aligning the ratc het with the ratchet guide.
'86 , '87 :
Make sure that the punch mark on the spindle faces up .
' 86, ' 87 :

Install the spring seat and cam spring onto the shaft .
Align the punch marks and install the decompressor cam .
9-23
Assemble the thrust washers and kick starter' S1 idle gear

onto the 151 idle gear shaft and install them in the crankcase.
Install the kick starter 2nd idle gear bushing onto the 2nd idle
gear shaft with its flange side facing inside.
Install the 2nd idle gear.
Install the bearing stopper plate and t ighten the socket bolts.
T ORQUE : 10 - 14 N·m ~1.0 - 1 .4 kg-m, 7 - 10 ft-lb)
Install the remaining removed parts in the reverse order of re -

moval.
OIL FILTER SCREEN

Drain the engine oil (page 2-2).
Remove the right crankcase cover, gasket and dowel pins
(page 9-3).
Remove and clean the oil filter screen.
Inspect the screen for damage and replace it if necessary.
Install the oil filter screen and tight crankcase cover in the re-
verse order of remo val.
RIGHT CRANKCASE COVER INSTALLATION

Install the dowel pins and a new gasket .
Make sure that the clutch lever is positioned as shown (page
9-11 ).
Install the right crank case cover and bolts, and tighten the
bolts .
9-24
Install the reverse stopper lever onto the reverse shaft. (1) REVERSE STOPPER , (5) NEUTRAL AND.....
Be sure the punch mark aligns with the index mark. "'=
CAB'~L"E
121 IN]'X MARK
REVERSE SWITCH
Connect the reverse stopper cable to the lever.
Connect the neutral and reverse switch connectors.

Connect the oil temperature sensor wire connectors IA her
'87: connector. I
(6) Oil
TEMPERATURE
SENSOR
WIRE CONNECTORS
Install the oil hose Q-rings in the crank case and then the hoses .
Install the oil hose set piece and tighten the bolts.
T ORQUE: 10- 14 N- m ' 1 .0 - 1.4 kg-m. 7 - 10 ft -Ib l
Connect the oil path pipe to the cover and tighten the bolt to ~ (1) DECOMPRESSION
the specified torque. 1'86, 'S7
TORQUE: 12- 16 N·m 11.2- 1. 6 kg-m . 9 - 12 ft -Ibl

- decompression cable ('86, '87 only)
- oil hose guard
- reverse stopper lever cover
- kick starter pedal (by aligning the punch marks)
- right foot peg
Adjust the clutch and reverse cable (page 3·10).

Fill the engine with recommended oil (page 2-21-
Check the clutch and reverse gear for smooth operation.
Make sure there are no oil leaks.
9-25
ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE
100- 120 N·m

110.0- 12.0 kg-m ,
72 - 87 ft·lb)
~
20 - 25 N'm (2.0 - 2.5 kg-m,
14 - 18 ft -Ib)
'86 MODEL SHOWN
SEE PAGE 10-2
£) FOR AFTER ' 86
C1 ~ --
@h"'"
•
10-0
10. ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION 10-1 STARTER CLUTCH 10-8
TROUBLESHOOTING 10-1 GEARSHIFT LINKAGE 10-10
STARTER REDUCTION GEAR 10-2 LEFT CRANKCASE COVER
INSTALLATION 10-13
LEFT CRANKCASE COVER REMOVAL 10-4
ALTERNATOR 10 -6
SERVICE INFORMATION
GENERAL
• This section covers the removal and installation of t he st arter reduction gea r, alternator, starter clutch and gearshift link-
age.
• Refer to Section 17 and 18 for alternator inspection.
TORQUE VALUES
Flywheel bolt , 00-120 N' m ( 10.0 - 12.0 kg-m, 72-87 ft·lbl

Starter clutch torx boh 20-25 N'm 12.0-2.5 kg-m, 14-18 ft -Ibi Apply locking agent to the threads.
Drive shaft holder bott 20 -25 N·m (2.0 - 2.5 kg-m, 14-18 fl ·lbl
TOOLS
Special
Remover weight 07741 - 0010201 or 07936-3710200
Bearing remover set, 10 mm 07936 - GEOOOOO
Common
Flywheel holder 07725 - 0040000 or strap wrench . commercially available in U.S.A.
Aotor puller 07733 - 0020001
ToOl: driver bit 1T40) 07703 - 0010100 or equivalent commerciallv available in U .S.A.
Attachment, 24 x 26 mm 07746 - 0010700
Driver 07749 -0010000
TROUBLESHOOTING
Engine does not turn
Faultv one·wav starter clutch
• Starter reduction gear broken
Transmission ju mps out of gear

• Shift drum st opper broken
Hard to shift
• Shift drum cam plate damaged
Gearshift pedal w ill not return

Weak or broken shift return spring
• Shift spindle binding with case
10-1
STARTER REDUCTION GEAR

REMOV AL
Remove the starter reduction gea r cover bolts and the cover.

Remo ve reduction gears A /B, C, 0 and the shafts.
INSPECTION I I I STARTER REDUCTION GEAR COVEA

(AFTER '86 MODEL SHOWN)
Inspect the starter reduction gear teeth for wear or damage.
Aher ' 86 :
Check the reduction gear bearing for eKcessive play or damage
and replace if necessary.
# .
(5) REDUCTION
GEAR BEARING
'(3) GEAR
(4) GEAR Al B
0-11 ::..
BEARING REPLACEMENT IAFTER '86:) ( 1) BEARING REI~O'VERSET, 10 mm
Remove the gear cover protector by removing the screws.

Remove the reduction gear bearing using the bearing remover
tool.
TOOLS:
Bearing remover set , 10 mm 07936 - GEOOOOO
Remover weight 07741 - 00 10201 or
07936 - 3 710200
Drive the reduction gear bearing out of the reduction gear

cover .
10-2
AL TERIllATOR/ STARTER CLUTCH/GEARSHIFT LlIIIKAGE
Drive 3 new bearing into the starter reduction gear cover.
TOOLS:
Driver 07749 - 0010000
Att achment, 24 x 26 mm 07746- 0010700
Install the gear cover protector with screws.
INSTA LLATI ON
Install the starter reduction gear 0 into the left crankcase.
Install the gear shaft into the left crankcase through the
reduction gear D.
Install the thrust washer and starter reduction gear C onto the
shaft .
Install the gear A l B and its shaft.
Install the thrust washer onto the starter reduction shaft.
Install the gasket, dowel pins and starter reduction gear cover
with fOUf bolts.
10-3
ALTERNATOR/STARTER CLUTCH/GEARSHIFT LIN KA GE
lEFT CRANKCASE COVER REMOVAL

Remove the gearshift pedal and the left foot peg.
Remove the front drive shaft cover .
Loosen the boot band screw.
Remove the drive shaft holder bolts.
Push the drive shaft holder forward and then remove the snap
ring .
Using 8 drift or punch, carefully tap t he f ront drive shaft joint,

moving it fo rward until it separates from t he cross shaft.
10-4
Remove the front drive shaft and holder.
Remove the starter reduction cover and gears (page 10-21.
Remove the left crankcase cover breather hose (FOURTRAX

only) .
Remove the front fender (page 16-11.
Disconnect the alternator and pulse generator connectors.
Remove the alternator and pulse generator wire clamp.
Remove the left crankcase cover mounting bolts and cover.
10-5
ALTERNATOR
STATOR/PULSE GENERATOR REMOVAL
Remove the wire clamp by removing the bolt.
Remove the three stator bolts and stator.
Remove the pulse generator mounting screws.
Release the pulse generator wire from the clamp on the pulse (1) CLAMP (2) CONNECTOR
generator.
Disconnect the pulse generator wire connector from the pulse

generator, clamping the connec tor with your fingers.
(3) WIRE
STATOR/PULSE GENERATOR INSTAllATION (1) NEW PULSE GENERATOR
Pull the wire tube and keep the wire length below the terminal
insulator 40 mm ( ' .6 in).
Clamp the pulse generator wire securely as shown. 40mm

0.6 in)
(2) CLAMP
10-6
ALTERNATOR/STARTER CLUTCH /GEARSHIFT LINKAGE
Push the wire tube into the pulse generator clamp.
( , I WIRE TUBE
Connect the pulse generator wire connector to the pulse (1) CONNECTOR
generator terminal.
Insert the wire grommet into the groove in the left crankcase
cover.
Apply locking agent to the attaching bolts and tighten them to
secure the stator , pulse generator with the wire clamp.
FLYWHEEL REMOVA L
Hold the flywheel with the flywheel holder and remove the
bolt.
TOOL:
Flywheel holder 07725-0040000 or strap wrench
commercialJy available in U.S.A.
10-7
Remove the flywheel with the rotor puller.
TOOL:
Rotor pullet 07733 - 002 0001
FLYWHEEL INST A LLATI ON
Align the key way in the flywheel with the key in the crank -
shaft.
Hold the flywheel with the flywheel holder and tighten the
bolt .
TORQUE: 100- 120 N·m 11 0.0 - 12.0 kg-m , 72 - 87 ft-Ibl
TOOL:
Flywheel holder 07725 - 0040000 or strap w renc h
commercially available in U.S.A .
STARTER CLUTCH
REMO VAL
Remove the left crankcase cover and the flywhee l (pages 10-4
and 6),
Remove the starter driven gear.
Remove the needle bearing and washer.
10-8
Remove the one-way clutch from the flywheel using an impact

driver and torx driver bit.
TOOL:
Torx driver bit (T40) 07703 - 0010100 or
e quivalent commercially
arailable in U.S .A .
11) TOR X
INSPECTION (1) STARTER DRIVEN GEAR
Inspect the starter driven gear teeth for damage or abnormal

j
..... ear.
Check the needle bearing lor damage.
121 NEEDLE BEARING
(2) WASHER
Check the one-way clutch rollers for wear or damage.
(Af ter 'B6)
INSTALLATION
Install the one-way clutch to the starter clutch outer with its
flange side facing to the flywheel.
Install the washer (After '86).
(4 ) OUTER (3) FLANGE SIDEE-~~;tY
Apply locking agent to the threads of the torx bolts. HOLDER

Install the one-way clutch assembly to the flywheel and
tighten the torx bolts.
TORQUE: 20 - 25 N'm 12.0 - 2.5 kg-m , 14 - 18 ft-rb).
TOOLS:
Flywheel holder 07725 - 0040000 or strap wrench
Torx driver bit IT40l 07703 - 0010100 or aquivalent
(2) TORX DRIVER BIT
10-9
Install the starter driven gear into the one-way clutch by

turning it clockwise.
Check the operat ion of the one-way clutch by turning the
driven gear. You should be able to t urn the driven gear clock-
w ise smoothly, but not be able to turn it coun t erclockwise.
Refer to page 10-8 for flywheel installation.
GEARSHIFT LINKAGE
REMOVAL

- left crankcase cover (page 10-4)
- right crankcase cover (page 9-3)
- clutch lever
Pull the gearshift spindle out of the crankcase.
Remove the washer and return spring. 11) GEARSHIFT SPINDLE 121 """II"" SPRING
Check the gearshift spindle for trueness .
o
L
(3) WASHER
Remove the guide plate bolts, drum shifter with guide plate,
collars, dowel pins and bearing st opper plates.
10-10
Remove the stopper arm and shift drum center.
(2) STOPPER ARM
Disassemble the guide plate and drum shifter. 111 RATCHET PAWLr---..,,, ~(2) PLUNGER
Inspect the ratchet pawls, springs and drum shifter for damage / • ______ 131 SPRING
or abnormal wear. .
'" ~ / (4) DRUM SHIFTER
/
15) GUIDE PLATE
INSTALLATI ON (1) RATCHET (2) SPRING

PLUNGER
Apply clean engine oil to the ratchet pawls, springs and drum
shifter.
Assemble the ratchet pawls, springs, plungers and the drum

shifter, then install them in the guide plate.
NOTe
=L
Do not interchange the ratchet pawls; align the grooves of
the ratchet pawls with the plungers.
(5) GUIDE PLATE ) DRUM SHIFTER
Install the stopper arm and spring.
10-11
Align the drum center hole with the dowel pin on the shift
drum and install the drum center.
Apply locking agent to the threads of the drum center bolt and
tighten the drum center bolt.
Install the bearing stopper plates, dowel pins and collars onto
the crankcase.
Install the guide plate/drum shifter assembly.
Assemble the gearshift spindle, shift return spring and washer.
Install the shift collar onto the drum shilter pin .
Install the gearshift spindle into the crankcase, hooking the

return spring ends to the return spring pin and the gearshift
pawl to the shift collar.
10-12
Align the index mark on the crankcase with the punch mark on
Install the thrust washer .
Install the right crankcase cover (page 9~24).
LEFT CRANKCASE COVER INSTALLATION

Install the dowel pins and a new cover gasket.
InSleUthe c rankcase cover and t ighten the bolts.
NOTE
• Install a new sealing washer to the position as shown.
Install the starter reduction gears and gear cover (page 10-3) .
Connect the alternator/ pulse generator connectors.

Install the left crankcase breather hose .
Apply molybdenum disulfide grease to the front drive shaft

and the shaft yoke joint.
Align the splines and insert the shaft into the yoke joint.
I
10-13
Connect the drive shaft joint to the cross shaft . carefullv align-
ing the splines.
Install the washer and snap ring .
Install the drive shaft holder and tighten the bolts.
TORQUE : 20 - 25 N'm (2.0 -2. 5 kg·m. 14- 18 ft -Ib)
Tighten the boot band screw.
Install the drive shaft cover, shift pedal and right foot peg .
10-14
MEMO
CRANKCASE/CRANKSHAFT/TRANSMISSION
AFTER 'S6 :
90 - 110 N.m
(9.0 - 11.0 65 - 80 ft-Ib)
20- 25 N-m
(2.0 - 2.5 kg -m ,
14 - 18 fHb)
8- N·m
(0 .8 - 1.2 kg -m. 6 - 9 ft-Ib)
11-0
11. CRAN KCASE/CRANKSHAFTITRANSM ISSION
SERVI CE INFORMATION 11- 1 TRANSMISSION 11 -B
TROUBLESHOOTING 11 -3 CRANKCASE ASSEMBLY 11 - 13
CRANKCA SE SEPARATION 11 -4 OUTPUT GEAR 11-14
CRANKSHAFT/ BALANCER 11-5
SERVICE INFORMATION
GENERAL
• For crankshaft and transmission repair, the crankcase must be separated.

• Remove the following parts before separating the crankcase.
Cylinder head (section 7) Cylinder and piston (section 8)
Clutch, oil pump and kick starter (section 9) Starter motor (section 19)
Alternator and gearshift linkage (section 10!
• Use soft jaws to prevent damage to the output gear case when placing the case in a vise.
• When replacing the following output gear components, a new adjustment shim must be selected.
Output gear case
Output gear assembly
Output gear bearing
Output gear bearing holder
• Replace the output drive and driven gears as a set.
• When using the lock nut wrench, use a deflecting beam t ype torque wrench 20 inches long. The lock nut wrench increases
the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut.
The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench when used with
II
the lock nut wrench. The torque scale reading is given with the actual torque specifications.
SPECIFICATIONS
Crankshaft Connecting rod big end side

0.05 - 0.65 mm (0.002-0.026 in) 0.80 mm (0.031 in)
clearance
Connecting rod big end radial
0.006 - 0.018 mm (0.0002 - 0.0007 in) 0.05 mm (0.002 in)
clearance
Runout -- 0.05 mm (0.002 inf
Shift fork, Fork 1.0. 13.000 - 13.021 mm (0.51 18 - 0.5126 in) 13.04 mm (0.513 in)
shaft Claw thickness 4.93-5.00 mm (0.194-0.197 in) 4.50 mm (0.177 in)
Shaft 0.0. 12.966 - 1 2 .984 mm (0.5105 - 0.51 12 in) 12.96 mm (0.5 10 in)
Trans- Gear 1.0. M4 25.000-25.021 mm (0.9843-0.9851 in) 25.05 mm (0.986 in)
mission M5 20.020-20.041 mm (0.7882 - 0.7890 in) 20.07 mm (0.790 in)
C1,C2,C3,CR 28.020 - 28.041 mm (1. 1031 - 1.1040 in) 28.07 mm (1.105 in)
A idle 18.000-18.021 mm (0.7087-0.7095 in) 18.05 mm (0.71 1 in)
Shaft 0.0. M4 21.959 - 21.980 mm (0.8645-0.8654 in) 21.93 mm (0.863 in)
M5 16.983-16.994 mm (0.6686-0.6691 in) 16.95 mm (0.667 in)
C3 24.959-24.980 mm (0.9826-0.9835 in) 24.93 mm (D.981 in)
R idle 13.977-13.984 mm (0.5 503-0 .5506 in) 13.93 mm (0.548 in)
11 -1
CRANKCAS E/CRAN KSHAFT/TRANSMISSION
Trans- Gear C10.0 . 27.984 28.005 mm (1 . '017 1. 1026 in) 27.93 mm ( 1.100 inl
mission bushing C2, CR 0 .0 . 27 .979- 28.000 mm (1 . 1015 - 1.1024 in) 27 .93 mm (1.100 in)
C30.0. 27 .959 - 27 .980 mm 11.1 007 - 1.1016 inl 27 .93 mm (1.100 in)
C3I.D . 25 .000- 25 .021 mm (0.9843 - 0 .9851 in) 25.05 mm (0. 986 in)
M40 .0. 24 .959 - 24 .960 mm (0 .9826 0 .9 835 in) 24.93 mm (0.981 inJ
M4I.D . 22.000-22.021 mm (0.8661 - 0 .8670 in) 22.05 mm (0.868 in)
M50 .0 . 19.966 - 19.984 mm (0.7861 - 0 .7868 in) 19.93 mm (0 .785 in)
M5I.D . 17 .0 16 - 17.034 mm (0.6699 - 0.6706 in) 17 .06 mm (0.672 in)
R 0 .0. 17.966 - 17 .984 mm (0.7073 - 0 .7080 in) 17.93 mm (0.706 in )
R 1.0. 14.000 - 14.025 mm (0.5512 - 0.5522 in) 14.05 mm (0.553 in )
Gear-to- M4 0.020 - 0.062 mm (0.0008 - 0.0024 in) 0.10 mm (0.004 in)
bushing 0.036 - 0.075 mm (0.0014 - 0.0030 in) 0.10 mm (0.004 in)
M5
clearance
C1 0.015 - 0.057 mm W .0006 - 0.0022 in) 0 . 10 mm (0.004 in )
C2, CR 0.020 - 0 .062 mm W .0008 - 0 .0024 in) 0.10 mm (0.004 in)
C3 0.040 - 0 .082 mm (0.00 16 - 0.0032 in) 0.10 mm (0.004 in)
R 0.0 16 - 0 .055 mm (0.0006 - 0 .0022 in) 0 . 10 mm W.004 in)
BuShing-to- M4 0.020 - 0 .062 mm (0.0008 - 0 .0024 in) 0 . 10 mm (0.004 in )
shaft M5 0.022-0.05 1 mm (0 .0009 - 0 .0020 in) 0 . 10 mm (0.004 in)
clearance
C3 0 .020 - 0.062 mm (0 .0008 - 0 .0024 in) 0 . 10 mm (0.004 in)
R 0 .016 - 0 .059 mm 10 .0006 - 0 .0023 in) 0 . 10 mm (0.004 in)
Output gear backlash 0 .080 - 0 . 180 mm (0 .0031 - 0 .0071 in) 0 .25 mm /0.0 10 in )
TORQUE VALUES
Crankcase bolt 8 - 12 N-m (0.8 - 1.2 kg-m. 6 - 9 ft-Ib)

Output gear case mounting bolt 30 - 34 N'm (3.0 - 3.4 kg -m. 22 - 25 ft -Ib)
Output gear bearing lock nut (Outer) 90-110 N·m (9.0 - 1 1.0 kg -m . 65 - 80 ft -Ib)
(Inner) 70 - 80 N·m 17 .0 - 8.0 kg -m. 51 - 581t-lb)
Output gaar bearing holder socket bolt 20 - 25 N·m 12.0 - 2 . 5 kg -m, 14 - 18 ft -Ib)
11 -2
TOOLS
Special
Bearing remover, 1 7 mm 07936-3710300
Remover weight 07741 - 0010201 or 07936 - 3710200
Shaft holder 07923 - 6890101
Lock nut wrench, 30 x 64 mm 07916 - MBOOOOl
lock nut wrench attachment 07GMA - HA 70110 or 07916 - HA0020A
Attachment , 61.5 mm 07946 - 3600000
Bearing remover, 20 mm 07936 - 3710600
lock nut wrench , 34 x 44 mm 07916 - MESOOOI
Lock nut wrench attachment 07916 - 9690100
Universal bearing puller 07931 - 4630000 or 07631 - 0010000 or equivalent commercially available
in U.S.A.
Crank assembly tool set 07931 - KFOOOOO (Not avai lable in U.S. A .)
- Crankshaft assembly collar 07931 - KF00100
- Shah puller 07931 - ME40000
- Threaded adaptor 07931 - KF00200
Attachment. 28 I( 30 mm 07946 - 1B701oo
Attachment 07946 - HAooOOO
Common
Driver 07749 - 0010000
Attachment, 72 x 75 mm 07746 - 0010600
Attachment , 37 x 40 mm 07746 - 0010200
Pilot, 40 mm 07746 - 0040900
Attachment. 52 x 55 mm 07746 - 0010400
Pilot, 22 mm 07746 - 0041000
Attachment, 42 )( 47 mm 07746 - 0010300
Pilot, 20 mm 07746 - 0040500
Inner driver 07746 - 0030100
Attachment, 30 mm 1.0. 07746 - 0030300
Pilot, 17 mm 07746 - 0040400
Attachment, 32 x 35 mm 07946 - 0010100
TROUBLESHOOTING
Crankshaft noisy Excessive output gear noise
Worn connecting rod big end bearing Output drive and driven gears worn or damaged
Bent connecting rod Bearing worn or damaged
Worn crankshaft main journal bearing Excessive backlash between output drive and driven
gears
Jumps out of gear Improper shim thickness
Shift fork bent or damaged
Shift fork shaft bent
Shift claw bent
Gear engagement dogs or slots worn
Shift drum cam grooves damaged
Hard to shift
Incorrect clutch adjustment
Shift for k bent or damaged
Shift fork shaft bent
11-3
CRANKCASE SEPARATION
Remove the cam chain.
..
.
f_
( 1) CAM CHAIN
Remove the left crankcase bolts .
NOTE
Loosen the bolts in 8 crisscross pattern in 2 or 3 steps to
prevent crankcase distortion.
Remove the right crankcase cOlier bolt. Place the engine with
the left crankcase down and remolle the right crankcase.
Remove the dowel pins and gasket.
11-4
CRANKSHAFT/BALANCER
REMOVAL
Remove the transmission (page 11-8).
Remove the crankshaft and balancer from the left crankcase III CRANKSHAFT
using a hydraulic press.
If the left crankshaft bearing remains on the crankshaft,

remove it with bearing puller.
"I CR"N':SHA'T (2) UNIVERSAL BEARING
PULLER
TOOL:
Universal bearing puller 07931-4630000 or
07631 - 0010000 or
equivalent commercially
available in U.S .A.
If the bearing remains in the left crankcase, drive it out from

the outside.
Discard the left crankshaft bearing .
NOTE
Always replace the left bearing with 8 new one whenever
the crankshaft is removed from the left crankcase.
C D
INSPECTION
Set the crankshaft horizontally with the A and B points of the

shaft supported and fead the runout using dial indicators at the
C and 0 points as shown.
6 mm B mm
10.24 in) 10.32 in)
SERVICE LIMIT; 0.05 mm 10.002 Inl
11-5
Measure the side clearance between the connecting rod big

end and the crankshaft fl yweight wi th 8 feeler gauge.
SERVICE LIMIT: 0 .80 mm (0.03 1 Inl
Measure the radial clearance at the connecting rod big end, at

two points in the X and Y directions.
SERVICE LIMIT: 0 .05 mm (0 .002 in)
Turn the inner race of each bearing wi th your finger. The bear- (1) BALANCER BEARINGS
ings should turn smoothly and quietly. Also check that the
bearing outer race fits tightly in the crankcase.
Remove and discard the bearings if the races do not turn
smoothly, quietl y, or if they f it loosely in the crankcase.
m RIGHT
_ _ _ _ __ _--=CRANKSHAFT BEARING
BEARING REPLACEMENT
Remove the balancer bearings using the bearing remover

tools. •
TOOLS :
Besring remover, 17 mm 07936 - 3710300
Remover handie 07936-3710100
Remover weight 07741 - 0010201 or
07936 - 3710200
Drive the right crankshaft bearing out from t he outside.
11-6
I
j
Drive new bearings in with the following tools. (1) DRIVER
TOOLS : (2) A TTACHM ENT

Right c rankshaft bearing :
Driver 07749 - 0010000
Attachment, 72 l{ 75 mm 07746 - 0010600
Pilot, 40 mm 07746 - 0040900
Belancer bearings:
Driver 07749 - 0010000
Attac hment. 37 x 40 mm 07746 - 0010200
Drive a new left crankshaft bearing into the left crankcase. (1 DRIVE R
TOOLS:
Driver 07749 - 0010000
Attachment , 72 x 75 mm 01746 - 0010600
INSTALLATION
A lign the timing marks on the balancer and c rankshaft.
Draw the crankshaft into the left crankcase using the special 121 CRANKSH AFT
tools . : • • rASSE~'BLY COLLAR
TOOLS:
Crank assembly 1001 set 07931 - KFOOOOO
(Not 8vailalbe in U .S.A .)
- Threaded adapto r 07931 - KF00200
- Puller shaft 07931 - ME40000
- Crankshaft assembly collar 07931 - KF00100
11-7
TRANSMISSION 21 DOWEL PINS
RE MOVAL
Temporarily install the gearshift drum bearing stopper plates,

dowel pins, collars and shifter plate to prevent the beering
from falling out while disassmbHng and assembling the trans-
mission .
Pull the shift fork shaft out , and remove the shift forks and
shift drum.
Remove the thrust washer and C1 gear from the countershaft. (1 I THRUST WASHER 121 GEAR
Remove the thrust washer and reverse idle gear .
141 IDLE GEAR
Remove the reverse idle gear bushings, washer and reverse

idle gear shaft .
11-8
Remove the mainshaft and counters haft as an assembly . (1 ) MAINSHAFT
OI SA SSEMBLY
Disassemble the mainshaft and countershaft gears.
Remove the snap ring . washer and M4 gear from the main- (2 ) WASHER
shaft.
111 RING
r
(3) M4 GEAR
INSPECTION
Check the shift fork and shaft f or wear or damage.

M easure the t o. of the shift fork .
Measure the shi ft fork claw t h ickness as shown . ,I

SERVICE LIMIT: 4 .50 mm (0 . 177 in)
/
M easure the shif t fork shaft 0.0.
/
SERVICE LIMIT: 12.96 mm (0 .510 in)
Inspect the shif t drum fig ht journal for scoring, scrat ches or
lack of lubrication.
Check the shift drum grooves for damage.
11-9
Check the gear dogs, dog holes and teeth for abnormal wear or
lack of lubrication.
Measure the 1.0. of each gear.
SERVICE LIMITS :
Cl , C2, C3, CR 28.07 mm (1.105 In)
M' 25.05 mm (0.986 in)
M5 20.07 mm 10.790 in)
R Idler 18.05 mm 10 .711 in t
Measure the 1.0. and 0.0. of each gear bushing.
SERVICE LIMITS :
C1 . C2, C3, CR 0 .0 . 27 .93 mm (1.100 in)
C3 1.0 . 25.05 mm (0.986 Inl
M40.0 . 24 .93 mm (0.981 Inl
M41.D. 22 .05 mm 10.868 in t
M5 0 .o . 19.93 mm (0 .785 in)
M5 1.0 . 17 .06 mm (0.672 in)
R 0.0. 17.93 mm (0 .706 In)
R 1.0 . 14 .05 mm (0 .553 in)
Calculate the gear-la-bushing clearance.
SERVICE LIMIT: 0 . 10 rnm (0 .004 inl
Measure the 0.0. of the reverse idle gear shaft.
SERVICE LIMIT: 13.93 mm 10.548 Inl

I
'l
/
Measure the 0.0. of the countershaft and mainshaft. '86 MODEL SHOWN
SEE PAGE 11 -0
FOR AFTER '86
SERVICE LIMITS: M5
M'
M5
21.93 mm (0 .863 in)
16 .95 mm 10.667 in)
I I
e3 24.93 mm (0 .981 in)
; .,
I
11-10
Turn the inner face of each bearing with your finger. The bear-
ings should turn smoothly and quietly. Also check that the
,
( ' ) MAINSHAFT BEARINGS
bearing outer race fits tightly in the crankcase.

smoothly, quietly, or if they fit loosely in the crankcase .
(2 ) COUNTERS HAFT BEARINGS
BEARING REPLACEMENT (1) BEARING REMOVER
Remove the mainshaft bea ring from the lett crankcase.
TOOLS:
Bearing remover, 17 mm 07936 -3710300
07936 -3710200
Remove the countershaft cap from the left crankcase .

-. ..
II I CQUNTERSHAFT
Remove the countershaft needle bearing from the left crank -

case.
Remove the mainshaft and countershaft bearings from the

fight c ra nkcase.
11-11
Drive new bearings In with the following tools. DRIVER
TOOLS:
RIGHT CRANKCASE
M ainshaft bearing: I ATTACHMENT
Driver 07749 - 0010000
Attachment , 42 x 47 mm 07746 - 0010300
Piclt, 2 2 mm 01746 - 0041000
Countershaft bearing:
Driver 07749 - 0010000
Attachment . 4 2 )It 47 mm 07746 - 0010300
Pilot . 20 mm 07746 - 0040500
Press 8 new countershaft needle bearing into the left crank-

case .
TOOLS:
Driver 07749 - 0010000
Atta chment, 32 x 35 mm 07946- 0010100
Pilot . 22 mm 07746 - 0041000
Check the O-ring, and then install the countetshaft cap to the
left crankcase.
Drive a new mainshaft bearing:
TOOLS :
Driver 07749- 0010000
Attachme nt, 37 x 40 mm 07746 - 0010200
Pilot. 11 mm 07746 - 0040400
A SSEMBLYIINSTALLAT ION
Assemble the mainshaft, countershaf t and reverse idle gear in the reverse order of disassembly.
NOTE
Apply molybdenum disulfide grease to both inside and outside of the reverse idle gear bushing, M4 and M5 bushings end
outside of the C1, reverse /C2 and C3 bushings.
Install the snap ring with its chamfered side facing to the gear.
@m(i9@
(2) REVERSE IDLE GEAR
a
@ I I ( 0 C·I
'---(3) REVERSE IDLE SHAFT
14)~i:T~ I5 G:R~'23T) 16) M5 GEAR 132Ti

11) MAINrAFT
ca:r~@gP CO~ 00 ~ 1M (Q)

b
18)
(2)C 1 GEAR
(49T)
1111 COUNTER
REVERSE GEA R 11 0))
(7)C
Ci~2,~G:~E:A~R~I'~4:3;T~)~~~~~~
'86 MODEL SHOWN SEE PAGE 1 1-0 FOR AFTER '86
11 -12
NOTE
The shih fork marks are marked : l for left . C for center and
R for right.
Install the shift forks with their marks facing up.
Install the shift drum and align each shift fork guide pin with
the guide groove in the drum.
Insert the shift fork shaft through the shift forks into the hole in
the left crankcase with the threaded 1.0. toward the right side.
After installation. apply oil to mainshaft and countershaft. and
check each gear for smooth rotation.
CRANKCASE ASSEMBLY 111 GASKET (2) DOWEL PINS
Install the dowel pins and a new gasket .
Install the right crankcase onto the left crankcase .
NOTE
• Make sure that the gasket stays in place.
Tighten the left crankcase 6 mm bolts in a criss·cross pattern

in two or three steps.
T ORQUE: 8- 12 N.m (0.8- 1.2 kg·m. 6-9 ft· lbl
11-13
Tighten the right crankcase bolt to the specified torque.
TORQUE: 8 - 12 N'm 10 .8 - 1.2 kg-m, 6 - 9 fHb )
Install the cam chain.
OUTPUT GEAR
Remove the four output gear case mounting bolts and remove
the output gear case.
BA CK LASH INSPECTIO N
Remove the snap ring and final driven gear from the drive
shaft.
11-14
Place the output gear case in a vise . (1) SHAFT HOLDER
CAUTION
Use SOfl jaws to prevent damage /0 the gear case.
Set a horizontal type dial indicator on the output drive shaft as

shown.
Hold the output driven gear shaft and rotate the drive shaft
until the gear slack. is taken up. Turn the countershah back and
forth to read the backlash.
TOOL:
Shaft holder 07923 - 68901 01
•
STANDARD: 0 .080 - 0 .180 mm 10 ,0031 - 0 .0071 in )
SERVICE LIMIT ; 0 .25 mm (0.0 10 in)
(1) ADJUSTMENT SHIM
--+,. \
Remove the dial indicator. Turn the output drive shaft 120°
and measure the backlash . Repeat this procedure once more.
Compare the difference of the three measurements.
OIFFERENCE OF MEASUREMENT
If the difference in the measurements exceeds the limit, it

indicates that the bearing is not installed squarely. Inspect the
bearings and replace if necessary.
If backlash is excessive, remove the driven gear and replace

the driven shaft adjustment shim with a thinner one. If the
backlash is too small, replace the driven shaft adjustment shim
with a thicker one.
Backlash is changed by about 0.06 mm 10.002 inl when the

thickness of the shim is changed by 0.10 mm (0.004 in).
OUTPUT DRIVEN GEAR SHAFT ADJUSTMENT SHIMS:

A : 0 .90 mm (0.035 in)
B: 0 .95 mm (0.037 in)
c: 1.00 mm (0.039 in) Standard
0 : 1.05 mm (0.041 in)
E: 1. 10 mm (0 .043 in )
(1) INNER RACE
F: 1 . 15 mm (0.045 in )
LOCK NUT
G: 1.20 mm (0 .047 in)
OUTPUT ORIVE GEAR OISASSEMBLY
Unstake the drive gear bearing race lock nuts with a dri ll or
grinder. Be careful that metal particles do not enter the bear-
ing, and that the threads on the shaft are not damaged .
•
131
11-15
Place the output gear case in a vise, being careful not to distort
it.
CAUTION
• Use soil jaws (0 prevenl damage 10 the gear case.
Hold the driven gear shah and remove the drive gear bearing
inner race lock nut .
TOOLS :
Lock nut wrenc h, 30 )I; 64 mm 07g16 - MBOOOOl
Shaft holder 07923 - 6890101
121 SH~~~l!!.I~_"
Remove the outer bearing race lock nut and lock washer . Dis- ( 11 LOCK NUT
card the lock nut. =-"""':0:=""",,,,,,,,, W RENC H
TOOLS:
lock nut wrench, 34 .I( 44 mm 0791S - ME50001
loc k nut wrench attachment 07916 - 9690100
Heat the output gear case around the drive shaft bearing to
BO De (176 ° FL
,..
""
Always H'l!'Qr g/o l'es when handling a heated gear case to pre-
"t nt burning J'our hands.
Remove the output drive gear.
Remove t he adjustment shim . (1) A DJUSTMENT

SHIM
/
11-16
DRI VE GEAR BE ARIN G REPLAC EMENT
Remove t he bearing from the shaft using t he bearing puller.
111 UNIVE'R"AL BEARING PULLER
Press in a new bearing.
TOOLS : ( 1) INNER DRIVER

Inner driver 0 7746 - 0030100
Attachme nt , 30 mm 1.0 . 07746 - 0 0 30300
ATTACHMENT
OU TPUT DRI VEN GEA R DI SASSEMBLY 111 5T'O PI"R RING
Remove the oil seal stopper ring and oil seal.
Unstake the driven gear bearing race lock nuts with a drill or (1) ST (2) OUTER RACE
grinder. Be careful that metal particles do not enter the bear- LOCK NUT
ing , and that the threads on t he shaft are not damaged .
11-17
Place the output gear case in a vise, being careful not to dist ort (1) SHAFT HO'. D>H
it.
CAUTION
• Use sofr jaws to prevenl damage (0 the gear case.
Hold the driven gear shaft and remove the bearing inner race
lock nut.
TOOLS:
Shaft holder 07923 - 6890101
Lock nut wrench , 30 x 64 mm 07916 - MBOOOOl
Remove the outer race lock nut and lock washer and discard (1) LOCK NUT W RENCH
the lock nut .
TOOL:
Lock nut wren ch. 30 x 64 mm 07916 - MBOOOOl
Remove the 8 mm socket bolts attaching the output driven 111 ~EAi1iNGHol.OER
gear bearing holder, and remove the driven gear assembly
from the gear case .
DRI V EN GEAR BEARIN G REPLAC EMENT
NOTE
The driven gear must be rem oved before replacing the bear-
ing .
Place the bearing holde r in 8 press and remove the driven gear .
11-18
Place the bearing holder in the press and remove the bea ring. (1) DRIVER (2) A TT ACHMENT
TOOLS:
Driver 07749 - 0010000
Attachment, 52 II 55 mm 07746 - 0010400
Press in a new bearing. 11) DR 'VER
TOOLS :
Driver 07749 - 0010000
Attachment, 61 . 5 mm 07946 - 3600000 12) An"ACHM'ENT
Press the output driven gear in to the bearing . 11) ATH,CH MEr"
TOOLS:
Inner driver 07746 - 0030100
Attachment, 30 mm 1.0. 07746 - 0030300
__ L
(2) INNER DRIVER
GEAR CASE BEARING REPLA CEMENT (11 OIL "AC ' - 12) . EP,R"'G
Remove the oil seal and drive the bearing out of the case.
11-19
Drive a new bearing int o the output gear case.
TOOLS :
Driver 07749 - 0010000
Attachment , 42:1147 mm 07746 - 0010300
Pilot, 20 mm 07746 - 0040500
~3f ATTACHMENT
- -(2) PILOT
Clean the output gear case in non-flammable solvent and blow

dry with compressed air .
·m
Do nor spin the bearing with compressed air, il could explode
and cause pusanaf injury.
DRI VEN GEAR SHAFT BEARING (11 BEARING STOPPER

REPLACEMENT
Remove the bearing stopper from the right crankcase.
Remove the needle bearing using the special tools.
TOOLS :
Bearing remover. 20 mm 07936 - 3710600
07936 - 3110200
Instatl a new bearing. (1) BEARING
TOOLS :
Driver 07749 - 0010000
Atta chment, 28 )( 30 mm 07946 - 1870100
Pilot , 20 mm 07746 - 0040500
Install the bearing stopper.
11-20
CRANKCASE/ CRANKSHAFT/TRANSMISSION
OUTPUT GEAR CASE ASSEMBLY
Place the shim and output drive gear into the case.
NOTE
When the gear set, driven gear bearing holder, driven gear
bearing and/or gear case have been replaced, use a shim of
1.00 mm (0.039 in) thickness for initial reference.
m
~
OUTPUT DRIVE
GEAR
Heat the output gear case around the drive shaft bearing to (1) '"mERpRlllER
BD Ge (176°F) .
, . ·Ii
Always wear glores when handling a heated gear case to pre-
rent burning your hands.
Press the output drive gear into the case. 121 ATTACI,MIONT
TOOLS :
Inner driver 07746 - 0030100
Attachment 07946 - HAOOOOO
Install the lock washer with its "NUT" mark facing out side.
• (1 ) " NUT "
Tighten the drive gear bearing outer race lock nut .
TORQUE : 90 - 1 10 N·m (9.0 - 11.0 kg-m , 65-80 ft-Ibl
Torque wrench scale reading;

82 - 100 N·m (8.2-10.0 kg·m. 59 -72 ft·lb)
TOOLS;
lock nut wrench, 34 x 44 mm 07916 - ME50001
lock nut wrenc h attachment 07916 - 9690100
11-21
Apply Prussian Blue to the driven geer teeth.

Place the shim and output driven gear assembly into the case.
Install the driven gear bearing holder with t he four B mm
socket bolts.
TORQUE : 20 - 25 N·m (2.0 - 2.5 kg-m . 14 - 18 ft-Ibl
111 LOCK WASHER (2) ,

Install the lock washer with its "NUT" mark facing out side.
Install and tighten the driven gear bearing outer race lock nut . 111 LOCK NUT WRENCH
TORQUE: 90 - 110 N·m (9 .0 - 11 .0 kg-m . 65 - 80 ft -Ibl
Torque wrench scale reading:

82 - 100 N' m (8.2 - 10.0 kg-rn, 59 - 72 ft -Ibl
TOOLS:
lock nut wrench, 30 J( 64 mm 07916 - MBOOOOl
Lock nut wrench attachment 07GMA - HA701,O or
07916 - HA0020A
Hold the driven shaft with the shaft holder and tighten the ( 1) SHAFT HOLD',A
inner race lock nut.
TORQUE : 70 - 80 N·m 17.0 - 8 .0 kg-m . 51 - 58 ft·lbl

64 - 73 N·m 16.4-7.3 kg.m , 46 - 53 ft-Ibl
TOOLS :
Shaft holder 07923 - 6890101
Lock nut wrench, 30 x 64 mm 07916 - MBOOOOl
11-22
•
j
Hold the driven shaft with the shaft holder and tighten the
drive gear inner race lock nut.
TORQUE: 70 - 80 N·m (7.0-8.0 kg -m , 5 1- 58 ft·lbl

64-73 N-m 16.4-7.3 kg-m . 46 - 53 ft -Ib)
TOOLS:
Shaft holder 07923 - 6890101
l ock nut wrench , 30 x 64 rnm Q7916 - MBOOOOl
(2 ) SHAFT
GEAR TOOTH CONTACT PATTERN CHECK
Rotate the drive gear several times in both directions of rota -

tion.
\
Remove the four bolts attaching the driven gear bearing holder
and the driven gear assembly.
Check the gear tooth contact pattern after removing the driven
gear.
Contact is normal if Prussian Blue is transfeted to the approxi-
~
(1) SH IM (2) DRIVE GEAR
mate center of each tooth and slightly to the side. SHAFT
~
_~ (3) DRIVEN
• GEAR SHAFT
(8)
(4) HEEL
191FACE t r
FLANK +
-
(5) TOE
-
~ t
(4) HEEL
+
!7l DRIVE SIDE (6) COAST SIDE
If the pattern is not correct, remove and replace the drive gear (1) TOO HIGH :
adjustment shim.
Replace the shim with a thinner one if the contact pattern is

too high.
(2) FACE (2) FACE
t ~ ~ t
(4) DRIVE SIDE (3) COAST SIDE
11-23
Replace the drive gear adjustment shim with a thicker one if (11 TOO lOW:
the contact is too low.
The pattern will shift about 1.0 mm (0..0.4 in) when the thi ck·
ness of the shim is changed by 0. 10 mm (0..0.4 in).
OUTPUT DRIVE GEAR ADJUSTMENT SHIM:

A : 0..40. mm (C.016Inl
B: 0..45 mm (0..018 in)
C: 0. .50. mm (0..020. in) Standard
0 : 0..55 mm (0.0.22 in)
E: 0..60. mm (0. .0.24 in) (2IFlANK + ~ .. (2) FLANK
Check the backlash (See page 11-14). (4 ) DRIVE SIDE (3) COAST SIDE
Stake the outer and inner face lock nuts.
Install 8 new oil seal and stopper ring. (1) OIL SEAL "" t3) FINAL GEAR !"
Install the final gear and snap ring to the drive shaft.
Install the dowel pin and then install the gear case on the right
crankcase.
Install and tighten the output gear cese mounting bolts.
TORQUE: 30. - 34 N·m 13.0. - 3 .4 kg -m . 22-25 ft-Ib)
11-24
MEMO
100 - 130 N·m ' 86, '87 :

00.0 - 13.0 kg-rn , 60 - 80 N·m
72 - 94 ft -Ibl (6.0 - 8.0 kg-rn,
43 - 58 ft ·lb)
:o- Aher '87 :
35 - 45 N·m
13.5 - 4 5 kg-m,
33 ft· lb)
40 - 48 "'""//
(4.0- 4 .8 kg-m,
}9- 35 ft- Ib)
l QO - 120N' m
110.0 - 12.0,g-m,,_
72 - 87 ft-Ib )
/ 100 -
60 - 70 N' m (6.0 - ,.~ ' " _"', --~:"!:'l N-m
43 - 51 ft -Ib) (10.0-' 3.0 kg-rn,
72 - 94 ft·lb)
' 86, ' 87 :
65 -7 5 N'm
(6.5 - 7.5 kg-m,
50- 54 ft -Ibl
:O- Aft er '87:
-----,,_..:s""'-;~:::!~
35 - 45 N· m
13.5 - 4 . 5 kg-m,
25 - 33 ft -lbJ
' 86, '87 :

' 87:
;: 00 N·m (8.0 - 10 .0 kg-m,

" 58 - 72 ft · lb)
~
"""27 - 33 N' m
, 12.7- 3 .3 kg-m ,
~ ~J'~~~ ~~- 24 ft -Ib)
N'r:.rn ~ )~
~"""",,-After '87
50 -
(5.0 - 7.0 kg-m , ,
37 - 51 ft -Ibl ~~ l
~~
,:,/,
12-0
12. FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION 12· 2 TIE ROD 12· 12
TROUBLESHOOTING 12· 3 KNUCKLE/KNUCKLE HOLDER/
HANDLEBAR
DRIVE SHAFT 12· 14
12·4
THROTTLE HOUSING
FRONT SHOCK ABSORBER 12· 19
12· 6
SWINGARM 12· 21
FRONT WHEEL 12· 7
STEERING STEM 12·25
TIRES 12·8
' B6 , 'S7 :
60 - 80 N'm
16.0 - 8.0 kg -rn, 43 - 58 ft-Ib)
'tr Aftsr ' 87 :
35 - 45 N'm
/3 .5 - 4 . 5 kg -m , 25 - 33 ft-Ib )
' 86, '87:
D
' 86, ' 87 : 60 - 80 N'm
80 _ ° 0 ' " , . _ /6.0 - 8 .0 kg-m. 43 - 58 ft -Ib)
'tr Aftor '87 :
(8 .0 - 9 .0 kg -m .
35 - 45 N·m
58 - 65 ft -Ib)
R After '87: ~ 13 . kg -m . 25 - 33 ft -Ib)
35 - 45 N·m
/3 .5 - 4 .5 kg-m. ~
/ '-~ 25 - 33 fHb)
18 - 25 N'm 18-25 N' m

11.8 - 2.5 kg -m. 13 - 16 ft -Ib ) /1.8 - 2.5 kg-rn , 13 - 18 ft -Ib) --- '8 ·- 25 N'm
11.8 - 2 .5 kg -m, 13 - 18 ft -lbJ
FRT
*: CAUTION (See page 12-3)
12-1
SERVICE INFORMATION
, it
Inhaled asbestos jibers haYe bun found 10 cause respiratory disease and cancer. Ne l'er use an ai, host or dry brush to clean broke
or clutch assemblies. In the Un iud States, use OSHA .Qpproy,d I'Qcuum cleaner or alurnale method approl'td by OSHA designed
to minimil.e the hQtard caused by airborne tubUIOS fibers.
• This section covers maintenance of the front w heel, front shock absorber, steering stem and suspension .
• A jack or other support is required to support the vehicle .
• A djust toe-in whenever the tie rod, knuckle or knuckle holder are replaced or removed.
• Do not twist or bend the brake hoses and pipes when removing them from the knuckle or sw ingarm .
• The knu ckle holder bearings are assemblv w ith the knuc kl e holder . If the bearings are damaged , repla ce them as assembly.
SPECIFICATION S
Pivot arm Bushing 1.0. 20.000 - 20.052 mm (0 .7874 - 0.7894 in) 20.10 mm (0 .791 in)
Coliar 0 .0 . 19.927 - 19.960 mm 10.7845 - 0.7858 in) 19. 50 mm (0.768 in)
Tie rod installation length Tie rod (AI 161.5 164.5 mm (6.36 6 .48 in)
Tie rod (81 302 .5 - 305. 5 mm 111.91 12.03 inl
Tie rod (e l 348 .5 - 351.5 mm (13.72 - 13 .84 in) --
Toe-in o mm (0 in)
Front wheel turning angle I Inside radius 35"
I Outside radius 25 " --
Drive shah boot-t o-knu ckle holder clearance min. 2 mm (0 .01 in)
Front shoc k absorber spring length 231 .4 mm 19.11 inl 226.0 mm (8 .90 in )
TORQUE VALUES
Handlebar upper holder bolt 18 - 30 N-m (, .8 - 3 .0 kg-m , 13 - 22 ft -Ib)
Handlebar low er holder nut 40 - 48 N-m (4 .0 - 4.8 kg-m , 29 - 35 ft -Ib)
Front wheel nut 60 - 70 N-m (6 .0 - 7.0 kg-m , 43 - 5 1 ft -Ib)
T ie rod end nut '86 . ' 8 7: 65 - 75 N'm 16. 5 - 7.5 kg-m , 50 - 54 ft -Ib)
* After ' 87 : 35 - 45 N-m 13.5 - 4 . 5 kg-m, 25 - 33 ft -Ib)
Tie rod lock nut 35 - 45 N' m (3 .5 - 4 .5 kg-m. 25 - 33 ft -Ib)
Pivot arm nut 60 - 70 N'm (6 .0 - 7.0 kg-m. 43 - 51 fHb )
Knu ckle holder nut ' 86. ' 87 : 60 - 80 N·m (6 .0 - 8.0 kg-m. 43 - 58 ft-Ib)
\'r After ' 87 : 35 - 45 N·m (3 .5 - 4 .5 kg-m, 25 - 33 ft -Ib)
l ower kingpin bolt 50 - 70 N·m 15.0 - 7.0 kg-m, 37 - 51 ft -Ib)
Upper kingpin bolt 5 - 10 N·m (0 .5 - 1.0 kg -m , 4 - 7 ft -Ib)
Kingpin lock nut 50 - 70 N·m (5.0 - 7.0 kg-m , 37 - 51 ft -tb)
Front brake panel bolt 27 - 33 N·m 12. 7 - 3.3 kg-m, 20 - 24 ft -Ib) After '87 Only: Using again strictly
prohibited.
Front shock absorber
lower mounting bolt (left) 60 - 80 N'm 16.0 - 8 .0 kg-m. 43 - 58 ft -Ib)
upper/lower (right)
mounting nut ' 86 . ' 87 : 60 - 80 N·m (6 .0 - 8 .0 kg-m . 43 - 58 ft -Ib)
* After ' 87 :35 - 45 N-m (3 .5 - 4 .5 kg-m, 25 - 33 ft -Ibl
upper joint 30 - 45 N-m 13.0 - 4 .5 kg-m, 25 - 38 h -Ibl
Swingarm leh pivot bolt 100 - 130 N-m 00.0 - 13.0 kg -m . 72 - 94 ft-Ib )
Sw ingarm right pivot bolt 16-20 N·m /1.6 - 2.0 kg-m. 12 - 14 ft-Ib)
lock nut 100 - 130 N·m It 0.0 - 13.0 kg-m, 72 - 9 4 tt-Ib)
Different ial gear case nut '86 , ' 87 : 60 - 80 N'm (6 .0 - 8 .0 kg-m , 43 - 58 ft -Ib)
*
After ' 87 : 35 - 45 N·m (3.5 - 4.5 N·m , 25 - 33 ft -Ib)
Front aKl e nut 80 - 100 N-m 18.0 - 10.0 kg -m , 58 - 72 ft-Ibl
Swingarm joint nut ' 86, ' 87 : 80 - 90 N' m (8 .0 - 9.0 kg-m, 58 - 65 ft-Ib)
* After ' 87 : 35 - 4 5 N·m (3.5 - 4 . 5 kg-m. 25 - 33 ft -Ib)
Steering stem nut 100 - 120 N-m 110.0 - 12.0 kg -m , 72 - 87 tt-Ib)
Steering lower stay lock nut 50 - 70 N·m (5.0 - 7.0 kg-m. 37 - 51 ft -Ib)
Front skid plate bolt 18 - 25 N·m It .8 - 2. 5 kg-m. 13 - 18 ft-Ib)
Front guard plate /pipe bolt 18 - 25 N'm 11 .8 - 2. 5 kg-m, 13 - 18 ft -Ib)
12-2
CAUTION
*.' NIII jor After '87 is a self-locking nut with Ihe nUl-head peened; nut jor '86 and '87 is a
self-locking nut (V-locking nut). Tighlen each nUllO each specified torque, or (he nUl is
broken or loosened.
1'86, '87) (After '87)
TOOLS
Special
Spring compressor adaptor 07967 - KClOOoo (Not available in U.S.A.)
lock nut w rench 07908 - 4690001 or KS - HBA - 08 - 469 (U.S.A. only)
Bearing remover set 07936 - 8890101 (Not available in U.S .A .)
- Remover head 07936 - 8890200 INot available in U.S.A. )
- Bearing remover, 30 mm 07936 - 8890300
- Remover weight 07741 - 00 10201 or 07936 - 3710200
- Remover handle 07936 - 37 10100
Wrench adaptor 07GMA - HA702oo
Commo n
Shock absorber compressor 07959 - 329000 1
Driver 07749 - 0010000
Socket bit, 17 mm 07703 - 0020500 or equivalent commercially available in U.S .A.
Attachment, 32 x 35 mm 07746 - 00 10100
Attachment, 37 x 40 mm 07746 - 00 10200
Attachment, 42 x 47 mm 07748 - 00 10300
Attachment , 52 x 55 mm 07746 - 0010400
Pilot, 20 mm 07746 - 0040500
Pilot, 22 mm 07746 - 0041000
Pilot, 28 mm 07746 - 004 1100
Pilot, 30 mm IAlter '87 ) 07746 - 0040700
Tire bead breaker set 07772 - 00500013-
Breaker arm 07772-0050200 or Universal bead breaker GN - AH - 95B - BBI
Breaker arm compressor 07772-0050100 (U.S.A. only)
TROUBLESHOOTING
Hard steering Front wheel wobbling
Steering stem nut too tight Bent rim
Excessive steering stem bearing play Worn front drum bearing
Damaged steering stem bearing Faulty tire
Insufficient tire pressure Axle nut not tightened properly
Improperly adjusted knuckle pivot
Damaged knuckle pivot bearing Hard suspension
Bent shock absorber
Steers t o one side or does not track straight Improperly adjusted swing arm pivot
Bent tie -rod Faulty pivot bearing
Insufficient tire pressure
Inconect wheel alignment Suspension noise
Bent knuckle and knuckle holder Shock case binding
Weak front shock absorber • l oose fasteners
Soh suspension
• Weak spring
12-3
HANDLEBAR (2) WIRE BA,ms

\1) SWITCH HOUSING
REMOVAL

- wire bands
- throttle lever housing
- switch housing land disconnect the choke cable)
I
- front and rear brake lever brackets
151 CHIO~i:!~~~
Remove the handlebar cover cap and screws, then remove the
cover.
Remove the coliars and mount rubbers from the cover.
Remove the handlebar upper holder bolts and holders .

Remove the handlebar.
INSTALLATION
Place the handlebar on the lower holders.

Align the punch mark on the handlebar with the top of the
lower holders.
Install the upper holders on the handlebar with their punch
marks forward.
Tighten the forward bolts first , then tighten the rear bolts.
TORQUE; 18 - 30 N'm 11.8-3 .0 kg-m. 13 - 22 ft-Ibl
12-4
Connect the choke cable to the choke lever. (3) UPPER SCFIEW
Install the switch housing, aligning its mating surfaces with
the punch mark on the handlebar.
Tighten the upper screw first, then tighten the lower screw.
If the handlebar grips were removed, apply Honda Bond A or

Honda Hand Grip Cement (U.S.A. only) to the inside of the grip
and to the clean surfaces of the right and left handlebar .
Wait 3 - 5 minutes and install the grip.
Rotate the grip for even application of the adhesive.
NOTE
• Allow the adhesive to dry for an hour before using.
(2) MARK
InstaU the rear brake lever bracket with the dot on the holder
facing up. Align the end of the holder with the punch mark on
the handlebar.
Tighten the upper screw first, then the lower screw .
(3 ) LEVER BR.'CI(ET
Install the master cylinder and front brake lever bracket with 11) MASTER CYLINDER
the "UP" mark on the holder facing up . {BRAKE RR.'C'(ET
Tighten the upper bracket screw first, then the lower screw
lightly.
III THROTTl~E HOUSING

Install the throttle housing on the handlebar.
First align the end of the housing with the punch mark on the
handlebar. Then align the line on the housing with the end of
the brake lever bracket.
Tighten the screws securely.
121
12-5
Install the handlebar cover mount rubber. upper rubber. plain

t1) PLAIN
washer and collar in the handle covar as shown.
WASHER
(2) UPPER
Install the cover and tighten it with the two screws.
RUBBER
Install the cover cap.
Install the wire bands (page ' · 10).
l!
(3) MOUNT
RUBBER
(4) COLLAR
THROTTLE HOUSING
DISASSEMBLY
Remove the three throttle housing cover screws and the

cover. Remove the gasket.
Slide the rubber boot off the cable adjuster.

loosen the throttle cable adjuster.
Bend down the lock washer tab and remove the nut and lock
washer.
Disconnect the throttle cable from the throttle arm.
Remove the throttle arm, spring and throttle lever from the
throttle housing.
ASSEMBLY i (2) ARM SPRING
Connect the throttle cable to the throttle arm.
InSlali the throttle arm spring and afm onto the throttle lever .
aligning their flats.
? ,
12-6
FRONT WHEEl/SUSPENSION/STEERING
Install a new lock washer and tighten the nut.

Bend up the lock washer tab against the nut.
Install a new gasket, then install the throttle housing cover

using the three screws.
Adjust the thronle lever free play (page 3-3).
FRONT WHEEL
REMOVAL
Place a support block under the engine 10 rai se the front

wheels off the ground.
Remove the wheel cap and inspection hole cap, loosen the
wheel nuts and remove the wheel.
INSTALLATION
Install the front wheel, aligning a hole in the wheel with a hole
in the brake drum so that the tires show a "V" pattern when
viewed from the front.
NOTE
• 00 not interchange the right and left tires.
It'
(2) FRONT
Install the wheel nuts with their curved sides facing inward
and tighten to the specified torque.
TOROUE: 60-70 N·m (6.0-7.0 kg-m , 4 3-51 ft-Ib)
Install the wheel cap and inspection hole cap securely (page
3·8).
12-7
TIRES
REMOVAL (U.S.A. ONlYI
NOTE
This service requires the Universal Bead Breaker IGN-AH -
958-BB1) available in U.S.A. only_
Remove and instatl tires from the rim side opposite the
valve stem.
Remove the core from the valve stem.
CAUTION
Use oj the Bend Breaker /001 is required jor tire removal.
Do not damage Ihe bead sealing area of the rim.
Use a Coo/s1]O Tire Changer or equivalent /0 remove the tire
from the rim. If Q tire changer is not available, rim protectors
and lire irons may be used. 7
~ 1) PRESS BLOCK
~2) BREAKjR ARM ASSEMBLY
Install the blade for 9"11 1 " rims ont o the breaker arm assemb-
ly . I
CAU TION
f-J
Use of an improper size blade may result in damage to the ,im,
lire or blade.
(3) BLADE
Place the proper size adapter onto the threaded shaft and then
~3) BREAKER ARM ASSEMBLY
put the wheel over the threaded shaft and adapter.
~ 1) TIRE ~2) RiM ,",
.'
Lube the bead area with water, pressing down on the tire side-
wall fbead area in several places to allow the water to run into
and around the bead. Also lube the area where the breaker arm
will con tact the sidewall of the tire.
Use only warer as a lubricant when removing or mounting tires.

Soap or some mounting lubricants ma)' lea\'e a slipper}' residue
which can cause the rire to shift on the rim and lose air pressure (4 ) THREADED SHAFT
during riding, IS) ADAPTER
While holding the breaker arm assembly at an approximate

45 0 position, insert the blade of the breaker arm between the
tire and rim, Push the breaker arm inward and downward until
it is in the horizontal position with its press block in contact
with the rim .
12-8
With the breaker arm in the horizontal position, place the (5) PRESS HEAD
breaker press head assembly over the breaker arm press block. A SSEMBLY
(1) PRESS HEAD BOLT -
Make su re the press head bolt is backed out all the way and
(2) LEVER NUT
then position the nylon buttons on the press head against the
inside edge of the rim.
Insert the threaded shah through the appropriat e hole in the

breaker press head assembly and then tighten the lever nut
until both ends of the breaker p ress head assembly are in firm
contact with the rim.
Tighten the press head bolt until the reference mar k on the
press block is aligned with the top edge of the press head. !7) 9 " RIM (6) 7 " RIM
If the rest of t he bead cannot be pushed down into t he center

(2) TOP EDGE OF
of the rim by hand, loosen t he press head bolt and the lever
PRESS HEAD
nut. Rotate the breaker arm assembly and breaker press head
assembly 1/8 to 1/4 the circumference of the rim. Tighten the
lever nut and then tighten the press head bolt as described.
Repeat this procedure as necessary until the remainder of the

bead can be pushed down into t he center of the rim.
Assemble the Universal Bead Breaker on the other side of the

wheel and break the bead following the same procedures.
Remove the tire from the rim using a tire changer machine or
tire irons and rim protectors. (31 RIM BEAD LOCKS
Remove tire from rim t hat has t he smallest shoulder ares t o

simplify removal.
REMOVA L (EXC EPT U.S. A .I
NOTE
This service requires the Tire Bead Breaker Set (07772 -
0050001) not available in U.S.A.
CAUTION
Do not apply waler, soapy water, oil etc. 10 the lire, rim and
/001 when removing the lire. The tool breaker arm may slip of/ (2) NARROW END (A SIDE)
the lire and the bead can not be broken all the tire.
Do not damage Ihe bead seating area o/Ihe rim.
Follow the breaker manu/aclllrer's ins/ruction.
(1) RIM CENTER (2) BREAKER ARM
COMPRESSOR
Insert the narrow end (A side) of the breaker arm between the
tire and the rim.
TOOL :
Breaker arm 07772 - 00502 00
Position the breaker arm compressor onto the rim center as

shown.
TOOL:
Breaker arm compressor 0 7772 - 0050100
12-9
Keep the breaker arm horizontal and align the end of the com·
pressor bolt with the arm hole .
Screw in the breaker arm compressor bolt to break the beed

from the tire .
If the rest of the bead cannot be pushed down into the center
of the rim, rem ove and reposition the compressor and arm 1/8
to 1 /4 the circumference of the rim . Tighten the compressor
bolt to break the bead. Repeat this procedure as necessary
until the remainder. of the bead can be pushed down into the
center of the rim.
If the bead breaking is difficult with the narrow end (A side) of

the breaker arm. use the wide end (8 sidel of the arm and
\11 WIDE END (8 SIDE)
repeat the procedure above.
TIRE REPAIR
NOTE
Use the manufacturer's instructions for the tire repa ir kit
you are using. If your kit does not have instructions, use the
procedures provided here.
Check the tire for puncturing objects. Chalk mark the punc-
tured area and remove the puncturing object.
Inspect and measure the injury. Tire repairs for injuries larger
than 15 mm (5/8 in) should be a section repair. Section repairs
should be done by a professional tire repa ir shop.
If the injury is smaller than 15 mm (5/8 in). proceed with the
repa ir as described here.
12-10
Install a rubber plug into the injury as follows:

Apply cement to a plug inserting needle and work the needle
into the injury to clean and lubricate 11. Do this three times. 00
not let the cement dry.
Insert and center a rubb er plug through the eye of the inserting
needle .
Apply cement to the rubber plug .

Push the inserting needle with plug into the injury until the plug
is slightly above the tire. Twist the needle and remo ve it from
the tire; the plug will stay in the tire .
NOTE
Be careful not to push the plug all the way into the tire to
prevent it from falling Inside.
Trim the plug 6 mm (1 /4 in l above the tire surface .

Aepeat the above procedure if the puncture is large.
Do not use more than two plugs per injury .
Allow the repair to dry . Drying time will vary with air tempera-
ture. Refer to the tire repair kit manufacturer's recommenda-
tions .
Inflate the tire and test the seal by dabbing a small amount of
cement around the plug. Escaping air will cause a bubble in the
cement . If there is leakage, remove the tire (page 12· 8) and
apply a cold patch to the inside of the tire as described.
If a plug has been inserted, trim it even with the inner tire sur·
face.
Temporarily place a rubber patch that is at least twice the size

of the puncture over the injury . Make a mark around the patch,
slightly larger than the patch itself.
Remove the patch.
Roughen the area marked inside the tire with a tire buffer or a
wire brush . Clean the rubber dust from the buffed area.
Apply cement over the area marked and allow it to dry .

Remove the lining from the patch and center it over the injury.
Press the patch against the injury using a special roller.
NOTE
Allow cement to dry until tacky before applying patch.
• Do not touch the cement with dirty or greasy hands.
12-11
FRONT WHEEL/SUSPENSION /STEERING
ASSEMBLY
Install the tire onto the rim, where the rim shoulder width is the
narrowest , to simpllfV installation .
Clean the rim bead seat and flanges.

Apply clean water to the rim flanges. bead seal and base .
Use only W/JUf as /J lubricant when remolling or mounting tires.

Soap or some mOllnting lubricants may leal'l! /J slippery residue
which clln cause the tire to shift on the rim IJnd lose air pressure
during riding.
Install the valve core in the valve stem .

Install the tire and inflate it to seat the tire bead .
Deflate the tire. Wait 1 hour and inflate the tire to the specified
pressure .
TIRE PRESSURE:
Front : 2.2 psi (15 kPa, 0.15 kg/cm2)
Rea r: 2.2 psi (1 5 kPa, 0 .' 5 kg /cml )
Check for air leaks and install the valve cap.
TIE·ROD
REMO VA L
Place a support block under the engine to raise the front

wheels off the ground .
Remove the front wheels (page 12-7) .
Remove the cotter pin and 10 mm U-nut, then remove the right
tie-rod 18) and left tie-rod Ie ) between the pivot arm and
knuckle.
Loosen the pivot arm 14 mm U-nut.

Remove the cotter pin and U-nut, then remove the tie -rod (A).
Remove the nut, dust seal, pivot arm bushings and collar to-
gether with the pivot arm .
(2) PIVOT ARM BUSHINGS
INSPECTION (1 ) COLLAR
Inspect the pivot arm bushings and collar for wear Of damage,
and replace if necessary .
Measure the 1.0 . of the bushings. Q
Measure the 0 .0. of the collar .

'0,=~7"---(3) DUST SEAL
SERVICE LIMIT: 19.50 mm (0 .7681nl
12-12
Inspect the tie-rod for distortion or damage.

Inspect the ball joint rubbers for tears or other damage bV
joggling the ball joint ends. They should move f reely and
smoothly.
Replace the ball joint rubbers if necessary.
m
t
TlE·ROO
131 RU;'BEllS
A SSEMBLY (3) NUT AND BAll JOINT

(SILVER)
Install a gold nut and ball joint on one end of the t ie-rod (end
(1) FLAT
(\
w ith flats) and a sillier nut end ball joint on the other end
(flanged side).
\ __ ,121 TlrOD
:'\
,-,
\1~---'
Adjust the tie-rods (A), (B) and (e) so that each ball joint cen - (5) BALL JOINT AND NUT
(4 ) FLANGE
ter -to -center length is as specified below. (GOLD)
NOTE
Assemble the ball joint so that tie-rod -to-ball joint distance
® is 21 mm {0.82 inJ.
~
TIE-ROD IN STALLATION LENGTH :

TIE· ROD A: 161.5 - 164.5 mm (6 .36 - 6 .48 in)
~ \lj
TIE·ROD B: 302.5 -30 5.5 mm (11 .91 - 12.03 inl
TIE·ROD C: 348.5-351.5 mm 113.72 - 13.84 in) ~ If 1 T
~
=
I. ~ 2-
.1
INSTALLATIO N ( 1) INSTALLATION LENGTH
Install the pivot arm and temporarily install the nuts.

Install each tie-rod between the parts stated below re-
spectively with the flanged end toward the pivot arm as
shown to right.
~~
TIE-ROD A : Between the st eering arm and pivot arm 1)'TIEROD~A) .....
"
'rI~i ~
TIE-ROD B: Between the pivot arm and right knu ckle arm
TIE-ROD C: Between the pivot arm and left knuc kle arm
Ie " ..
Tighten the tie-rod end nuts to the specified torque. 1 ROD e ' 1sTEERING
TORQUE : IBI ' ~ ,- ARM
' 86, ' 87 : 65 - 75 N·m 16 .5 - 7.5 kg- m . 50-54 ft-Ibl
After '87 : 35 - 45 N·m 13.5- 4 .5 kg-m , 2 5 - 3 3 ft -Ibl 151 KNUCKLE ARM " /~
Install new cotter pins.
141 PIVOT ARM / •
ICI~
Tighten the pivot arm nut to the specified torque.
TORQUE: 60 - 70 N 'm 16 .0 -7.0 kg-m , 43 -5 1 ft-Ib) (3) TIE ROD
Install t he front wheel (page 12-7).
12-13
TOE-IN ADJUSTMENT
Mark the centers of the tires with chalk to indicate the axle
center height.
Align the toe-in gauge with the marks on the tires.
Check the readings on the gauges scales (page 3-13),
TOE·IN : 0 mm (0 inl
To adjust the toe-in, loosen the lock nut and turn the tie-rod.
After the adjustment, tighten the tie-rod lock nut.
TOROUE: 35 - 45 N·m (3.5- 4 .5 kg -m , 25-33 tt -Ib)
NOTE
Turn both right and left tie-rods equally until the toe reading
is correct.
FRONT WHEEL TURNING ANGLE ADJUSTMENT
Install the turning radius gauge.

Steer the handlebars to right and left fully with the brake lever
depressed and check the reading.
FRONT WHEEL TURNING ANGLE:

INSIDE RADIUS : 35°
OUTSIDE RADIUS : 25 °
If the front wheels inside and outside turning angles are out of
speci f ication, adjust by turning the tie-rods while measuring
the toe-in.
KNUCKLE/KNUCKLE HOLDER/
DRIVE SHAFT
KNUCKLE REMOVAL

- front wheel
- cotter pin, axle nut, brake drum and wheel hub
- tie rod (page 12-12)
Remove the front brake panel bolts.
CAUTION
(After '87 Only): Using again slriclly prohibited, because the
bolt threadsfor After '87 is specially clXlted. You can exchange
the '86 and '87 bolts for the After '87 bofts, bur the reverse is
no good.
Remove the brake panel With the brake hose connected.
NOTE
Do not operate the front brake lever after removing the
brake panel assembly. To do so will make it difficult to refit
the brake and brake shoes.
12-14
Disconnect the tie rod from the knuckle (page 12- 12) and
remove the brake hose guard.
l oosen the kingpin lock nut by holding the kingpin bolt.
Remove the upper kingpin bolt.
Bend up the tab of washer and remove the lower kingpin bolt.
Remove the knuckle.
_~" • • LOWER KINGPIN BOLT
KNU CKLE BEA RI NG INSPECTI ON
Turn the inner race of each bearing with your finger.

The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the knuck-
le.
Remove and discard the bea rings if the races do nOt turn
smoothly, quietly or if they fit loosely in the knuckle.
NOTE
• Replace the bearings in pairs.
KN UCK LE BE A RI NG AN D DUST SEA L

REPLAC EMENT
(1) DUST SEALS (3) DR I VE~4) ATTACH -
Remove the dust seals from both sides of the knuckle. MENT
Remove the snap ring.
Place the knuckle in a press with the special 1001 and press the
bearings out of the knu ckle.
TOOLS :
Dr;ver 07749 - 0010000
Attachm ent. 42 )t 47 mm 07746- 001 0300
Pilot. 28 mm 07746- 0041100
NOTE
• Be careful not to damage the knuckle bore surface. 121 SNAP RING
12·15
Press the new bearings into the knuckle with the special toots.
TOOLS :
Driver 07749 - 0010000
Attachment, 52 .II 55 mm 07746 - 0010400
Pilot, 28 mm 1'86. ' 87 ) 07746 - 0041100
Pilot, 30 mm IAfter '87) 07746 - 0040700
NOTE
• Be careful not to damage the knuckle bore surface.
Install the snap ring.
Drive each dust seal into the knuckle with the lip toward the
outside.
Apply multipurpose grease to the lips of the dust seals.
KNUCKLE HOLDERIDRIVE SHAFT REMOVAL
NOTE
(2) KNUCKLE
The knuckle holder is an assembly with the pivot bearings. HOLDER
If the knuckle holder is damaged, replace the assembly .
Remove the guard plate by rem oving the bolts )page 2 · 3) .

Remove the brake hose clamp and pull out the drive shaft.
Remo ve the knuckle holder by removing four nuts.
(1 ) BOOT
DRIVE SHAFT BOOT REPLACEMENT
Check the boot for cuts or other damage.

Remove the boot from the drive shaft by removing the bands A
and B.
NOTE
Replace the bands with new ones whenever removing
them.
Check the drive shaft ball joint for excessive play or noise by
moving the ball joint in a circular direction.
Pack the boot with 40-60 g of grease and install it on the drive
shaft.
Install the boot bands as following;

1. Bend down the tab of the boot band .
2 . Secure the bent down tab wi th the locking clips and tap
them with a plastic hammer.
NOTE
Be careful not to damage the boot.
• Install the bands with their tabs facing rearward .
11) LO(OKI"G CLIPS
12-16
FRONT WHEELISUSPENSIONI STEERING
KNUCKLE HOLDER DU ST SEA L REPLACEMENT (1) DUST SEA LS (2) O-R ING
Remove the O-ring and oil seal.
Apply grease (5· ' 0 g) to the bearing outer race.

Install the bearings and drive new upper and lower pivot dust
seals into their positions.
Apply grease to the lips of the dust seals.
Orive new oil seal in the knuckle holder and apply grease to the
lips of the seal.
TOOLS:
Driver 07749 - 0010000
Attac hment, 42 x 47 07746 - 0010300 (1) OIL SEAL
Pilot, 22 mm 07746 - 0041000
Install a new O-ring on the knuckle holder.
12-17
FRONT WHEEL/SUSPEN SION/STEERING
KN UCKLE HOLO ER INSTA LLA TI ON
I
Install a new O-ring.
Install the knuckle holder w ith the part fo r the brake hose
----
clamp upward .
TIghten the nuts to the specified torque in 8 crisscross pattern
in 2 or 3 steps.
TORQUE :
'86 , ' 87 : 60 - 80 N·m 16.0 - 8 .0 kg-m . 43 - 58 ft-Ibl
After ' S7 : 35 - 45 N·m 13.5 - 4 .5 kg-m . 25 - 33 It-Ibl
NOTE
• Do not forget to install the D· ring .
ApplV grease to the splines and install the drive shaft.

Install the brake hose clamp onlO the knuckle holder .
NOT E
• Make sure t hat the drive shaft boot is not t urned up .
(1) M A RK
KNU CKLE IN STALLATION
Following the mark on the reverse side of the knuckle , install

the knuckle with the part for the brake hose guard upward.
" A" - right knuckle
" l " - left knuckle
Temporarilv install the lock washer , lower king pin bolt and
upper king pin boll.
NOTE
Apply grease to the knuckle dust seat. Inst all after making
sure that the dust seal lip is nOI t urned up.
First, tighten the lower king pin bolt t o the speci f ied torque and
stake the bolt bv bending the lock washer claws.
TORQUE: 50 - 70 N·m (5 .0 - 7 .0 kg·m, 37 - 5 1 f Hb)

( 1) SOC KET BIT (3 ) KNUCKLE
( 5 ) AT l EA ST HOLDER
Then tighten the upper king pin bolt to the specified torque and
2 .0 m m
tighten the lock nut w hile holding t he king pin bolt. (O.OB in)
TORQUE:
UPPER KINGPIN BOLT:
5 - 10 N' m (0.5 - 1.0 kg-m , 4 - 7 ft-Ibl
KINGPIN LOCK NUT:
50 - 70 N·m (5.0 - 7 .0 kg -m . 3 7 -5 1 ft -Ib)
NOTE
(4 ) BOOT
Make sure that the drive shaft boot-to-knuckle holder clear- (2) lOCK NUT W RENCH
ance is at least 2 .0 m m (0.08 in) .
12-18
Install the hose clamp (After '871 and brake hose guard on the
knuckle.
Connect the tie-rods (page 12- 1 3).
Install the brake panel.
Tighten the bohs (After '87: new bolts) to the specified
torque .
TORQUE: 27 - 33 N·m (2.7 - 3.3 kg-m , 20-24 ft·lb)
CAUTION
(A/ler '87 Only): Using agoin strictly prohibited, because Ihe
boll threads/or A/rer '87 is specially coaled, YOII can exchangl'
the '86 and '87 bollS for the A/rt'r '87 bolts, but the reverse is
no good.
Install the wheel hub and brake drum.
Tighten the axle nut so its slots will be as close as possible 10

the holes in the axle.
TORQUE : 80 - 100 N·m /8.0 - 10.0 kg-m. 58 -72 ft-Ib)
Install a new cotter pin .

Install the front wheel (page 12-71.
Adjust the front brake (page 3 · 8).
Check the steering system and adjust the toe-in if necessary
(page 12- 14). (3) COTTER PIN
(4) AXLE NUT
FRONT SHOCK ABSORBER

REMOVAL
Raise the front wheels off the ground with a jack or block
under the frame.
Straighten the lock washer tab of the left shock absorber.
Remove the upper and lower mounting bolts and nuts.
Remove the shock absorber from the frame.
DISASSEMBLY ') SPRING COMPRESSOR

ADAPTER
Compress the front shock absorber with the shock compres-
sor, adaptor and attachment.
CAUTION
Be careful that the upper end of the damper does not slip OUI oj
the compressor.
TOOLS:
Shock absorber compressor 07959 -3290001
Spring compressor adapter 07967 -KC1000Q (2) SHOCK ABSORBER
(Not available in U.S.A.) COMPRESSOR
12-19
Lower the boot and pull the shock rod out.

Separate the upper joint by loosening the lock nut and remove
,11 UP\" JOINT
the shock compressor.
• ,
INSPECTION
Inspect the spring for damage and measure its free length.
\
(2) LOCK NUT
SERVICE LIMIT : 226 .0 mm (8.90 lnl.
ASSEMBLY
Apply locking agent 10 the rod threads and install the lock nut.
Install the shock absorber spring with the closely wound coils
toward the top.
Compress the shock absorber spring with the compressor and

attachment.
Apply locking agent to the damper rod threads and screw the
upper joint on. Hold the lock nut in e vise and tighten the upper
joint securely .
..
(11 TOP
TORQUE: 30 - 45 N·m (3.0 - 4 .5 kg-m , 25-33 ft -Ibl
NOTE
Check that the lock nut is seated against the rod's bottom
thread.
INSTALLATION
Align the spring seat with the upper joint while releasing the
compressor.
Install the shock absorber in the frame.

Install the left shock lower mounting bolt with the lock wash·
".Install the bolts and nuts, and t ighten the bolts and nuts to the
specified torque .
NOTE
Don't fOlget to install the lock washel on the lowel left
mounting bolt.
TORQUE :
Lower mounting bolt nefti :
60 - 80 N·m 16.0 - 8.0 kg·m , 43 -58 ft-Ibl
Upperflower Irightl mounting nut:
'86, ' 07 : 60-80 N·m (6 .0 - 8 .0 kg -m . 43 - 58 ft -Ibl
After '87 : 35 - 45 N·m (3 .5 - 4 .5 kg -m , 25 - 33 ft -Ibl
Bend up the lock washer lab for the lower left bolt.
12-20
SWINGARM
REMOVAL

- front wheels [page 12-7 )
- tie rod (page' 2- 121
- knuckle /knuckle holder/drive shaft (page' 2-14)
- front guard plate (page 2-3 )
- front skid plate
Remove the right shock absorber lower mounting bolt /nut.

Remove the axle housing by removing three special bolts and
four nuts.
Bend down the lock washer tabs and remove the left shock ab- (11 LOWER MOUNTIN~( 2 ) BR"AT
sorber lower mounting bolt . BOLT
Disconnect the breather tube from the differential gear case .
Free the breather tube from the clamp on the swingarm.

\,
Remove the differential gear case by removing four mounting
nuts .
,. , W","p
Loosen and remove the boot band from the engine.
Remove the br ake pipe clamps and brake pressure control

valve mounting bolts, then remove the pipe and the control
velve from the swingarm.
12-21
Remove the right and left pivot caps.

Loosen the right pivot lock nut.
TOOL:
Lock nut wrench 07908 - 4690001 or
KS-HBA·08·469 (U .S.A . only)
Remove the right and left pivot bolts .
TOOL :
Socket bit, 17 mm 07703 -0020500 or equivalent
Remove the 5wingarm from the frame , then remove the drive
shaft from the engine.
PI VOT BEARING REPLACEMENT 121 BEARING-

OU ~rEARACE
Remove the dust seals and bearings.

Remove the bearing outer races from the swingarm.
TOOLS:
Beating remover set 07936 - 8890101
(Not available in U.S. A.)
- Remover head 07936 - 8890200
(Not available in U.S. A .J
- Remover weight 07741 - 0010201 or
07936 - 3710200
- Remover handle 07936 - 3710100
Press the new bearing outer races into the swingarm. ( 1) DRIVER (2) ATTACHMENT
NOTE
• Replace the bearings and outer races as a set.
TOOLS;
Driver 07749 - 0010000 RACE
Attachment, 37 x 40 mm 07746 - 0010200
12-22
FRONT WHEEL/ SUSPENSION/STEERING
Apply grease to the new bearing rollers and dust seal lips.
Install the bearings in their posit ions and drive the dust seals
into the swingarm.
(11 BEARING
DRI VE SHAFT IN SPECTION (1) UNIVERSAL JOINT
Inspect the universal joint bearings for e)(cessive play or dam-

age .
Apply molybde num disulfide grease to the splines .
121 _!Ijjjjift.
(MOLYBDENUM)
SW INGA RM INSTALLATION
Install the boot with its " HA 7" mark up onto t he swingarm.
Install the drive shah to the engine's drive shaft joint , aligning
their splines.
Install the swingarm into t he f rame.
Install and tighten the leh pivot bolt.
TORQUE : 100 - 130 N·m (10.0 - 13.0 kg·m, 72 - 94 ft-Ibl
TOOL :
Socket bit. 17 mm 07703 - 0020500 or equiv alent
c ommercially available in U .S.A .
12-23
Install and tighten the right pivot bolt 10 20 N-m 12.0 kg-m, 14
ft -Ib), loosen it and retighten to the specified torque.
TOROUE: 16 - 20 N·m 11 .6 - 2.0 kg-m . 12 - 14 ft-Ibl
TOOL:
Socket bit. 17 mm 07703 - 0020500 or e quiva lent
Move the swingarrn up and down several times.

Retighten the right pivot bolt to the specified torque Isee
above).
121 SCIO'ET BIT, 17 mm
Tighten the right pivot lock nut while holding the pivot bolt.
TORQUE : 100 - 130 N·m 110.0 - 13.0 kg-m , 72 - 94 ft·lbl
Torque wrench scale reading :

91 - 118 N'm (9 . 1 - 11 .8 kg-m. 66 - 85 ft -Ibl
TOOLS :
Soc ke t bit. 17 mm 01703 - 0020500 or equivalent
commercialtv available in U.S .A.
l ock nut wre nch 07908 - 4690001 or
KS -HBA-08-469 (U .S.A . only)
Install the right and left pivot caps.

Install the boot and tighten the boot band securely .
Install the brake pipes and pressure control valve to t he swing-

arm with the mounting bolts .
Install a new O-ring on to the swingarm, then grease the 0 -

ring.
Install the differential gear case on the swingarm.

Tighten the nuts to the specified torque .
TORQUE :
' 86 , ' 87 : 60 - 80 N'm (6 .0 - 8 .0 kg -m , 43 - 58 ft-Ibl
After ' 87 : 35 - 45 N'm 13 .5 - 4 .5 kg -m , 25 - 33 ft·lb)
Connect the breather tube to the differential gear case and

damp it.
Install the left shock absorber wi th t he lock w asher and lower

mounting boll.
Tighten the bolt to the speci f ied torque .
TORQUE: 60 - 80 N·m 16 .0 - 8 .0 kg-m , 43 - 58 ft -Ibl
Bend up the lock washer tabs.
12-24
Install the a)(le housing onto the swingarrn and differential gear
case .
Install the differential gear case nut and swingarm joint boltsl
nuts. and tighten them.
TORQUE :
Differential gear case:
'86, '87 : 60 - 80 N·m (6.0 - 8.0 kg-m. 43 - 58 ft -Ibl
After '87 : 35 - 45 N·m (3 .5 - 4.5 kg-m , 25 - 33 ft-Ibl
Swingarrn joint :
'86, 'S7 : 80 - 90 N·m (8.0 - 9 .0 kg -m , 58 - 65 fHbl
After ' S7 : 35 - 45 N·m (3 .5 - 4 .5 kg -m , 25 - 33 ft -fbl
Secure the right shock absorber to the axle housing with t he

lower mounting boltl nut and tighten it to the specified torque .
TORQUE:
' 86 , '87 : 60 - 80 N·m (6.0-8.0 kg-m , 43 - 58 ft-Ibl
After '87 : 35 - 45 N·m (3.5-4 .5 kg-m , 25 - 33 ft·lbl
Install the front skid plate securely.

Install the following :
- knuckl e! knuckle holderl drive shaft (page 12- 1 8)
- tie rod (page 12 - 1 3)
- front guard plate (page 2-3)
- front wheel (page 12-7)
STEERING STEM -
REMOVAL
RemOlle the following : (2) THRUST

WASHER
- handlebar (page 12-4)
- swingarm (page 12-21 )
Remolle the pin, steering stem nut and thrust washer.

Remove the steering arm and pull t he steering shaft upward
and out.
(3) COTTER PIN
Remove the steering lower stay by removing the mounting

bolts and nuts.
12-25
BEARIN G IN SPECTION
Turn the inner race of boering with your finger.

The bearing should turn smoothly and quietly.
Also check that the bearing outer fBce fits tightly in the Sleer-
ing lower stay.
smoothly. quietly or if they fit loosely in the steering lower
stay.
BEARING REPLACEM ENT
Place the steering lower stay in a vice, being careful not to dis-
tort it, and remove the top and bottom dust seals. (1) WRENCH ADAPTOR
Remove the lock nut with a wrench adaptor.
TOOL:
Wrench adaptor 07GMA - HA70200
- •• (2) LOCK NUT
Set the lower stay in a press and, press out the bearing. (,) DRIVI'R_t"
TOOLS : 121 ATTACHMENT,

Driver 07749 - 0010000 32 X 37 mm
Attac hment, 32 )( 35 mm 07746 - 0010100
Pilot, 20 mm 07746 - 0040500
Press a new bearing into the stay.
TOOLS :
Driver 07749-0010000
Attachment, 42 .. 47 mm 07746 - 0010300
Pilot, 20 mm 07746 - 0040500
Place the stay in a vice and install the lock nut with a wrench
adaptor.
TOOL: ( 1 ) WRENCH ADAPTOR

Wrench adaptor 07GMA- HA70200
Tigh t en the lock nut to the specified torQu e.
~~~f~~~~~;-
TOROUE : 50-70 N·m (5.0-7.0 kg-m, 37 - 5 1 ft-Ibl
- (2) LOCK NUT
12-26
FRONT WHEEL/SUSPENSION/ STEERING
Drive new top and lower dust seals in the lower stay. (11 SEALS
ApplV grease to the lips of the dust seals.
(2l LIPS
INSTALLATION
Install the steering lower stay on the frame with the four bolts
and nuts.
InSlallthe bushing on the lower stay.
Install the steering shaft through the frame.

Apply grease to the steering shaft splines.
Install the steering arm, aligning the wide groove on the shaft
with the mark on the steering arm.
Inslall the thrust washer and steering stem nut. Tighten the
nut to the specified torque.
TORQUE : 100 - 120 N·m (10.0 - 12.0 kg-m, 72 - 87 ft-Ib)
Turn the steering stem lock to lock several times and retighten
the nut to the specified torque (see above).
Make sure that there is no vertical movement and that the
stem rotates freelv.
Install a new coner pin.

- handlebar (page 12-4)
(3l STEERING STEM NUT !21 COTTER PIN
- swingarm (page 12-23)
12-27
BRAKES
25 - 35 Nom
(2.5- 3 .5 kg-m. 18-25 ft·lb)
\
\
'86 '87 :
50 - 60 N·m (5.0 - 6.0 kg-m,
36 - 43 ft· lb)
'* After ' 87 :
35 - 45 N'm (3.5 - 4 .5 kg-m,
25 - 33 ft -Ib )
~~~:_:s;::::.::::~ 25 - 35 N'm
(2.5-3.5 kg-m ,
18 - 25 ft· lb)
'87
120- 160 N·m

112.0 - 16.0 kg-m,
87 - 116 fHb)
- 35 N'm
80 - 100 N'm
18 .0 - 10 .0 kg -m , 58 - 72 ft -Ib)
*: CAUTION (See page 13· 2)
13-0
13. BRAKES
SERVICE INFORMATION 13- 1 MASTER CYLINDER 13- 11
TROUBLESHOOTING 13-2 REAR BRAKE 13- 13
FRONT BRAKE 13-3 REAR BRAKE PEDAL 13- 1 B
BRAKE SHOES/WHEEL CYLINDER/
ADJUSTER ASSEMBLY 13-B
SERVICE INFORMATION
,[
Inhaled asbestos fibers hal'l! been found to cause respiratory disease and cancer, N,I'u ust' an air hose or dr)' brush to ciean brake
or clutch assemblies. In the United States. use OSHA-apprOI'ed ,'acuum cleaner or allernate method apprm'ed bJ' OSHA dl'Slgned
to minimize the hazard caused by airborne IlSbestos fibers.
• This section covers maintenance of the front drum hydraulic brake and rear drum brake systems.
• A jack or other support is required to support the vehicle.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Do not allow foreign material to enter the system when filling the reservoir.
• Brake fluid will damage painted, plastic and rubber parts. Whenever handling brake flu id, protect the painted, plastic and
rubber parts by covering them with a rag. If fluid does get on these parts, wipe it off with a clean cloth.
• Always check brake operation before riding the vehicle.
SPECIFICATI ONS
Front brake drum 1.0. 160 mm (6.2 in) 161 mm (6.3 in)
Front brake lining thickness 4 .0 mm (0.16 in] 1.0 mm (0.04 in)
After '87: Front brake panel
warpage
-- 0.4 mm (0.02 in)
After '87: Front brake panel wear

(by the waterproof seal lip)
-- 0.5 mm 10.02 inl
After '87: Front brake waterproof

22.0 mm (0.87 in) 20.0 mm (0.79 inl
seal lip length
Wheel cylinder piston 0.0 . 18.997 - 19.030 mm (0.7479-0.7492 inl 18.81 mm {O.741 inl
Wheel cylinder 1.0. 19.050-19.102 mm (0.7500 - 0.7520 inl 19.12 mm (O.753 in)
Front master cylinder 1.0. 12.700-12.743 mm (0.5000 - 0.5017 inl 12.75 mm (O.502 in)
Front master cylinder piston 0.0. 12.657 - 12.684 mm (0.4983 - 0.4994 inl 12.64 mm (0.498 in)
Rear brake lining thickness 4.0 mm to. 16 in) 2.0 mm (0.08 in)
Rear brake drum LD. 180 mm (7.09 inl 181 mm/7.1 in)
TORQUE VA LUES
Front wheel nut 60- 70 N·m (6.0 - 7.0 kg~m, 43 - 51 ft-lb)
Front axle nut 80-100 N·m /8.0 - 10.0 kg-m, 58 - 72 ft-Ibl
Rear wheel nut 60 - 70 N·m (6.0 - 7.0 kg-m, 43- 51 ft-Ib)
Rear axle nut 120- 1 60 N·m (12 .0 - 16.0 kg-m. 87 - 116 ft-Ibl
Master cylinder hose bolt 25 - 35 N·m (2.5 - 3 . 5 kg-m, 18 - 25 ft-Ib)
Wheel cylinder hose bolt 25-35 N·m (2.5 - 3.5 kg-m. 18-25 ft-Ib)
Front brake panel bolt 27 - 33 N·m 12.7-3.3 kg-m, 20-24 ft·lb) After '87 Only: Using again strictly
prohibited
Rear brake panel nut '86 '87: 50-60 N'm (5.0 - 6.0 kg-m, 36 - 43 ft -Ib)
of( After '87: 35-45 N·m (3.5 - 4.5 kg-m, 25-33 ft-lb)
Reservoir cover screw 1-2 N·m (0.1 - 0.2 kg·m, 0 .7 -1 .4 fHb)
Foot peg bolt 40 -50 N·m (4.0 - 5.0 kg-m, 29-36 ft -Ib)
Brake pipe joint 12 - 15 N'm 11.2 - 1.5 kg -m , 9 - 1 1 ft -Ibl
13-1
BRAKES
CAUTION
~: Nut lor After '87 is a sel/.locking nut with the nut -head peened; nul for '86
and '87 is a self·locking mil (U.locking nUl). Tighten each nUllO each speci-
fied torque, or the nlll is broken or loosened.
('86, '87) ~After '871
TOOLS
Special
Snap ring pliers 07914 - 3230001
Attachment 07965 - SA00600
Common
Driver 07749 - 0010000
TROUBLESHOOTING
Front wheel wobbling and noise Wate r entering front brake drum (Afte r '871
Worn front brake drum bearings Faulty or improperly installed waterproof seal
• Worn brake shoes Warped or worn brake panel
Damaged tension pin. tension pin seal or seal cap
Poor brake performance Improperly sealed wheel cylinder assembly
Brake not adjusted properly Damaged or loose wheel cylinder or adjuster mounting
Worn brake shoes bolt
Brake fluid leak Damaged or loose brake panel bolt
Incorrectly installed rear brake arm Disconnected or damaged breather tube
Contaminated brake shoes Improperly routed breather tube
Worn rear brake cam Faulty or improperly installed inspection hole cap
Worn rear brake drum loose axle nut due to improper cotter pin installation
loose bolt attaching the drum to the hub
Faulty O-ring on the hub
Faulty O-ring on the brake panel
Improperly sealed or damaged wheel bolt
Faulty wheel bearing
Faulty wheel hub dust seal
Faulty wheel hub
Faulty brake drum dust seal
Faulty brake drum
Faulty 8)(le seal at the knuckle
13-2
BRAKES
FRONT BRAKE (') RESERVOIR COVER
BRAK E FLU ID DRAINING
CAUTION
Do not allow foreign material to enter the system when filling
the reservoir.
A void spilling fluid on painted, plus/ic or rubber parts. Place a
rag over these parts whenever the system is serviced.
With the fluid reservoir paratiel to the ground, remove the res -
ervoir cover and diaphragm.
Piece a suppa" block under the engine to raise the front (1) BLEED VALVE
Remove the front wheels (page 12-71.
Connect a bleed hose to the bleed valve.

Loosen the bleed valve and pump the brake lever.
Stop pumping the lever when no more fluid flows out of the
bleed valve.
BRA KE FLUID FI LLING
Fill the reservoir with DOT-3 or 4 brake ftuid from a sealed con-
tainer.
CAUTION
• Do not mix different types oj fluid. They are nor compatible.
,
Connect the commercially available brake bleeder to the bleed
valve.
Pump the brake bleeder and loosen the bleed valve, adding
fluid when the fluid level in the master cylinder reservoir is low.
NOTE
Check the fluid level often while bleeding the brakes to pre- (1) BRAKE BLEEDER
vent air from being pumped into the system.
When using a brake bleeding tool , follow the manufactur-
er's operating instructions .
Repeat the above procedures until air bubbles do not appear in

the plastic hose.
NOTE
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
If a brake bleeder is not available, fill the master cylinder
and operate the brake lever to fill the system (page 13-4) .
Close the bleed valve. Ne)(t, perform the available BLEEDING

procedure (page 13-4).
13-3
BRAKES
BRAKE BLEEDING 11 I BLEED YALVt
Connect a bleed hose to the bleed valve.

Pump up the system pressure with the lever until there are no
air bubbles in the fluid fl owing out of the reservoir small hole
and lever resistance is felt.
1. Squeeze the brake lever, open the bleed valve 1/2 turn and
then dose the valve.
NOTE
Do not release the brake lever until the bleed valve has been
closed.
2. Release the brake lever slowly and wait several seconds

after it reaches the end of its travel.
Repeat steps 1 and 2 until bubbles cease to appear in the fluid

coming out of the bleed velve.
Fill the fluid reservoir to the upper level mark .
Reinstall the diaphragm and reservoir cover, and tighten the

screws.
TORQUE : 1 - 2 N·m (0.1 - 0 .2 kg-m , 0 .7 - 1.4 ft -Ibl
BRAKE HOSE/ PIPE INSPE CTION
Remove the air cleaner cover. upper cover and front fender
(page 16-11.
Check the upper brake hose for damage and brake flu id leaks.
111 ue"tH
Check the p.e.v. joint, lower brake pipes and brake hoses for BRAKE
damage and brake fluid leaks. HOSE
LOWER
(2) P.C .V ---+--\",'1 BRAKE
JOINT PIPES
(4 ) BRAKE
HOSES
13-4
BRAKES
FRONT BRAKE DRUM REMOVAL/INSPECTION
Place a support block under the engine to raise the front

wheels off the ground and remove the wheels.
Remove the cotter pin from the axle nut, then remove the axle
nut and brake drum.
131
DRUM
Inspect the brake drum for scoring, cracks and concentricity.
Measure the 1.0. of the drum .
SERVICE LIMIT : 161 mm (6.3 in)
FRONT BRAKE PANEL INSPECTION IAfter '871 (1) WATERPROOF

SEAL
Check the brake panel for wear where the outer lip of the
waterproof seal contacts the panel.
SERVICE LIMIT : 0.5 mm (0 .02 in)
(2) BRAKE
PANEL
Remove the wheel hub from the brake drum and temporarily
install the hub to the axle shaft. Tighten the axle nut securely .
Install a suitable steel plate to the wheel hub and tighten the
plate with the wheel nut securely.
Clean off any grease material from the brake panel.
(4) BRAKE
PANEL
~~~~i:~----- ( 1 )
(he brake linings reduces stopping power. Keep
grease off the linings. STEEL
PLATE
Measure the brake panel for warpage where it contacts the ~.d~s:rl.--(2) AXLE NUT
waterproof seal lip as shown.
SERVICE LIMIT : 0.4 mm 10.02 in) (3) WHEEL

HUB
Replace t he brake panel if warpage is great er than the service
limit.
13-5
BRAKES
FRONT BRAKE WATERPR OO F SEAL INSPE CTI ON

IAfter '871
Check the front brake waterproof seal for damage, fatigue or

improper installation.
Measure the front brake waterproof seal lip length. Ic:::;
SERVICE LIM IT: 20.0 mm (0.79 in)
r----'
''ll lJ
I
FRONT BRAKE WATERPROOF SEA L

REPLACEMENT IAfter '871
Remove the waterproof seal from the brake drum by prying

open the seal edge.
Remove the wheel hub.
B
• CALCULATE T HE CLEARANCES BeTWeEN THE DRUM ~
AND SEAL
t
Measure and record the drum and seal length of a, b, C and d as
shown. Calculate the clearances A and B between the drum
and seal.
A = a- c B = d - b
Apply water to the whole of a new waterproof seal.

Place a waterproof seal on a clean surface plate, and press the ....J.._(1) BRAKE DRUM
brake drum into the waterproof seal, making sure that the
clearances between the seal and drum will reach the
calculated clearance (see abo .... e).
CAUTION f[li'~~-(2) APPLY WATER

Place a steel plate labout 140 mm (5.5 in) in diameter and more
Ihan 10 mm (0.4 in) in thickness! on Ihe brake drum 10 prevenl
the brake drum from being warped or damaged.
Make certain that the /ips are not damaged when instalfing seal
on Ihe drum and fhaf the pressure on Ihe drum is even. (3) A PPLY WATER
CAUTION
Do not damage the seal rim and seal lips; if damaged or foullY
inslalled, discard Ihe waterproof seal and try it again wi/h a
new seal.
(1) DO NOT D AMAGE
13-6
BRAKES
Clean off water from the waterproof seal.

Pack the cavity and lips of the brake seal as shown with 111 BRI'KE
grease. SEAL
AMOUNT OF GREASE: 14 - 16 9
+--121 DO NOT
APPLY
GREASE
Do not apply grease to the inner sur/ace oj the brake drum.
areas/! on the Inner surface 0/ drum reduces stopping pOK'er.
Keep grease off the drum.
' 86, '87:

FRONT WHEEL HUB REMOVAL (21 WHEEL HUB
Remove the dust seal.

Remove the mounting bolt IAfter ' 87 : mounting bolts) and
separate the wheel hub and brake drum.
FRONT W HEEL HUB INSTALLATION
Install the O-ring to the groove of the brake drum.

Install the wheel hub into the brake drum with the mounting
bolts .
Install a new dust seat into the wheel hub.
Apply grease to the dust seal.
After ' 87 : I I I WHEEL HUB
12) BOLTS
BRAKE DRUM INSTALLATION
Apply multipurpose grease to the drive shaft splines.

Install the brake drum.
Tighten the axle nut so its slots will be as close as possible to
the holes in the axle.
TORQUE: 80 - 100 N'm (8.0 - 10.0 kg -m , 58-72 f1 -lbl
Install a new cotter pin.
Install the front wheel (page 12· 71.
13-7
BRAKES
BRAKE SHOES/ WHEEl CYLINDER/

ADJUSTER ASSEMBLY
REMOVAL/INSPECTION
Remove the front brake drum (page' 3-5).

Measure the brake lining thickness.
Replace the brake shoes if the lining thickness is less than the
service limit.
Inspect the brake linings for cracking, glazing, wear or contam-
ination.
Check the springs for damage.
Remove the pins by pushing on the pin holder ends and turning
the holders.
Remove the brake shoe springs and shoes.
(41 BRAdiiioi ~='" SPRINGS
Disconnect the brake hose from the wheel cylinder by remov-

ing the brake hose bolt.
Remove the brake pipe.
Remove wheel cylinder assemblies A and B by removing the
mounting botts.
Disconnect the front brake breather tubes from the panel

(After '87).
Remove the front brake panel bolts.
CAUTION
(After '87 Only): Using again strictly prohibited, because the
bolt threads for A/ter '87 is specially coated.
You can exchange the '86 and '87 bolls/or the After '87 boIlS,
bUI the re~'erse is no good.
Remove the panel.
13-8
BRAKES
Inspect the wheel cylinder bore and the pistons for scoring or (2) PISTON (3) ADJUSTER
grooving .
(1) BOOT \
)\
Inspect the piston cup and O-ring for wear or damage.
CAUTION \
Clean 01/ paris, excluding the boots. (hroughly with BRAKE
FLUID only.
Bfow QUI passages with compressed air.
Apply rubber grease to the lips o/Ihe boots and silicon grease
to Ihe adjuster.
(6)
-/
PISTON CUP
\ (4) O-RING
(5) CYLINDER
Measure the wheel cylinder 1.0.
SERVICE LIMIT: 19. 12 mm (0.753 Inl
Measure the wheel cylinder piston 0.0.
SERVICE LIMIT : 18.81 mm (0 .741 in )
ASSEMBLY I IN STALLAT ION (1) BRAKE PANEL
Apply sealant to the cylinder assemblies and the brake panel

8S shown.
Install the cylinder assemblies onto the brake panel as shown.
Install t he backing plate with the cut -out down.
Tighten the bolts (After '87: new bolts) to the specified

t o rQue .
TOROUE: 27-33 N'm (2.7-3 .3 kg -m, 20 - 24 ft-Ib)
CAUTION
(A/ter '87 Only): Using oguin strictly prohibiled, because the
boftthreads for A/ter '87 is spedally coaled.
You can exchange the '86 alld '87 bolts/or the After '87 bofts,
but the reverse is no good.
. (2\ BOLTS
13-9
BRA KES
Connect the brake hose to the cylinder with the hose bolt and
new sealing washer .
Tighten the hose bolt to the specified torque.
TORQUE : 25 - 35 N·m (2.5 - 3.5 kg.m, 18-2 5 ft-)bl
Connect the brake pipe to the cvlinders.
Apply silicone grease on the metal contact areas indicated.
Install the brake shoes, springs. pin holders and pins.
Do not get grease or oil on the brake fining surface.
Install the brake drum, axle nut and cotter pin (page 13-7).
Fill the brake flu id reservoir and bleed the brake system (page
13-4 ),
,
NOTE
The master cylinder reservoir must be full at the start of
bleeding and checked afterwards.
Install the front wheel (page 12-7) and adjust the brake shoe
lining-la-drum clearance.
13-10
BRAKES
BRAKE ADJUSTMENT
Turn the two brake shoe adjusters up with a screw driver until
the brake shoes lock, then back off three stops.
Install the caps securely (page 3-8).
MASTER CYLINDER (2) THROTTLE HOUSING

111 HOSE BOLT'SEAl.lNG
DISASSEMBLY
Drain the brake fluid from the hydraulic system.
Disconnect the brake hose from the master cylinder by remov-

ing the bolt and two sealing washers.
Remove the front brake lever nut and pivot bolt.
Loosen the throttle housing bracket screws.
Remove the screws from the master cylinder holder and
remove the master cylinder.
Remove the piston boot and the snap ring from the master cyl- (1) SNAP RING
inder body.
TOOL:
Snap ring pliers 07914-3230001
(2) SNAP RING

PLIERS
Remove the secondary cup and piston , then remove the pri- (1) PRIMARY CUP
mary cup and spring.
Clean the inside of the cylinder and reservoir With brake fluid.
/~ J~
"12"'<S"E"C'<O"Ni"iO"A"R"Y7c
C"U:Op
13-11
BRAKES
INSPECTION
Measure the master cylinder I.D.
SERVICE LIMIT : 12.75 mm (0 .502 inl
Check the master cylinder for scores, scratches or nicks.
Measure the master cylinder piston 0.0.
SERVICE LIMIT: 12.64 mm (0 .498 inl
Check the primary and secondary cups for damage before as-
sembly.
(l) CUPS--_
ASSEMBLY
CAUTION
Keep the master cylinder pis/on, cups, snap ring, cylinder Qnd
spring as a set; don't substitute individual parts.
Assemble the master cylinder. Coat all parts with clean brake
fluid before assembly. Install the spring and primary cup to-
gether. (2) SECONDARY CUP 9 i31 DIAPHRAGM
(1) PISTON
Dip the secondary cup in brake fluid before assembly.
Install the piston, snap ring and boot.
CAUTION
~: \' ~~
When instolling the cups, do no/ alfow the lips /0 turn inside
out and be certain (he snap ring is/irmly sealed in Ihe groove.
Place the master cylinder on the handlebar.

.~ ~
~
.
fI
(4) MASTER CYLINDER BODY
Install the master cylinder holder with the UP mark facing up.
Tighten the upper screw first. then tighten the lower screw
loosely.
Align the end of the throttle housing with the punch mark on 11 I HOSE BOLT/
the handlebar_ " . ,ALlN" WASHER
Align the end of the master cylinder holder with the line of the
throttle housing_
Tighten the screws.
Install the brake hose with the bolt and two new sealing wash-
ers.
TORQUE : 25 - 35 N·m (2.5 - 3 .5 kg -m , 18 - 25 ft -Ibl
Install the brake lever.

Fill the reservoir to the upper level and bleed the brake system
according to page 13-4 .
13-12
BRAKES
REAR BRAKE
REM OVA L
Place a support block under the rear frame t o raise the rear
Remove the right rear wheel cap, the wheel nuts and the
wheel (page 14-3 ).
Remove the cotter pin, axle nut and wheel hu b from the axle.
Remove the brake drum cover by removing the mounting
, (4 ) BRAKE DRUM COVER
bolts .
~- '\
Loosen the rear brake cable adjusting nuts.

Remove t he O-ring and the brake drum .
INSPECTI ON
( 3) BRAKE
Check the brake drum cover dust seal for damage and replace DRUM
it if necessary. COVER
Remove the seal from the cover.
Instatl the new dust seal using the attachment and driver.
TOOLS :
Attac hment 07965 - SA00600
Driver 07749-001 0 000
NOTE
(4 ) DUST
Install the new dust seat with the lips toward the outside of
the brake drum.
( 1) OIL SEAL
Check the wheel hub oil seal for damage and replace it if nec-
essary.
Remove the oil seal from the wheel hub.
Install a new oil seal into the wheel hub and grease the oil seal
lip.
13-13
BRAKES
Measure the rear brake drum t.D.
SERVICE LIMIT: 181 mm 17. 1 in)
Inspect the brake drum for scoring, cracks and concentricity.
Measure the brake lining thickness.
SERVICE LIMIT : 2.0 mm 10.08 In)
DISASSEMBLY 111
Remove the cotter pins and anchor pin washer .

Remove the brake shoes and springs.
Remove the brake adjusting nuts and disconnect the brake

cables from the brake panel.
Remove the brake arm by removing the bolt and nut.

Remove the indicator plate, brake cam and return spring.
13-14
BRAKES
Remove the felt seal and disconnect the breather tube.

Remove the brake panel nuts and the panel.
Remove the grease seals f rom both sides of the brake cam
hole .
-•
BRAKE PA NEL ASS EMBLY
For w heel bearing inspection and replacement, see page 14-5.
Apply grease to new g rease seals and install them into the
b rake cam hole.
Install the brake panel onto the swing arm and tighten the
nuts.
TORQUE :
'96, ' 87 : 50 - 60 N-m 15 .0 - 6 .0 kg-m , 36 - 43 ft -Ib)
After ' 87 ; 35 - 45 N-m 13 .5 - 4 .5 kg-m , 25 - 33 ft-Ib)
Install the felt seal into the brake cam hole.
Connect the breather tube.
Apply grease to the anchor pins and brake cam.
13-15
BRAKES
Install the return spring and then install the indicator plate,
aligning the wide tooth on the plate with the wide groove on
the brake cam.
-
Install the brake arm, aligning the punch marks on the brake
arm and cam.
Hook the return spring end onto the brake arm.
Tighten the brake arm bolt securely. •
Connect the brake cables to the brake arm and install the ad-
justing nuts.
NUTS
Install the brake shoes and springs.
14tii,jfi!dd
Contaminated brake linings reduce stopping power. Keep
grease oil the linings. Wipe excess grease 011 the cam.
Install the anchor pin washer and new cotter pins as shown.
13- 16
BRAKES
Install the brake drum and a new O-ring onto the brake panel.
-/
L\
/
(1) BRAKE DRUM
Apply grease to the brake drum cover dust seal lips as shown.
Install the cover and tighten the mounting bolts.
Install the w heel hub.

Apply oil to the threads.
Install and tighten the axle nut .
T ORQUE: 120 - 160 N·m 112 .0 - 16 .0 kg-m . 87 - " 6 ft -lbl
Secure the nut with a new cotter pin .
(3) COTTER PIN
Install the right rear wheel and tighten the wheel nuts.
T ORQUE: 60 - 70 N·m 16.0 - 7 .0 kg-m . 43 - 51 h ·lb)
Adjust the rear brake lever and pedal free play (page 3 ·9).
13-17
BRAKES
REAR BRAKE PEDAL

REMOVAL
Loosen and remove the rear brake pedal adjusting nut.

Remove the foot peg mounting bolts and the foot peg .
Remove the cotter pin and washer from the pedal pivot shaft.
Disconnect the brake cable and return spring from the pedal
and remove the pedal from the shaft.
INSTALLATION
Install the brake pedal in the re verse order of removal.
NOTE
Apply grease to the brake pedal pivot shaft and brake cable
end.
Install the foot peg and tighten the mounting bolts to the speci-
f ied torque.
TORQUE: 40 - 50 N·m (4.0 - 5.0 kg-m, 29 - 36 ft-Ib)
Adjust the rear brake (page 3-9).
(2) WASHER
111 COTTER-_ _ _--,

PIN
fJJ
(3) RETURN
SPRING
.. ~ (4 ) DUST SEALS
13-18
MEMO
REAR WHEEL/ SUSPENSION
60-70 N'm
120 - 160 N-m
16.0- 7.0 kg-m, 43 - 51 ft-Ibl
t 12 .0 - 16.0 kg-m, 87 - 116 It-Ibl
'86, '87 : ~ After '87:

70-80 N·m 50 - 60 N' m (NOTE)
t7 .0-8.0 kg -m, {S.O-S.O kg-m ,
51 - 58 ft-Ib) 36 - 43 ft -Ibl
' 86. '87 :

60-80 N·m
'S6, ' 16.0-8.0 kg-m,
80 - 90 ~-.~""', "'1l 43 - 58 h-Ibl
(8.0-9.0 kg-m,
58-66 It-Ibl
*After '87 : * After '87 :
(NOTE) (NOTE)
After ' 86
'20 - 160 N·m,
2.0 - 1 6.0 kg-m,
87 - 116 ft -tb)
'86, '87:
60 - 80 N·m
(6.0-8.0 kg-m,
43-58 It-fb I
'I'l' After ' 87 :
(NOTE)
100- 130 N·m

(10.0- 13.0 kg-m,
72 - 94 ft -Ibl
16 - 20 N·m
(1.6-2.0 kg -m,
12 - 14 It-fbi
100 - 130 N·m ' 86 , '87 : 40 - 50 N·m (4.0 - 5.0 kg-m.

" 0 .0- ' 3.0 kg-m , 40 - 50 N·m 29 - 36 It· lbl
72-94 ft -Ibl * Aft er '87 : (NOTE)
(NOTE): * After ' 87 35- 4 5 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-Ibl
14-0
14. REAR WHEEL/SUSPENSION
SERVICE INFORMATION 14-1 REAR A XLE/WHEEL BEARINGS 14-4
TROUBLESHOOTING 14-2 REAR SHOCK ABSORBER 14-7
REAR WHEEL 14-3 SWINGARM 14-9
SERVICE INFORMATION
GENERAL
Inhaled asbestos fibers have been found 10 cause respiratory disease and cancer. Nel'er use an air hose or dry brush 10 efeon brake
or clutch assemblies. In th e United States, use OSHA-approved l"aCllllm cfeanu or alternate method approl'ed by OSHA designed
to minim/:e the ha:ard caused by airborne asbestos jibers.
• This section covers maintenance of the rear wheels, suspension and drive shaft.
• A jack or block is required to support the vehicle.
• See section 12 for tire removal/ repair procedures .
SPECIFICATIONS
ITE M STANDARD SERVICE LIMIT

Rear axle runout 3.0 mm (0.12 in)
'86: 252 . 1 mm (9.93 inl 247.0 mm (9.72 inl
Rear shock absorber spring free length
After '86: 250.9 mm (9.88 in) 246.0 mm 19. 69 in)
TORQUE V ALUES
Rear wheel nut 60 -70 N'm (6.0-7.0 kg -m, 43 - 5 1 ft-Ib)

Rear a)(le nut 120 - 160 N·m (12.0 - 16.0 kg -m, 87 - 116 ft-Ib)
Shock absorber upper mount nut
'86, '87: 40 -50 N·m (4 .0 - 5 .0 kg -m , 29 - 36 ft·Jbl
* After '87: 35 - 45 N·m (3.5- 4 .5 kg-m, 25-33 ft-lb)
Shock absorber lower mount bolt/nut
'86, '87: SO - 80 N·m {S.0 - 8.0 kg -m, 43 - 58 ft -Ibl
-(( After '87: 35-45 N'm (3.5 - 4 .5 kg-m, 25 - 33 ft -Ibl
Swingarm right pivot bolt 1S-20 N· m 11.S - 2.0 kg-m, 12 - 1 4 ft -Ibl
Swingarm pivot lock nut 100 - 1 30 N·m (10.0 - 13.0 kg -m, 72 - S4 ft -lbl
Swingarm left pivot bolt 100 - 1 30 N·m (10.0 - 13.0 kg. m, 72 - S4 ft·lb)
Trailer hitch 70 -80 N'm (7.0 - 8.0 kg.m, 51-58 ft -Ib)
Swingarm joint nut '86, '87: 80 - S0 N· m (8.0 - S.0 kg-m, 58-66 ft-lb)
,:r After '87: 35 - 45 N' m (3.5 - 4 .5 kg-m, 25 - 33 ft -Ibl
Rear brake panel nut '86, '87: 50 -60 N·m (5.0 - 6 .0 kg -m, 36 - 43 ft·lbl
* After '87: 35 - 45 N·m (3.5 - 4 .5 kg -m , 25 - 33 ft -Ibl
Final gear case (cover) joint nut
'86, '87: 60 -80 N·m (S.0 - 8.0 kg -m. 43 - 58 ft -Ibl
,:r After '87: 35-45 N·m (3.5 - 4 ,5 kg·m, 25 - 33 ft·lb)
CAUTION
-tl : NUffor A/u!r '87 is a self-locking nut with the nut ~head peened; nlll for '86
and '87 is a self-locking nut (V-locking nul). Tighten each nut to each speci·
fied torque, or the nUl is broken or loosened.
r8S, '87) {A fter '871
14-1
TOOLS
Special
Shock absorber compressor base 07959-MB10000
Spring compressor adaptor 07967 - KC10000 (Not available in U.S.A)
Pivot lock nut wrench 07908 - 4690001 or KS·HBA-08·469 (U.S.A. only)
Bearing remover set 07936 - 889010 1 (Not available in U.S.A.)
- Remover head 07936 - 8890200 (Not available in U.S.A.)
- Remover weight 07741 - 0010201 or 07936 - 371 0200
Ball race driver 07945 - 3330300
Driver 07949 - 3710001
Common
Driver 07749 - 0010000
Attachment, 62 x 68 mm 07746 - 0010500
Shock absorber compressor 07959 - 3290001 (must be used with 07959-MB10000)
Attachment, 32 )( 35 mm 07746 - 0010100
Attachment, 52 l( 55 mm 07746 - 0010400
Attachment , 37 x 40 mm 07746 - 0010200
Pilot, 28 mm 07746 - 0041 100
Socket bit, 17 mm 07703 - 0020500 or equivalent commercially available in U.S.A.
TROUBLESHOOTING
Wobble or vibration in vehicle
Bent rim
Loose wheel bearing
Faulty rear axle bearing holder
Faulty tire
Axle not tightened properly
Swingarrn bearings worn
Soft suspension
• Weak spring
Hard suspension
Bent shock absorber
Improperly adjusted swingarrn pivot
Faulty pivot bearing
Suspension noise
Shock case binding
• loose fasteners
14-2
REAR WHEEl
REMO VA L
Raise the rear wheels off the ground with a jack or block under
the engine.
Remove the wheel caps, nuts and wheels.
INSTALLATION
Install the rear wheel with the tire valve facing out so that the
tires show a "V" pattern when viewed from front.
NOTE
• 00 not interchange the right and left tires.
111 FRONT
Install the wheel nuts with the curved sides facing inward and
tighten to the specified torque.
TORQUE: 60 - 70 N·m (6 .0 - 7.0 kg-m , 43 -5 1 ft -Ibl
Install the wheel cap.
p",:j]d
m WHEEL NUT
CURVED SIDE
14-3
REAR AXlE/ WHEEL BEARING

REMOVAL
Remove the following :

- right and left tear wheels
- cotter pin, axle nut and right wheel hub (page 13-131
- brake drum cover and drum (page 13-131
- brake cables, breather tube and brake panel (pages 13- 1 3
and 13-14)
- cotter pin, axle nut and lett wheel hub
(3) AXLE
~ (2) WHEEL HUB
Remove the left shock absorber lower mounting bolt and nut.
Remove the rear skid plate mounting bolt and the final gear
case joint nuts .
Remove the bearing housing and stopper from the axle.

Remove the O-ring from the bearing housing.
Drive the axle out from the left side using a plastic hammer.
....
131
HOUSING
14-4
REA R AXL E INSPE CTIO N
Install the wheel hubs onto both ends of the axle.

Place the feafax le in V-blocks and measure the runout .
SERVICE LIMIT: 3 .0 rnm 10. 12 in)
11) WH • • ' HUBS
REAR W HEEL BEA RING INSPECTION
Turn the inner race of each bearing with your finger.

The bearings should turn smoothly and quietly .
Also check that the bearing outer races fit tightly in the bearing
housing and brake panel.
Remove and discard the bearings i f t he races do not turn

smoothly or quietly, or if they fit loosely in the bearing housing
and brake panel.
NOTE
• Replace the bearings in pairs.
REAR WHEEL BEARING REPLACEMENT 12IDRI'VER
Remove the dust seal.

Press the bearings out of the housing using the attachment
and driver.
TOOLS :
Driver 07949 - 3710001
Attachment . 32 x 35 mm 07746 - 0010100
Press the new bearings into the housing . (1) DRIVER
TOOLS:
Driver 07749 - 0010000
~
Attachment, 62 x 68 mm 07746 - 0010500
Apply grease to a new dust seal lip .

Instaii the dust seal until it is flush with the bearing housing
flange.
14-5
Remove the brake shoes, 8rm and cam from the brake panel (11 DRIVER 131 DRIV'.~-'l
(pages 13· ' 2 and 13-131.
Drive the bearings out.
TOOLS : 14 ) ATTA(;H"ii
Driver 07749 - 0010000
Ball race driver 07945 - 3330300
Press the new bearings into the panel with the sealed side
facing outward.
TOOLS :
Attachment, 52 )C 55 mm 07746 - 0010400
Pilot , 28 mm 01746 - 0041100
Driver 07749 - 0010000
(2) D -RING
INSTALLATION
Insert the rear axle into the final gear through the axle housing
(right side).
Install the bearing stopper onto the left end of the axle with 8
chamfered face out.
Install a new O-ring onto the bearing housing.

n) BEARING
HOUSING
Install the bearing housing and tighten the joint nuts.
TORQUE:
'86, '87 : 60 - 80 N·m 16.0 - 8 .0 kg -m , 43 - 58 ft-Ib)
Aher ' 87 : 35 - 45 N·m \3.5 - 4 .5 kg.m , 25 - 33 h -Ibl
Install the tear skid plate and tighten the mounting bolt secure-
ly.
Install and tighten the left shock absorber lower mounting

boltl nut.
TORQUE :
' 86, '87 : 60 - 80 N-m 16.0 - 8 .0 kg·m. 43 - 58 h -Ibl
After '87 : 35 - 45 N-m 13.5 - 4 .5 kg.m , 25 - 33 ft -Ibl
Install the brake panel onto the swingarm and tighten the nuts.
TORQUE :
'86. '87 : 50 - 60 N·m 15.0 - 6 _0 kg -m , 36 - 43 It-Ibl
After '87 : 35 - 45 N·m 13.5 - 4 .5 kg -m. 25 - 33 ft -Ib)
Install the brake shoes, cam and arm on the panel Ipages 13-
15 and 13-161.
Install the brake cables and connect the breather tube.
Install the brake drum and cover (page 13-16!.
Install tha right wheel hub. lock washer and axle nut (page 1 3-
17!.
Tighten the axle nut and install a new cottor pin.
TORQUE: 120 - 160 N'm 112 .0 - 16 .0 kg -m , 87 - 116 ft-Ibl
14-6
Install the left wheel hub onto the axle.

Apply oil to the threads.
Install the axle nut and tighten it to the specified torque.
TORQUE : 120 - 160 N·m 11 2.0 - 16.0 kg-m . 87 - 11 6 h -Ibl
Install a new cotter pin.

Install the right and left rear wheels and tighten the wheel nuts
(page 14·3).
TOROUE: 60 - 70 N·m 16 .0 - 7 .0 kg-m . 43 -51 ft -fb l
13) COTTI'R PIN
REAR SHOCK ABSORBER

REMOV AL
Raise the rear wheels off the ground by placing a jack or block
under the engine .
Remove the fear shock absorber lower mount nut and bolt .
Remove the rear shock absorber upper mount nut and remove
the shock absorber.
Compress the feaf shock absorber with the shock compressor, __-----------111 ADAPTER
adaptor and base.
CAUTION
Be sure Ihe base is adjusted correctly jor the shock spring seal
and the clevis pin is all the way in.
TOOLS :
Shock absorber compre ssor 07959 - 3290001
)3)
Adapter 07967 - KC10000
INot evailable in U .S.A .)
Base 07959 - MB10000 (2) SHOCtiJlSi'lRsiER
COMPRESSOR
Place the upper joint in a vise and pull out the shock rod.
l oosen the lock nut and remove the upper joint.
Remove the compressor and disassemble the rear shock ab-

sorber.
(2) LOCK NUT
14-7
SPRING FREE LENGTH INSPECTION
Measure the rear shock absorber spring free length.

AFTER ' 86 :
ASSEMBLY
Apply locking agent to the rod threads and install the lock nut
all the way .
Attach the shock absorber compressor , screwing in the com·

pressor's base adjuster nut.
Apply locking agent to the damper rod threads and screw t he

upper joint on. Hold the upper joint in a vice and tighten the
lock nut securely.
NOTE
Check that the lock nut is seated against the rod's bottom
thread .
Align the spring seat with the upper joint while releasing the
compressor.
INSTALLATION
Install the shock absorber onto the frame and swingarm, and
tighten the upper mounting nut and lower mounting bolt/nut .
TOAQUE :
'86, '87 :
Upper mounting nut :
40 -50 N' m 14.0-5.0 kg-m , 29 - 36 ft-Ibl
lower mounting bolt/nut :
60 - 80 N·m (6 .0 - 8 .0 kg-m , 43 - 58 ft-Ibl
After '87 :
Upper mounting nut , lower mounting bolt /nut:
35 - 4 5 N·m 13.5-4.5 kg -m . 25-33 ft -Ibl
14-8
SWINGARM
REMOVAL ,
- fear wheels (page 1 4-3)
- rear axle (page 14-4)
Remove the skid plate by removing three bolts.
Remove the trailer hitch by removing four mounting bolts.
Remove the right shock absorber lower mounting bolt/ nut.

Remove the swingram joint bolts/nuts and remove the housing
from the right side of the swingarm.
JOINT BOLTS/NUTS
Disconnect the breather tube from the final gear case.

Remove the final gear case from the swingarm by removing
final gear case joint nuts.
Loosen the swingarm boot band and remove the pivot cap .
14-9
Remove the pivot lock nut.
TOOL:
Pivot lock nut wrench 07908 - 4690001 or
KS -HBA-OB-469 (U.S.A . onlyl
Remove t he pivot bolt.
TOOL :
Socket bit. 17 mm 07703 - 0020500 or equivalent
Remove the 5wingarm from the frame and disconnect the

drive shaft from the engine.
PI VOT BEARING REPLACEMENT I'B6)
NOTE
After '86: the bearings BfB loose against the 5wingarm, and
dust seat is installed to the bearing as an assembly.
Remove the dust seal and bearing.
Remove the outer race from t he 5wingarm using the bearing

remover 8S shown.
TOOLS:
Bearing remover set 07936 - 8890101
(Not available in U.S .A.)
- Remover head 07936 - 8890200
INot available in U.S.A .)
- Remover weight 07741 - 0010201 or
07936 - 3710200
Press 8 new bearing outer race into the swingarm.
NOTE
• Replace the bearing and outer race as a set.
TOOLS :
Driver 07749 - 0010000
Attachmant, 37 II 40 mm 07746 - 0010200
14-10
Apply grease to the new bearing and dust seal.
Install the bearings to their positions and drive the dust seals in
to the swingarm.
DRI V E SHAFT IN SPECTION

_~ (MOLYBDENUM)
Inspect the universal joint bearings for excessive play or dam-
,r- - - - -- - - - - - - --."....- :;:
I
age. I
I
Apply molybdenum disulfied grease to the splines. ,
I
," IINIVERS'"
JOINT
INSTALLATION
Install the swingarm boot with its " HA 7" mark up.
Install t he drive shaft to the engine's drive shaft joint while

aligning their splines.
Install the swingarm into the frame.
Install and tighten the left pivot bolt.
TORQUE : 100 - 130 N·m (10.0 - 13.0 kg -m , 72 - 94 ft-lb )
TOOL:
Socket bit, 17 mm 07703 - 0020500 or equivalent
14-11
Install and tighten the right pivot bolt to 20 N·m (2.0 kg-m. 14
ft-lbL loosen it and retighten 10 the specified torque.
TORQUE ; 16- 20 N'm 11,6 - 2.0 kg-m, 12- 14 ft -Ib)
TOOL:
Move the swingarm up and down several times .

Retighten the right pivot bolt to the specified torque (see
abovel. I {II "J'e",
BIT,
Tighten the right pivot lock nut while holding the pivot bolt.
TORQUE : 100- 130 N·m (10,0 - 13.0 kg-m. 72 - 94 ft-Ibl

91 - 118 N·m (9. 1 - 11 .8 kg-m, 66 - 85 ft-Ibl
TOOLS :
commercially available In U.S.A .
Pivot lock nut wrench 07908 - 4690001 or
KS -HBA-08-469 (U.S.A . only)
Clean the mating surfaces of the gear case and the swingarm.
Install the O-ring and final gear case to the swingarm.
NOTE
Do not tighten the joint nuts until the axle housing is in-
11
stalled.
Connect the breather tube to the final gear case.

"- "-
"-
I
'-',
NUTS "{3"'I'O'-R'"' "N''G
14-12
,! Install the axle housing to the swingarm and tighten the joint
nuts.
TORQUE:
'86, 'S1 : 80 - 90 N·m (8 .0 - 9 .0 kg-m. 58 - 66 ft-lbl
After 'S 7 : 35 - 45 N·m (3.5 - 4 .5 kg-m. 25-33 ft ·lb)
Install and tighten tha right shock absorber lower mounting

bolt.
TORQUE:
'86 , '87 : 60 - 80 N·m (6.0-8.0 kg-m. 43 - 58 ft -Ibl •
After '81 : 35 - 45 N·m (3.5 - 4 .5 kg-m , 25-33 ft ·lbl HOUSING
Install and tighten the axle housing joint nuts Ifinal gear cese
cover joint nuls llo the specified torque.
TORQUE:
'86, '87 : 60 - 80 N·m (6.0 - 8.0 kg-m , 43 - 58 ft ·lbl
After '87 : 35 - 45 N·m (3.5 - 4 .5 kg-m . 25-33 ft ·lbl
Tighten the final gear case joint nuts.
TORQUE:
'86, '87 : 60 - 80 N·m (6.0 - 8 .0 kg-m , 43 -58 ft· lbl
After '87 : 35 - 45 N·m (3.5 - 4 .5 kg -m . 25-33 ft ·lbl
Install the skid plate onto the final gear case.

Install the trailer hitch and t ighten the mounting bolts.
TORQUE : 70 - 80 N ·m (7.0 - 8.0 kg-m , 51-58 ft-Ibl
(2 1 1
HITCH
Install the follow ing parts: (1 I BEARIN G

- bearing housing (page 14-6 1
- brake panel , brake shoes , brake c am and brake arm (pages
13-15 and 13- 161
- brake drum, cover and wheel hub (page 13- 16)
- axle nut and cottar pin (page 14- 7)
- rear wheel (page 14-3)
14-13
8 rnm BOLT :
23 - 28 N·m " ' : - - - - - -_ " .. _
12.3- 2.8 kg -m .
17 - 20 ft -Ib)
10 mm BOLT:
45 - 50 N'm
14 . 5 - 5 .0 kg-m.
33 - 36 fHb )
100- 120 N·m
(10.0-12 .0 .72 - 87 it-Ibl
10Q- 120N·m
110.0 - 12.0
72 - 87 ft -Ib)
30- 35 N·m
(3.0 - 3.5 kg -rn, 22 - 33 ft -Ib) 90- 10 N·m
(9 .0 - 11 .0 kg -m,
~.~~
65 - 80 ft-Ibl
90 - 110
(9.0- 11.0 kg-m, 65-80 ft-Ib)
r@@1T,;\\
1Q!'~
~ 30 - 35 N·m
(J ~ 13.0 - 3.5 kg-m. 22 - 33 ft -Ib)
~@@~j
45 - 55 N'm
(4.5 - 5 .5 kg -rn,
,FRT
33 - 40 ft-Ib)
8 mm BOLT:
23 - 28 N·m (2.3 - 2.8 kg-m , 17 - 20 ft-Ibl
10 mm BOLT:
45 - 50 N·m 14.5 - 5 .0 kg-m , 33 - 36 ft· lb)
15-0
15. FRONT DIFFERENTIAL/FINAL DRIVE
SERVICE INFORMATION 15-1 FINAL DRIVE REMOVAL 15-13
TROUBLESHOOTING 15-2 FINAL DRIVE DISASSEMBLY 15-13
FRONT DIFFERENTIAL REMOVAL 15-3 CASE BEARING AND OIL SEAL
REPLACEMENT 15-16
PINION GEAR REMOVAL 15-7
FINAL DRIVE ASSEMBLY 15-17
CASE BEARING AND OIL SEAL
REPLACEMENT 15-B FINAL DRIVE INSTALLATION 15-22
PINION GEAR INSTALLATION 15-9
FRONT DIFFERENTIAL
INSTALLATION 15-13
SERVICE INFORMATION
GENERA L
• This section covers maintenance of the front differential and f inal drive gears.
• Replace all oil seals and O-rings whenever the front differential and final drive gear assemblies are disassembled .
• Check the tooth contact pattern and gear backlash when the differential or final drive bearing. gear set and ror gear case are
replaced.
SPECIFICATI ONS
Front Oil capacity '86 135 cc 14 .6 azl

differential at disassembly After '86 225 cc (7.6 ozl
gear
Recommended oil Hypoid gaar oil SAE#BO --
Differential Clutch spring
2.65 mm (0 . 10 inl 2 .5 mm (0.09 in)
assembly free height
Clutch disc A 2.7 -2.8 mm (0. 106-0.1 10 in) 2.4 mm (0.09 in)
thickness 2.3 - 2.4 mm 10 .091 - 0.094 in) 2.1 mm W.OS in)
IE
B
Pinion gear J.D . 12.000 - 12.018 mm 10.4 724 -0 .4731 in) 12.05 mm 10.474 in)
Pinion gear
11.973 - 11.984 mm (0.4 714 -0. 4718 in) 11.75 mm (0.463 in)
shaft 0 .0 .
Gear backlash 0.08 - 0.18 mm (0.003 - 0.007 in) 0.25 mm (0.0 10 in)
Gear assembly preload 0 .1 - 0 .2 N·m (1 - 2 kg -cm , 0.85 - 1. 7 in-Ibl
Final Oil capacity 135 ec 14.6 oz) at disassembly --
drive gear
Recommended oil Hypoid gear oil SAE#80 --
Gear backlash 0.08-0.18 mm (0.003-0.007 in) 0 .25 mm (0.010 in)
Gear assembly preload 0.2 - 0.4 N·m 12-4 kg-em, 1.7 - 3 . 5 in-Ib) --
TORQUE VA LUES
Differential assembly
case rear cap torx bolt 30 -35 N·m (3.0-3.5 kg -m, 22-25 ft-Ib)
case cap tor)( bolt 30 - 35 N'm (3.0 - 3 . 5 kg-m, 22 - 25 f t -Ib l
Ring gear bolt 45 - 55 N·m (4. 5 - 5.5 kg -m, 33 - 40 f t -Ibl
Pinion bearing lock nut 90 - 1 10 N'm (9.0-11.0 kg-m , 65-80 ft -I b)
Differential gear cover 10 mm bolt 45-50 N·m (4.5-5.0 kg -m, 33 - 36 ft-lbJ
8 mm bolt 23 - 28 N·m (2.3-2.8 kg -m , 17 - 20 ft -Ib)
Differential gear pinion joint nut 100 - 120 N·m (10.0-12.0 kg -m . 72 - 87 ft -Ib)
Final drive gear lock nut 90 - 11 0 N·m (9.0-11.0 kg-m , 65 - 80 ft -Ib)
Final drive gear cover 10 mm bolt 45 - 50 N·m (4.5-5.0 kg -m, 33 - 36 ft -Ib )
8 mm bolt 23-28 N·m (2.3-2.8 kg-m, 17 - 20 ft-Ib)
Final drive gear pinion joint nut 100-1 20 N·m (10.0-12.0 kg -m, 72 - 87 ft -Ib)
15-1
TOOLS
Special
Differential inspection attachment 07GM K - HA 70100
Pinion holder 0792 4 - HAOOOOO Must be modified pinion holder 14 1 hole.
Increase to , 0.5 mm.
Lock nut wrench, 34 :II: 44 mm 079 16 - MESOOOl or Lock nut wrench. 3 4 )( 4 4 rnm 07916 - ME50000
and Attachment 079 16-HA00 10A (U.S.A. only)
Shaft pulier 0793 1 - ME40000 or 07931 - M E4 0DOA (U.S.A. only)
Bearing remover, 12 mm 07 9 36-1660 100
Remover weight 07741 - 0010201 or 07936 - 37 10200
Remover handle 07936 - 3710 100
Pinion gear driver 0794 5 - HAOODOD (Not available in U.S.A.) or Driver 40 mm 1. 0.
07746 - 0030100
Universal bearing puller 07931 - 4630000 or 07631 - 00 10000 or equivalent commercially avaitable
in U.S.A.
Attachment 07960-1870100
Common
Oriver 0774 9 - 0010000
Attachment, 62 x 68 mm 07746 - 0010500
Pilot, 35 mm 077 4 6 - 0040800
Pilot, 12 mm 0774 6 - 004 0200
Pilot , 28 mm 0774 6 - 004 11 00
Inner driver 077 4 6-0020 100
Attachment, 32 x 35 mm 0774 6 - 00 10100
Attachment , 42 x 47 mm 07746-0010300
Pilot , 22 mm 07746 - 0041000
Attachment, 52 x 55 mm 07746 - 0010400
Attachment, 35 mm 1.0. 0774 6 - 0030400
Inner driver 0774 6 - 0030100
TROUBLESHOOTI NG
FR ONT DIFFEREN TIAL GEAR A bnorm al noises at st art or during acceleration
Consistent noise during crui sing Excessive backlash bet ween ring gear and drive pinion
Oil level too low Improper ring gear or drive pinion preload
Foreign matter stuck in gears Excessive pinion backlash
Improper tooth contact between ring gear and drive Worn different ial splines
pinion loose pInion joint nut and other fas t eners
Worn or damaged side bearing Worn clut ch disc/plate
Worn Of damaged ring gear and drive pinion Worn clutch spring
Worn pinion shah or pinion gear's side washer Oil leak
Deformed ring gear or differential case Oil level too high
Chipped or damaged gears • Clogged breat her hole
Gear noises w hile running • Worn of damaged oil seal
Oil level too low Ov erheating
Foreign matter stuck in gears Oil level too low
Improper drive pinion preload • Insufficient ring gear-to-pinion backlash
Chipped or damaged gears • Excessive ring gear or drive pinion preload
Gear noises while coasting FINA L DRI V E GEAR
• Improper drive pinion preload Excessive noise
• Damaged or chipped gears Worn or scored ring gear shaft and driven flange
Bearing noises while running and co asting Scored driven fl ange and wheel hub
• Cracked or damaged drive pinion bearing or side bearing Worn or scored dri ve pinion and splines
Abnormal noises when roun ding a curve Worn pinion and ring gears
Worn (excessive play) or damaged side bearing Excessive backlash between pinion and ring gear
Damaged side gear, pinion or pinion shaft Oil level too low
Worn clutch disc shoe Oil leak
Worn clutch spring Clogged breather hole
Worn or damaged slot s of the differential housing Oil level too high
Worn or damaged oil seal
l oosen cover bolt
15-2
FRONT DIFFERENTIAL REMOVAL

- front wheel (page 12-7 )
- front guard plate (page 2-3 )
.),
- tie rod (page 12-12J
- knuckle /knuckle holder/ drive shaft (page 12-14)
- front skid plate (page 12 -21 )
Drain the gear oil (page 2-3) ,
Remove the left shock absorber lower mounting bolt by
(
bending down the lock washer tab . (page 12-19).
Disconnect the breather tube from the differential gear case.
Remove the differential gear case from the swingarm by re-
moving four mounting nuts.
Remove the eight case cover bolts.
(2 ) GEAR CASE ••
Carefully pry the cover off the case using a screw drive on the
pry point as shown.
Remove the differential gear assembly and the adjustment

spacers from the gear case .
(1) PR Y
POINT , 21 sp,h"s
DIFFERENTIAL ASSEMBLY IN SPECTI ON
(2 ) DIFFERENTIAL
NOTE INSPECTION
ATTACHMENT
This inspection is to be done fo r one clutch pack at a t ime .
The inspection must be done for each clutch pack (plates,
discs, springs and seat).
Remove one of the differential caps and remove one of the

clutch pack assemblies (page 15-41 .
Inspect the clutch pack components (page 15-5).
Then, install the differential cap, leaving out the clutch pack
you removed .
'"
Install the differential inspection attachments to both sides of
the differential.
TOOL:
DIFFERENTIAL INSPECTION ATTACHMENT
07GMK-HA70100
Hold the chamfered attachment With a bench vise.

Place a torque wrench on the other attachment and measure
the limited slip torque.
SLIP TORQUE : 20 - 25 N·m (2.0-2.5 kg-m, 14 - 18 ft-Ib)
If the slip torque is out of specification, the clutch spring seat

is worn.
Remove the inspection tool attachments.
15-3
FRONT OIFFERENTIAL/FINAL ORIVE
Remove the differential cap and the clutch pack from the dif- i 1) DIFFERENTIAL CAPS
ferential. Select a clutch spring seat of the required thickness
(page 15-6). Refer to page 15-5 for inspection of the other
components.
NOTE
Do not interchange components between the two clutch
pack assemblies.
Always install each clutch pack assembly in its original lo-
cation in the differential.
Install the second clutch pack assembly in its original side in

the differential. Keep out the first clutch pack .
Install both differential caps. Then, install the inspection tool ( 1)

attachments. Hold the chamfered attachment in the vise and
measure the slip torque of the second clutch pack.
If it is out of specification, remove it from the differential and

select a new spring seat (page 15-6).
Next, inspect the other clutch pack assembly in the same way.
OISASSEMBL Y
Remove the ring gear from the differential assembly by remov-

ing the mount ing bolts .
Remove the torx bolts from each side of the differential hous-
ing.
Remove the cap, case rear cap, clutch spring seats, clutch
springs, discs, plates, washers and side gears.
Remove the spring pins and pull the pinion shaft out.
Remove the pinion gears, side washers and center collar.
(12) SPRING PiN

(13) PINION SHAFT
(9) PINION GEAR
(7IWASHER~
151 CLUTCH DISCS ~ /, ' 1151 DIFFERENTIAL HOUSING
f" TDRX BOL T ~ ~! : , CENTER COLLAR
~~ fBI SIDE GEAR

~~ 16) CLUTCH PLATES
\ (4) CLUTCH SPRINGS

(3) CLUTCH SPRING SEAT
(2) CAP!
15-4
IN SPECTION
Measure and record the height of the clutch spring.
Check the clutch discs for scoring or discoloration. (1 ) CLUTCH PLATE (2) CLUTCH D)SC
Measure the thickness of each disc. -...l!
~
SERVICE LIMITS :
DISC A: 2 .4 mm (0.09 in)
DISC B: 2.1 mm 10.08 in)
NOTE
The clutch disc B has lining material on its inward facing
side.
Inspect the clutch plate surface for excessive scores or discol-

oration (purple) and replace if necessary.
Measure the pinion gear 1.0 . and pinion shaft 0.0.
SERVICE LIMITS: 1.0 .
.M
PINION GEAR 1.0.: 12.05 mm (0.474 in)
PINION SHAFT 0 .0 .: 11 .75!l'm (0.463 Inl
. ,
ASSEMBLY III PIINTci"NSiwT
Apply hypoid gear oil to the pinion gear and shaft.
Install th e washers, pinion gears and coliar into the housing .

Insert the pinion shaft end install the new spring pins securely.
PIN
I I
-, .
(3) WASHERS
15-5
FRDNT DIFFERENTIAl/FINAL DRIVE
ApplV hypoid gear oil 10 the side gear, discs and clutch plates ...____(1 ) SIDE GEAR
and install them into the differential housing.
NOTE
• Install clutch disc B with the lining facing inside.
(3) SPRING
Install the clutch springs. /SEAT
o '-:S:RINGS
(4) CLUTCH
I ~d']
DISC IB)
Install the spring seats on the case rear cap and the case cap
respectivelV·
Tighten the case rear cap and case cap with the torx bolts to
the specified torque.
NOTE
Temporarily install the drive shalt to center the side gear,
case rear cap and the case cap.
Tighten the torx bolts in a crisscross pattern in 2 or 3 steps.
TORQUE : 30 - 35 N·m 13.0 - 3 .5 kg-m , 22 - 25 ft -Ib)
Measure the slip torque (page 15-31-

If the slip torque is below specification, replace the spring
seats with thicker one.
If the slip torque is above specificat ion, replace the spring
seats with a thinner one.
Select the dutch spring seat from the list below.
A 1.0 mm 10.039 in)

B 1.2 mm (0.047 in)
C 1.4 mm 10.055 in)
o 1.6 mm 10.063 in)
E 1.8 mm 10.071 in)
Recheck the slip torque.
Install the ring gear and tighten the bolts 10 the specified ( 1) RING GEAR
~
torque.
TORQUE : 45 - 55 N·m 14.5-5.5 kg·m. 33- 40 ft -Ibl
15-6
FRDNT DIFFERENTIAL/FINAL DRIVE
PINION GEAR REMOVAL (1) OIL SEAL

[2[ P""Ol~~
Remove the oil seal.

Place the pinion holder on the pinion joint. Align t he holes in
the pinion holder with the four studs on t he differential gear
case and secure to the case with fou r 1 a mm nuts .
Secure t he holder in a vise.
Remo ve the pinion joint nut, then remove the pinion holder and
pinion joint.
TOOL:
Pinion holder 07924 - HAOOOOO
(Modified!
NOTE (1) LOCK NUT

Must be mod ified pinion holder (4 hole) with 10.5 mm diam- r
eter holes.
Unstake the pinion bearing lock nut w ith a drill or grinder.
Remove the pinion bearing lock nut with the lock nut wrench.
TOOLS:
Lock nut wrench, 34 x 44 mm 07916 - MESOOOl o r
Lock nut wrench , 34 x 44 mm 07916 - ME50000 and
Attachment 07916 - HA0010A
(U.S.A. only)
Position the pinion holder by putting 14 mm flange nuts be~

tween the pinion holder and the differential gear case .
Install the holder with four 8 mm bolt s.
Screw the shaft puller onto the end of the pinion gear shaft.
Screw the 27 mm special nut down until it contacts the pinion

holder, and hold it with a 27 mm w rench.
NOTE
8e sure that the 27 mm special nut is backed off far enough
to allow full thread engagement between the puller and the
01 14 mm FLANGE NUTS (2) 27 mm SPECIAL NUT
pinion gear shaft.
Turn the puller shaft clockwise with a 17 mm wrench to

remove the pinion gear from its housing.
I ~
Pull the p inion assemlby off with t he pinion puller.
TOOLS:
Shaft pullar 07931 - ME40000 or
07931 - ME4000A
(U .S.A. onlvl
(Modified)
15-7
PINI ON BEA RI NG REMOVA L (1) PINION BEiIRI>IC
Pull the bearing outer and inner races off t he shaft with the
bearing puller.
Pull the other inner race off with the same t ool.
Remove the pinion adjustment spacer.
,.
(3) AVAILABLE)
CASE BEARING AND OIL SEAL

REPLACEMENT
Heat the gear case to eooc (176°F). Tap the case wit h a plas-
tic hammer to remove the ring gear bearings.
Alwoys wear glo ves when handling the geof cose after if has
been heated.
Remove the oil seals.
Blow compressed air through the breather hole in the gear

case.
Drive a new oil seal and ring gear bearing into the case. m DRIVER mm
TOOLS:
Driver 07749 - 0010000
Attachment, 62 x 68 mm 07746 - 0010500
Pilot, 35 mm 07746 - 0040800
15-8
FRONT OIFFERENTIAL/FINAL DRIVE
Remove the oil seel, pinion gear bearing and stopper ring from (11 BEARING REMOVER
the gear case.
TOOLS:
Beanng remov er, 12 mm 07936 - 1660100
Remove w eight 07741 - 0010201 or
07936 - 3710200
Remove handle 07936 - 3710100
Install the stopper ring into the groove of pinion gear bearing ATTACHMENT
hole.
Press 8 new pin ion bearing into t he case.
TOOLS :
Driver 07749 - 0010000
Pilot, 12 mm 07746 - 0040200
Attachment (Pilot, 28 mmJ 07746 - 0041100
(31 STOPPER
RING
PINION GEAR INSTALLATION

PINIO N GEAR ASSEMBLY
(1) INNER RACES
Install the original pinion gear spacer.

/ ~ /
~
NOTE
When t he gear set, pinion bearing andlor gear case has
(4) PIN)ON /
°111 /11
been replaced, use a 2.0 mm (0.08 in) thick spacer.
~
Apply #80 gear oil to the inner races and the bearing.
GEAR
(3) SPACER __ L "
r.
(2) BEARING
Drive one inner face onto the pinion gear shaft, then drive the
bearing with the other inner race onto the pinion gear shaft.
TOOL:
Inner drive r 07746 - 0020100
15-9
Place the pinion assembly into the geBr housing and press it
into the gear case.
TOOL :
Pinion gear driver 07945 - HAOaDaG
(Not available in U.S.A.) or
Driver 40 mm 1.0 . 01746 - 0030100
NOTE
Keep the driver centered with the bearing outer race during
installation .
Install and tighten the pinion bearing lock nut.
TORQUE : 90 - 110 N·m (9.0- 11 .0 kg-m . 65 - 80 ft -Ib )

82 - 100 N·m 18.2- 10.0 kg-m, 59 - 72 ft -lbJ
TOOLS :
Lock nut wrenc h. 34 x 44 mm 07916 - ME500010r
Loc k nut wrench. 34 x 44 mm 07916 - MESOOOO and
Attachment 07916 - HAOQ10A
(U.S.A. only)
(1I=~'=
WRENCH
Install the original ring gear spacers onto the differential as-
sembly.
NOTE
When the bearing. gear set andl or gear case has been re-
placed. check the tooth contact pat tern and gear backlash.
Apply a thin coat of Prussian Blue to th e pinion gear teeth for a

gear tooth contact pattern check.
Apply gear oil to the lips of the oil seals on th e gear case and
differential case cover.
15-10
FRONT OIFFERENTIAL/FINAL ORIVE
Clean all sealing material off the mating surfaces of the gear
case and cover.
NOTE
Keep dust and dirt out of the gear case.
o Be careful not to damage the mating surf aces.
Apply liquid sealant to the mating surface of the gear case

cover .
Install the differential assembly with the spacers into the gear
case.
•
Apply locking agent to the 10 mm cover bolts.
Tighten the cover bolts in 2 or 3 steps until the cover evenly

t ouches the gear case, then tighten the bolts to the specified
el-"iit>-.
C~y~' l0mm
.J
•
torque in a crisscross pattern in two or more steps.
TORQUES : > \ BOLTS

10 mm bolt
8 mm bolt
45 - 50 N·m (4.5 - 5 .0 kg·m. 33-36 fHb )
23-28 N·m (2.3 - 2.8 kg-m , 17 - 20 h ·lb) r T
(
NOTE
Tighen bolts, rotating the pinion gear to prevent the gear or
case from being damage; in case the spacer is too thin, the
pinion gear will be locked by the ring gear with only light
tighting.
•
(1) NORMAL:
Remove the oil filler cap from the final gear case.
Rotate the ring gear several times in both directions. Check the
gear tooth contact pattern through the oil filler hole. The pat-
tern is indicated by t he Prussian Blue applied to the pinion
before assembly.
Contact is normal if the Prussian Blue is transfered to the ap- 141

proximate center of each tooth and slightly to the flank side. (6) TOE
HE EL
If the patterns are not correct, remove and replace the pinion
(2) FACE
(3) FLANK
t (4)
HEEL9"
..r. mFACE
--:-....
~
(3) FLANK
spacer. Replace the pinion spacer with a thicker one if the con -
tacts are too high, toward the face.
(1) TOO HIGH :
Replace the pinion spacer with a thinner one if the contacts are
too low, to the flank side. The patterns will shift about 1.5 -
2.0 mm (0.06 - 0.08 in~ when the thickness of the spacer is
changed by 0.10 mm (0.004 in).
15) PINION
SPACER
PINION SPACERS:
A: 1.82 mm 10.012 in)
B: 1.88 mm 10.074 in)
C: 1.94 mm 10.076 in)
0 : 2 .00 mm 10.079 In) Standard (2) FACE
(2) FACE
E: 2 .06 mm (0 .081 In)
F: 2 . 12 mm (0 .083 in) I ~ ~t
G: 2 . 18 mm 10.086 in)
15-11
BACKLASH INSPECTION - -- - ( 1 ) DRIVE

SHAFT
Install the pinion holder onto the pinion joint with four 10 mm
nuts.
Set the holder in the vise.
Set a horizontal type dial indicator on the ring gear, through
the oil filler hole.
Install the drive shaft into the right side of differential gear and
rotate the differential assembly/ring gear by turning the drive
shaft by hand untit gear slack is taken up. Turn the ring gear
back and forth to read backlash.
STANDARD: 0.08-0.18 mm (0.003-0.007 in) (2) PliN iaN " - ;;;:;:;::a......'-_

SERVICE LIMIT: 0.25 mm {0.01 0 Inl
Remove the dial indicator. Turn the ring gear and measure
backlash. Repeat this procedure once more.
DIFFERENCE OF MEASUREMENT
SERVICE LIMIT: 0.10 mm (0.004 In)
If the difference in measurements exceeds the limit, it indio

cates that the bearing is not installed squarely.
Inspect the bearings and reinstall them correctly, if necessary.
If backlash is too small, replace the ring gear left side spacer
with a thicker one.
Backlash is changed by about 0.06 mm (0.002 in) when thick-
ness of the spacer is changed by 0.10 mm (0.004 in).
(1) RING GEAR
RING GEAR SPACERS: RIGHT SPACER
A: 1.82 mm (0.072 in)
B: 1.88 mm (0.074 in)
C: 1.94 mm (0.076 in)
D: 2.00 mm (0.079 in)
E: 2.06 mm 10.081 in)
F: 2.12 mm (0.083 in)
G: 2.18 mm (0.086 in)
\
H: 2.24 mm (0.088 in)
I: 2.30 mm 10.091 in)
Change the right side spacer thickness an opposite amount to

what the left side spacer was changed; if the left spacer was (2) RING GEAR LEFT SPACER
replaced with a 0.10 mm 10.004 in) thicker spacer , replace the
right spacer with one that is 0.10 mm 10.004 in) thinner.
Place the pinion holder onto the pinion joint. Align the holes in
the pinion holder with the four studs on the differential gear
case and secure to the case with four 10 mm nuts.
Place the holder into a vise.
Tighten the pinion joint nut.
TORQUE : 100 - 120 N·m (10.0-12.0 kg -m , 72-87 ft-Ib)
TOOL:
(Modified)
Remove the pinion joint holder .
15-12
Make sure the gear assembly rotates smoothly without bind-

ing the pinion joint .
Install the torque wrench on the pinion joint nut .
Measure the different ial gear preload.
PRELOAD: 0.1 - 0 .2 N·m 11 - 2 kg-em . 0 .8 5 - 1.7 in-fbI
Stake the pinion bearing lock nut and drive in a new drive shah
bearing oil seal .
FRONT DIFFERENTIAL INSTALLATION

Apply molybdenum disulfide grease to the differential gear oil
seal lips, pinion joint and drive shaft splines .
Install the differential gear case onto the swingarm (page 12-
25).
Install the following :

- skid plate (page' 2-25 )
- knuckle/knuckle holder/ drive shaft (page 12- 181
- tie rod (page ' 2-13)
( 1) DIFFERENTIAL
- f ront wheel (page 12-7 )
GEAR CASE
Fill the gear case with the recommended oit (page 2-3).
FINAL DRIVE REMOVAL

Remove the fo llowings:
- rear wheels (page 14 -31
- rear brake panel (page 13-13)
- rear a)(le (page 14-41
- skid plate, trailer hitch and rear axle housing (page 14-9 )
Drain the gear oil (page 2-3).

Remove the gear case from the rear swingarm (page 14-91.
FINAL DRIVE DISASSEMBLY ( 1) COVER
Remove the eight case cover bolts and the cover. I.

•, ~.
)1"".
.-
15-13
If the ring gear stays in the cover, do the following : 111 DRilY" 121 ATfACHMENf
Place the cover in a press with the ring gear down.
Make sure the cover is securely supported.
Press the ring gear out of the cover. (4) COVER
TOOLS:
Driver 07749 - 0010000
Attachment, 32 x 35 mm 07746 - 0010100
Remove the ring gear and adjust ment spacer. (1) RING
(2) ADJUSTMENT
SPACER
Remove the ring gear bearing and adjustment spacer from the
ring gear. 121 AnrACIHMENf
TOOLS :
Universal bearing puller 07931 - 4630000 or (1) RING GEAR
07631 - 0010000 or equivalent
Atta chment 07960 - 1870100
If the ring gear bearing stays in the cover, use the following
tools to remove it.
TOOLS :
Driver 07749 - 0010000
Attachment, 4 2 x 47 mm 07746 - 0010300
Place the pinion holder on t he pinion joint. Align the holes in (1) PINION HOLDER
the pinion holder with the four studs on the final drive gear
Secure the holder in a vise.
Remove the pinion joint nut , then remove the pinion holder and
pinion joint.
TOO L:
PinIon holder 07924 - HAOOOOO
(Modified)
15-14
FRONT DIFFERENTIAL/ FINAL DRIVE
,, RemOlle the oil seal.
Unstake the pinion bearing lock nut with a drill or grinder.
Remove the pinion bearing lock nut with the lock nut wrench .
TOOLS:
lock nut wrench. 34 )I 44 mm 07916 - ME50001 or
lock nut wrench. 34 II 44 mm 07916 - ME50000 and
Attachment 07916-HA0010A
(U .S.A . only)
Position the pinion holder on the final gear case. (11 SHAFT PULLER
Screw the shaft puller onto the end of the pinion gear shaft .
Screw the 27 mm special nut down until it contacts the pinion

holder, and hold it with a 27 mm wrench.
NOTE
Be sure that the 27 mm special nut is backed off far enough
to allow full thread engagement between the puller and the
pinion gear shaft.
Turn the puller shaft clockwise wi th a 17 mm wrench to

remove the pinion gear from its housing . HOLDER
Pull the pinion assembly off with the pinion holder.

(1) PINION BEARING (2) INNER RACE
TOOLS:
Shaft puller
Pinion holder
07931 - ME40000
07924 - HAOOOOO
(Modjfied)
-
Pull the bearing outer and inner races off the shaft with the
bearing puller .
Pull the other inner race off with the same t ool.
Remove the pinion adjustment spacer.
15-15
FRDNT DIFFERENTIAL/FINAL DRIVE
CASE BEARING AND Oil SEAL III RING G.!':~~~!§:

REPLACEMENT
Remove the oii seal.
Heat the gear case BO oe (176° Fj. Tap the gear case with a
plastic hammer to remove the ring gear bearing.
Always wear glo ves when handling the gear case after it has
been heated.
Remove the oil seal, pinion gear bearing and stopper ring from (1)sEAAING REl~OVER
the gear case.
TOOLS :
Bearing remover. 12 mm 07936 - 1660100
0793 6 -3710200 ,
Remover handle 079 36 - 3710100
Blow compressed air through the breather hole in the gear

case.
". -
1111 'BREATHER
HOLE
Drive a new ring gear bearing into the case. 111
TOOLS :
Drive r 07749 - 0010000 (2) ATTACHMENT,
Attachment. 62 It 68 mm 07746 - 0010500 62)( 68
Pilot , 35 mm 07746 - 004080 0
/
/
(3) PILOT, 35 r:.m"'l> ...
15-16
Install the stopper ring into the groove of pinion gear bearing
hole.
'-" DRIVER ~ 121 .22 mm
Press a new pinion bearing into the case.

« r---'
TOOLS ;
Drive r 07749 - 0010000
Pilot. 22 mm 07746 - 0041000
(3) STOPPER .....

RING
CAS E OIL SEAL REPLAC EMENT
Remove the oil seals from the cover and case.
Drive in new oil seals w ith these tools:
TOOLS :
Driver 07749 - 0010000
Attachment, 42 x 47 mm 07746 - 0010300 (Case)
Attachment, 52 x 55 mm 07746 - 0010400I Cover)
FINAL DRIVE ASSEMBLY (2) SPACER
PINI ON GEA R ASS EMBLY ~3) INNER

RACES
Inst all the original pinion gear spacer. /
NOTE
When the gear set, pinion bearing and/or gear case have
been replaced, use a 2.0 mm (O.OB in) thick spacer.
Apply #80 gear oil to the inner races and the bearing.
(4) PINION BEARING
Orive the bearing and both inner races onto the pinion gear
s haft with the special tool shown.
TOOL:
Inner driver 07746 - 0020100
RACE
15-17
Place the pinion assembly into the gear housing and drive it GEAR DRIVER
int o the gear case.
TOOL :
Pinion gear driver 0794S - HAOOOOO or
Driver 40 mm 1.0. 07746 - 0030100
Install and tighten the pinion bearing lock nut.
TORQUE : 90 - 110 N·m (9 .0 - 1 1.0 kg-m, 65 - 80 ft -Ibl

82 - 100 N'm 18.2 - 10 .0 kg-m . 59 - 72 ft -Ibl
TOOLS :
Lock nut wrench. 34 x 44 mm 07916 - ME50001 or
Lock nut wren ch , 34 x 44 mm 01916 - ME50000 and
Lock nut wren ch attachment 07916 - HA0010A
(U.S.A . only )
RING GEAR ASSEMBLY ~ 1) INNER DRI VI'R (2) A TTA CHMENT ,
Install the original spacer onto the ring gear.
NOTE
If the gear set, pinion bearing, ring gear bearing and /or gear
case are rep laced, install a 2.0 mm thick spacer.
Press the ring gear bearing onto t he ring gear shaft.
TOOLS :
G EA R~
;!::';IIIIIM"
Inner driver 07746 - 0030100
Attac hment, 35 mm 1.0 . 07746 - 0030400 (4 ) RING
(2) ATTACHMENT
If necessary, press the ring gear bearing jnto the cover.
TOOLS :
Driver 07749 - 0010000
Atta chment, 62 x 68 mm 07746 - 0010500
Pilot, 35 mm 07746 - 0040800
15-18
Install the ring gear shaft with the spacer into the cover. It may
be necessary to press the ring gear into the cover bearing.
) RING GEAR
(3) COVER
Measure the clearance between the ring gear and the ring gear (1) FEELER
stop pin with a feeler gauge. GAUGE
CLEARANCE : 0 .30 -0. 60 mm 10.012 - 0.024 in)

•
Remove the ring gear . If the clearance exceeds the service

(2) STOP PIN
limit, heat the gear case cover to approximately BO°C 1176 °F)
and remove the stop pin by tapping the cover.
(1) RING GEAR
Alwoys weor gloves when handling the geor case o/ur it has " 0.30 -0 .60 mm
been healed 10 prevent burning )'our hands.
~J0012T24 inl
Install a stop pin shim to obtain the correct clearance ,
SHIM THICKNESS: A : 0.10 mm 10.004 in)
~~\Il
B: 0 .15 mm (0.006 in)
Install the shim and drive the stop pin into the case cover.
(3) STOP PIN (2) SHIM

Apply gear oil to the lip of the oil seal on the gear case cover.
Press the ring gear with the spacer into the case cover. (1) APPLY PRUSSIAN BLUE
Clean all sealing material off the mating surfaces of the gear
case and cover.
NOTE
Keep dust and dirt out of the gear case.
o Be careful not to damage the mating surfaces.
Apply a thin coat of Prussian Blue to the pinion gear teeth for a
tooth con t act pattern check.
Apply liquid sealant to the mating surface of the gear case

cover and install the gear case cover on the gear case.
15-19
Apply locking agent to the 10 mm cover bolts.
Tighten the cover bolts in 2 or 3 steps until the cover evenly

touches the gear case, then tighten the bolts to the specified
torque in a crisscross pattern in two or more steps.
TORQUES;
10 mm bolt 45 - 50 N·m (4 .5 - 5 .0 kg-m . 33 - 36 fl-Ib)
8 mm bolt 23- 28 N·m (2 .3 - 2 .B kg-m. 17 -20 ft-Ibl
TS
Remove the oil filler cap from the final gear case. (1) NORMAL :
Rotate the ring gear several t imes in both directions . Check the
gear tooth contact pattern through the oil filler hole. The pat-
tern is indicated by the Prussian Slue applied to the pinion
tnJ·
-~ ~]
before assembly . -( IL- -~
. [lJ
Contact is normal if the Pru ssian Blue is transfared to the ap- "'"1=-
proximate canter of each tooth and slightly to the flank side. ~ 161
~TOE ~HEEL
~
(2) FACE
(31 FLANK * ;iii'!!!
(7) DRIVE SIDE

(5)
COAST
SIDE
* (21 FACE
(3 ) FLANK
If the patterns are not correct, remove and replace the pinion (1) TOO HIGH :
spacer. Replace the pinion spacer with a thicker one if the con -
(5 ) PINION
tact s are too high, t oward the face.
SPAC ER
Il' Pl
- " ...
tlJ
-....:1-
~,y I
= I
( 2 ) FtC~ ~'t FACE

(4 ) DRIVE SIDE (3 ) COAST SIDE
Replace the pinion spacer with a thinner one if the contacts are
too low, to the flank side. The panerns will shift about 1.5 -
2.0 mm 1O.06-0.0B inl when the thickness of the spacer is
changed by 0 .10 mm (0.004 in!.
PINION SPACERS:
A: 1.82 mm to.072 in)
B: 1.88 mm (0.074 In)
C: 1.94 mm (0.076 in)
D: 2 .00 mm (0.079 Inl Standard
E: 2 .06 mm (0.081 In)
F: 2 . 12 mm (0.083 in)
G: 2 .18 mm (0.086 in)
15-20
BAC KLAS H INSPE CTION
Install the pinion holder onto the pinion joint with four 10 mm
nuts.
Set the holder in the vise.
Set a ho rizontal type dial indicator on the ring gear, through
the oil filler hole .
Rotate the ring gear by hand until gear slack is taken up . Turn
the ring gear back and forth to read backlash.
(11 PINION HOLDER
STANDARD: 0 .08-0. 18 mm (0.003 - 0 .007 inl
SERVICE LIMIT: 0.2 5 mrn 10 .01 0 inl
Remove the dial indicator. Turn the ring gear and measure
backlash. Repeat this procedure once more.
DIFFEREN CE OF MEASUREMENT
SERVICE LIMIT: 0 . 10 mm 10.0 04 In)
If the difference in measurements e)(ceeds the limit, it indi-

cates that the bearing is not installed squarely.
Inspect the bearings and reinstall if necessary.
If backlash is too small, replace the ring gear left side spacer
with a thicker one.
Backlash is changed by about 0.06 mm to.002 in) when thick-
ness of the spacer is changed by 0.10 mm (0.004 in). fl) RING GEAR
RING GEAR SPACERS : RIGHT SPACER
A: 1 .8 2 mm (0 .0 72 in)
B: 1 .88 mm (0.0 74 in)
C: 1.94 mm (0 .0 76 in)
0 : 2.00 mm (0.079 in)
E: 2 .06 mm (0 .081 in)
F: 2 . 12 mm (0.083 in)
G: 2 . 18 mm (0 .086 in) (2) RING GEAR LEFT SPACER
H: 2 .24 mm (0 .088 in)
I: 2 .30 mm (0 .091 in)
Change the right side spacer thickness an opposite amount to

what the left side spacer was changed; if the left spacer was
replaced with a 0. 10 mm (0.004 in) thicker spacer, replace the (1) PINION HOLDER
right spacer with one that is 0.10 mm (0.004 in) thinner.
Install the piniion joint onto the pinion.

Apply locking agent to the pinion threads.
Place the pinion holder onto the pinion joint. Align the holes in
the pinion holder with the four (4) studs on the final drive gear
Place the holder into a vise.
Tighten the pinion joint nut.
TORGUE: 100 - 120 N·m fl0 .0 - 12. 0 kg-m , 72-87 ft -Ib)
TOOLS:
(Mo dified )
15-21
Remove the pinion joint holder.
Make sure t he gear assembly rotates smoothly without bind-

ing by turning the pinion joint.
Meaure the final gear assembly preload.
PRELOAD : 0 .2 - 0 .4 N·m (2 - 4 kg -em, 1.7 - 3 .5 in-Ib)
Stake the pinion bearing lock nut and install a new drive shaft
bearing oil seal.
FINAL DRIVE INSTALLATION

Apply molybdenum disulfide grease to the drive shaft oil seal,
pinion joint and drive shaft splines.
Install the final drive gear case on t he swingarm (page 14- 121.
NOTE
00 not forget to install the spring into the drive shaft joint
before installing the gear case.
Install the followings:

- rear axle (page 14-61
- rear axle housing. trailer hitch and skid plate (page 14- 1 31
- rear brake panel (page 13-15)
- rear wheels (page 14-3)
Fill the gear case with the recomme nded oil (page 2-3\.
15-22
16. BUMPERS, FENDERS, CARRIERS
FRONT/REAR BUMPERS 16·1 REAR FENDER 16·4
FRONT FENDER 16-1 FRONT/ REAR CARRIERS
(FOREMAN) 16· 7
FRONT/REAR BUMPERS 111
Front bumper
Remove the front bumper by removing the four mounting
bolts.
Install the front bumper in the reverse order of removal.
Rear bumper
Remove the fuel tank guard under the fuel tank by removing
the mounting nuts.
Remove the rea r bumper by removing the mounting bolts.

Install the rear bumper in the reverse order of removel.
FRONT FENDER
REMOVAL
Remove the seat and both side covers.

Remove the air cleaner cover by removing the wing bott.
Remove the upper cover by removing the mounting bolts, col-
lars and special screws.
16-1
Remove the mud guard bracket mounting nuts from both

sides.
Disconnect the accessory wires and remove the accessory
lights (page 20-4).
Remove the fender mounting bolts, lock washers and cap nuts
from both of the side fender brackets.
Remove both side inner fenders by removing the 6 mm mount-

ing bolts.
Remove the special screws/washers and flange bolts/washers (2) FLANGE BOLTS
from the front fender.
Remove the front fender.
Remove the air intake cover from the intake duct inner rubber. RUBBER (2) AIR INTAKE
16-2
BUMPERS. FENDERS. CARRIERS
INSTALLATION
Installation is the reverse order of removal.

(3) AIR CLEANER COVER
Insert the tabs of upper cover and

air cleaner cover into the slots in
front fender .
(1) FRONT FENDER
Install the inner rubber

into the air intake cover
by seating the rubber 's
groove in the cover.
(4 ) INTAKE AIR DUCT RUBBERS
(5) AIR INTAKE

COVER
(6) INNER FENDER ---7~~~~~~~~~~
16-3
BUMPERS, FENDERS , CARRIERS
REAR FENDER
REMOVAL
Remove the tool box lid .
Remove the battery bQ)c mounting bolts and coliars.

Remove the battery i page 18-3).
Remove the feaf fender upper stay mounting bolts/ cap nuts .
III TAILLIGHT
Remove the taillight wires, tailtight mounting nuts and collars

and the taillight .
CAP NUT
Remove the fender lower stay from each side by removing the
mounting nuts and mud guard support stay.
Remove the rear fender from the frame.
After '88:
Remove the fender lower stay from each side by removing the
mounting nuts.
Remove the screws from the mud guard .
Remove the rear fender end mud guard assembly from the
frame.
16-4
BUMPERS. FENDERS. CARRIERS
INSTALLATION
Installation is the reverse order of removal.
'86 -'S8:
(1) TOOL BOX LID -----p
~-, .<, SA TTERY

BOX
131 REAR F"'DElR_~.
(4 ) FENDER LOWER ST •• ' _
~~~~~~~~~~~~~~---(6)FENDEA
UPPER STAY
16-5
BUMPERS , FENDERS, CARRIERS
AFTER 'S8 : , ) TOOL BOX LID
BATIERY
BOX
(3) REAR ,.,'OER ___
(4) FENDER LOWER STAY
FENDER
UPPER STAY
(6) FOOT
MUD GUARD
LOWER SUPPORT STAY
16-6
FRONT/REAR CARRIERS (FOREMAN)

'87: After '87:
(1) FRONT CARRIER
(1) FRONT CARRIER
~~.. ', .
~. ~ 'C
(2) FRONT BUMPER

(2) FRONT BUMPER
(3) REAR CARRIER
~~~~::::;1;31~R~E:A~A CARRIER
•
•
(4) REAR BUMPER (4) REAR BUMPER

RE MOVAL
(1) FRONT CARRIER
Remove both side inner lenders by removing the 6 mm mount-
ing bolts (page 16-21.
Remove the four front carrier mounting bolts and the carrier.
INSTA LLATION
Install the front carrier in the re verse order of removal.
Remove the four rear carrier mounting bolts and the carr ier. Tn REAR CARRIER
IN STALLATION ~~~
Install the feaf carrier in the reverse order of removal.
16-7
IGNITION SYSTEM
SYSTEM DIAGRAM
IGNITION
MAIN FUSE (FOREMAN)
(3) IGNITION
COIL
III ENGINE
SWITCH
BATIERY
(11) COl
0'
DC-COl UNIT (to) SP,'R' I Nf'UTI. . '
(FOREMAN) PLUG SWITCH
COl SYSTEM IFOURTRAXI
(2) IGNITION SWITCH (11) CDI UNIT

(8) AL TERNATOA
(EXCITER COlLI
.,/W
BIIY
o o
(3) IGNITION
III COil
III ENGINE STOP SWITCH (10) SPARK PLUG (7) NEUTRAL SWITCH (9) PULSE GENERATOR
17-0
17. IGNITION SYSTEM
DC-COl SYSTEM (FOREMAN)
'87:
(1 1) DC-COl UNIT 4-(1)

ENG INE STOP SWITCH
(6) FUSE B OX (SUB-FUSE)
/
,__ .1 BI/W
BI/G~
~l~~l
II
Bu/Y BI- - - -_ __
e Ell ~~I \
IGNITION
SWITCH
(5) BATTERY (4 ) MAIN FUSE
(7) SWITCH
NEUTRAL (10) SPARK PLUG (9) PULSE (8) ALTERNATOR
GENERATOR
After '87:
(11) DC-COl UNIT (1) ENGINE STOP SWITCH
I (6) FUSE
Or
;:!9~/R::~G:-_::J_G
...fW Bflwtt I BOX (SUB-FUSE)
rJL
Lg
1';;;:;:::::1~BII~l~7.",\'--
Bu/Y
y
BIIG-=r-.o--
(12) TO R 81 - - - - - - - -
EGULA TOR/RECTIFIER
~~21
131~~~Ti~ J e Ell
(5) BATTERY
\
IGNITION
SWITCH
(4) MAIN FUSE
' " NEUTRAL

SWITCH
/ ~
(10) SPARK PLUG (9) PULSE
GENERATOR
(8) ALTERNATOR
(CHARG ING COIL)
17-1
IGNITION SYSTEM
SYSTEM DIAGRAM 17-0 IGNITION COIL 17-4

SERVICE INFORMATION 17-2 PULSE GENERATOR 17-5
TROUBLESHOOTING 17-3 ALTERNATOR 17-5
COl UNIT SYSTEM INSPECTION 17-4 IGNITION TIMING 17-6
SERVICE INFORMATION
GENERAL
• The following color codes are used throughtout the electri cal system .
Bu = Blue G = Green Lg = Ught Green A = Red
BI = Black Gr = Gray 0 = orange W = White
Bf = Brown Lb = light Blue P = Pink Y = Yellow
• Ignition timing does not normally need to be adjusted since the COl (Capacitive Discharge Ignition 1 unit is factory preset.
• For spark plug inspection, refer to page 3-5.
• For alternator or pulse generat or removal / installation, see section 10.
• W hen inspecting the ignition system, check the sytem components and lines step-by-step according to the t roubleshoot -
ing sequence on the next page.
SPECIFICATION
ITEM STANDARD (at 2QoC /68°F)
Spark plug DRBES-l (NGK), X24ESR -U (NO)

DRSES (NGK), X 27ESA-U (N O)
OA7ES !NGK), X22ESA-U (NO)
Spark plug gap 0 .6 - 0.7 mm (0.0 24 - 0.028 in)
Ignition timing At idle (F mark) 10° ± 2° BTOC at 1,400 ± 100 rpm
Full advance 30° ± 2° STaC at 3,500 ± 100 rpm
Ignition coil Primary coil re sistance 0.1-0.20
Secondary coil resistance (Without spark plug cap) 3.7 - 4 .5 kO
(With spark plug cap) 7.5-10.8 kO
Alternator exciter coil re sistance (FOUATAAX) 50 - 2000
Pulse generat or resistance 300 -3600
TOOLS
Inspection adaptor (C) 07508 - 0012500 (Not available in U.S.A.!

Digital multitester 07411 - 0020000 or KS-AHM-32-003 (U .S.A. only )
0'
Circuit tester (SANWA) 07308 - 0020000
0'
Circuit tester (KOWAl TH-5H
17-2
IGNITION SYSTEM
TROUBLESHOOT ING
Weak or no spark 8t plug
GOOD SPARK
, . Try spark t est with known good spark plug. · Faulty spark plug
WEAK OR NO SPARK
2. Check spark plug wire for loose or poor con- GOOD SPARK
tact at the spark plug cap. then try spark test
again.
· Loose or poor contact of spark plug cap.
WEAK OR NO SPARK
3. Check COl unit connectors for loose or poor ABNORMAL

contact. I · loose or poor contact of CDI unit connectors.
NORMAL
4. Check the resistance, continuity and voltage at the CDI unit connectors of the wire harness side (page , 7·4). Also I
check ignition secondary coil resistance (page 17· 5).
ALL NORMAL
ABNORMAL
,--. Faulty COl unit.
5. Check the related components on the sus-

pected harness . After checking , compare the
measurements of (5) with these of (4 ).
NORMAL ABNORMAL
(DIFFERENT (SAME
MEASUREMENTS ) MEASUREMENTS)
·
-
Faulty related components
pulse generator (page 17-51.
- neutral switch (page 20-5).
- ignition coil (page 17-4 ).
- ignition switch (page 20·6).
- engine stop switch (page 20-6) .
- ground wire (G/W).
- alternator exciter coil IFOURTRAXl l page 17 -
5).
- re volution research line IAfter '87: FORE MAN)
(page 17-6).
- battery (FOREMAN) (page 18-3).
· l oose or poor contact of the related compo-

nent connectors.
Open or short circuit in the wire harness be-
tween the related component and COl unit .
17-3
IGNITION SYSTEM
COl UNIT SYSTEM INSPECTION (1 ) COl UNIT
NOTE
Check the system components and lines step-by-step ac-
cording to the troubleshooting on page 17-3 .
~
LC,
This method does not include an inspection of the ignition
timing advance system at the COl unit.
Disconnect the COl unit connectors and check them for loose
contact or corroded terminals.
Measure the resistance, continuity and vortage between con-

nector terminals of the wire harness side on the following
chart.
FOURTRAX FO REMAN
ITEM TERMINAL STANDARD ITEM TERMINAL STANDARD

Ignition coil primary 0 . 1 ~O.2 n Ignition coil primary 0 . 1- 0 .2 (}
BIIY and G/W BIIY and GIW
coil lat 20oC/ 68 ° F~ coil (at 20 o C/68 ° F)
Alternator exciter 50 - 2000 Pulse generator 300-360 (1
SIIA and G/W Bu/Y and GIW
coil {at 20° C/68 D FI (at 20 ° C/68 ° F)
Pulse generator 300 - 3600 Ignition and engine
Bu/Y and G/W
(at20°C/68 ° F) stop switches (Set
The battery
the ignition switch BIIW (+) and
Ignition and engine voltage should
stop swit ches (Set
ON, and engine stop GIW I- I
come.
the ignition switch switch RUN posl-
BIIW and G/W No continuity tions)
ON , or engine stop
switch RUN posi- Gearshift pedal in
19/R and G/W Continuity
t ions) neutral
Gearshift pedal in After ' 87 : Y and GIW No continuity
19/R and G/W Continuity
neutral Revolution research
line Y and Y Continuity
Disconnect the
..
regulator /rectifier
3P (Green) connector,
and check continuity between Y (COl unit 4P connector)
and Y (regulator/ rectifier 3P connector) of each wire har-
ness side.
IGNITION COIL
REMOVA L
Remove the front fender (page 16- 11.

Remove the spark plug cap from the spark plug.
Disconnect the ignit ion coil primary wires.
INSPECTION
Measure the primary coil resistance .
STANDARD; 0 .1 - 0 .2 (1 (at 20 ° C/68 ° F)
17-4
IGNITION SYSTEM
Measure the secondary coil resistance with the spark plug cap
(1) IGNITION COIL
in place by checking for continuity between the plug cap and
green terminal.
STANDARD: 7.5 - 10.8 kfl (at 20°C/68°F)
Remove the spark plug cap from the wires and measure the
secondary coil resistance.
STANDARD: 3.7 - 4.5 kG (at 20 ° C/68°F) (1) IGNITION C"O~IL_ _-.£--,;C[~
INSTALLATION II
Connect the BI/ Y wire connector to the black terminal of the

ignition coil and the G wire connector to the green terminal.
Install the spark plug cap to the plug .
PULSE GENERATOR
NOTE
11 is not necessary to remove the pulse generator to make
this test.
INSPECTION
Remove the right side cover.

Disconnect the pulse generator wire (Bu /V) at the connector.
Measure the resistance between the Bu/Y wire and body
ground.
STANDARD: 300-360 {} tat 20 oC/68°F)
Replace the pulse generator if the reading is not within the limit
!see section 10).
ALTERNATOR
NOTE
It is not necessary to remove the stator coil to make this
test.
EXCITER COIL INSPECTION IFOURTRA XI
Remove the right side covet.

Disconnect the exciter coil wire (BI / R) at the connector.
Measure the resistance between the BI/ R wire and body

ground.
STANDARD; 50-200 0 tat 20°C/ 68°F)
17-5
IGNITION SYSTEM
REVOLUTION RESEARCH LINE INSPECTION

(1) TO COl UNIT (3) REGULATOR!
IAfter '87 : FOREMAN)
RECTIFIER
Remove the right side cover.
Disconnect the revolution research wire (Y) connector from
~
the alternator changing coil.
And also disconnect the regulator/rectifier 3P (Green) connec-
+(21 CONTINUITY~::;:c::;J
I[j) 4
tor.
Measure the continuity between connector terminals on the
151
NO
following chart.
CONTI-
NUITY 14 )
Revolution research wire (V)
"7 ALTER-
Regulator Irectifier NATOR
3P connector IV) CONTINU ITY
terminal
Bodv ground NO CONTINUITY
IGNITION TIMING
NOTE
The CapaCitive Discharge Ignition (COl) system is factory
pre-set and does not require adjustment. To inspect the
function of the COl components, ignition timing inspection
procedures are given here.
Warm up the engine to the operating temperature.
Remove the timing hole cap.

Connect a tachometer and timing light.
Start the engine and allow it to idle.
IDLE SPEED: 1,400 ± 100 rpm
Inspect the ignition timing.

Timing is correct if the "F" mark on the alternator rotor is
aligned with the index mark on the left crankcase cover at idle.
To check the advance, raise the engine speed to 3,500 ± 100

rpm. The index mark should be between the advance m arks.
If the ignition timing is incorrect, perform the system inspec-

t ion (page 17 -4 ).
(3) F MARK (2) ADVANCE MARKS
17-6
MEMO
BATTERY/CHARGING SYSTEM
SYSTEM DIAGRAM
(3( R'GmATOR;IR":T'F"R
) IGNITION
SWITCH (2) MAIN FUSE
BATTERY
(51 ALTE"NATOF CH.'R(HNG

COIL
01 REGULATORI
RECTIFIER
1~__t'(2_'CM"A~'No-FU;E~_-9;,
(1) IGNITION (4) BATTERY
SWITCH
(5) ALTERNATOR
CHARGING COIL
18-0
18. BATTERY/CHARGING SYSTEM
SYSTEM DIAGRAM 18-0 CHARGING SYSTEM 18-4
SERVICE INFORMATION 18-1 ALTERNATOR CHARGING COIL 18-4
TROUBLESHOOTING 18-2 REGULATOR/RECTIFIER 18-4
BATTERY 18-3
SERVICE INFORMATION
GENERAL
Do not smoke, and keep flames away from Q charging ballery. The gas produced by a ballery will explode if Q flame or spark Is
brought near.
CAUTIO N
For battery charging, do nof exceed the charging current and lime specified on Ihe battery (ond shown below). Use 0/ excessi..,e
current or charging time may damage the bauery.
• Slow charge the battery w henever possible, quick charging should be an emergency procedure only.
• Remove the battery from the vehicle for charging.
• The battery on this vehicle is a sealed type. 0 0 not try to remove the filler hole caps even during charging. Do nut use a
non-sealed battery as 8 replacement.
• All charging system components can be checked on the vehicle.
• When inspecting the charging system, check the system components and lines step-by-step according to the trouble -
shoot ing sequence on the next page.
• Alternator removal is given in section 10.
SPECIFICATIONS
< > FOAEMAN
Battery Capacity 12 V - 12 AH
Voltage Fully charged 13.1 V

at 20 °C i68 ° F)
Needs charging 12.3 V
Charging current Standard: 1.4 A , Quick: 6.0 A
Charging time Standard: 5.0 hours, Quick: 1.0 hour
Alternator
Regulatorl
rectifier
Capacity
Charging coil resistance
Type
Regulated voltage
240 W/ 5,OOO rpm <31 0 W / 5,OOO rpm >
0.2 - 1.00 (at 20 o C/ 68 °F)
Three-phase / full-wave rectify,
13.5 - 1 5 .5 VI 5,DOO rpm
m
TOO LS
Digital multitester 07411 -0020 000 or KS·AHM·32·003 (U.S.A. only)

0'
Circuit tester (SANWA) 07308-0020000
0'
Circuit tester {K OWAl
18-1
TROUBLESHOOTI NG
Battery overcharged
Loose or poorly contact BI terminal of the regulatorfre ctifier 3P connector
Open circui t in BI wire
Faulty regulator/ re ct ifier
Battery undercharged
1. St8rt the engine and perform the

regulated voltage inspection
NORMAL
113 . 5 - 15.5 V / 5,OOO rpm )
. Faulty battery
(page 18·4).
lOW VOLTAGE
(SAME AS BATTERY
VOLTAGE)
2 . Disconnect the regulator/rec-

tifier 3P (Green) connector, and OUT OF ORDER
• Open circuit in stater coil wire
check the c harging coil re sis-
lance (page 18-4 ).
NORMAL 10.2- 1.0 m

3 . Check the regulator Irect ifier
connectors '0' loose o r poor
contact.
Disconnect ,he regulator/rec-
t ifier 3P connector, and meas-
'he voltage between ,he NO VOLTAGE
"'"
regula t o r Ire c ti fier connectors
• l oose or poor contact in connect ors
• Open circuit in wire harness
. twire harness side) (page 18·4 )
81 1+) and G (- ) - Battery volt·
. age with ignition switch ON .

R (+) and G I- I ..... Battery volt·
age .
BATTERY VOLTAGE
COMES
• Faulty regulator/rectifi er
18-2
BATTERY
REMOVAL/ IN SPECTION
Remove the seet and open the tool box lid.

Remove the tool box and tool box bottom plate by removing
their mounting bolts.
(3 ) TOOL BOX
BOnOM PLATE
Measure the battery voltage using 8 digital voltmeter.
VOLTAGE: Fully c harged : 13. 1 V

Needs charging: Below 12.3 V
Remove the battery holder bolt.
Disconnect the negative cable and then the positive cable, and
remove the battery.
CHARGING
Connect the charger positi ve (+) cable 10 the battery positive

1+) terminal.
Connect the charger negative I-I cable to the battery negative

1- ) te rminal.
Standard Quick
Charging current 1.4 A 6.0 A
Charg ing t ime 5 hours 1 hour
Specified voltage , 2.8 V min.
K~~p f1am~sand sparks away from a charging batl#!ry.

Tum pOtl'U ON/ OFF ot thr charger, not at the bQtter~ tum;·
nals.
CAUTION
Quick-charging should only lw done in an emergency; slow.
charging is pre/erred.
For bauery charging, do not uceed the charging current and
time specified on the baltery cover. Using ucessive current or
u tending the charging time may damage the battery.
INSTALLATION
Install the battery in the reverse order of removal.
After installing the battery, coat the terminals with clean

grease.
18-3
CHARGING SYSTEM
~ 111 VOLTMETER
REGULATED VOLTAGE INSPECTION
'e
~
NOTE
. Be sure the battery is in good condition before performing
this test .
Warm up the engine to normal operating temperature.

Stop the engine, and connect the voltmeter as shown.
Connect a tachometer.
Allow the engine to idle, and increase the engine speed gradu·
ally .
The \/oltage should be controlled to 13.5- 15.5 V at 5,000
rpm .
CAUTION
Be ~Q,eful not to conract (he bantry positive cable to the/rame
while testing.
ALTERNATOR CHARGING COIL

NOTE
It is not necessary to remove the stator coil to make this
test .
INSPECTION
Disconnect the regulator/rectifier I'" alternator) 3P iGreen)

connector.
Check the resistance between the connector terminals.
STANDARD : 0 .2 - 1.0 {} (a120 D Cf68 ° F)
Check for continuity between the connector terminals and

ground.
There should be no continuity.
Replace the alternator stator if readings are far beyond the
standard , or jf any wire has continui ty to ground. Refer to sec-
tion 10 for stator remo val .
REGULATOR/RECTIFIER
VO LTAGE INSPECTION
Remove the connector case lid under the right side rear fender
by removing four screws .
18-4
Disconnect the regulator/ rectifier 3P connector, and check it

for loose contact or corroded terminal.
If the regulated voltage reading is out of the specification,

check the items between connect or terminals ~wi re harne ss
side) following the chart below .
ITEM TERMINALS SPECIFICATION
Battery charging line A (+) and G H Battery voltage

Battery voltage feedback line 81 HI and G H Battery voltage with the ignition switch ON.
18-5
STARTER SYSTEM
SYSTEM DIAGRAM
(4) IGN ITION
)
(5) MAIN FUSE (6) STARTER

(3) NEUTRAL
(FOREMAN) RELAY
)
(2) SILICON
RECTIFIER -~<K
11) S"'RTFR _ _--jJ

SWITCH
) MAIN FUSE
(FOREMAN)
( 10) <TARTFR
MOTOA (8) FUSE
(6) STARTER
RELAY
. - _..:;S::.;WITCH
"1';:5)" M
'"'A
"'I"N""F"US"',"
17)
BATTERY
L
.....; . - _ _ _ _ _ _ _ _
LgIR: - - - - - - - -...... ,.;;.O:::......,
A-tube
(10) STARTER
MOTOR '-~------- YIR -------. Lg
~~UTAAl 1~
A~~ BI____()""\,...BI/Br1'"-=0
(4) IGNITION
SWITCH
(8) SUB FUSE
JJ
(1) STARTER
SWITCH
Lg /R
SWITCH
I
Lg/R
(3) NEUTRAL (2) SILICON
INDICATOR RECT IFIER
19-0
19. STARTER SYSTEM
SYSTEM DIAGRAM 19-0 STARTER MOTOR 19-3
SERVICE INFORMATION 19- 1 STARTER RELAY SWITCH 19-6
TROUBLESHOOTING 19-2
SERVICE INFORMATION
GENERAL
• The starter motor can be removed with the engine in the frame .
• For the starter reduction gear removal /installation, see section 10.
SPE CIFICATI ONS
ITEM STANDARD SERV ICE LIMIT
Starter motor Brush spring tension 800 ±120 9 (28 .2:i: 4 .2 Ol) 740 9 (26 oz)
Brush length 12.0 - 12.5 mm (0.47 - 0A9 in) 5.5 mm (0.22 in)
19-1
STARTER SYSTEM
TROUBLESHOOT ING
NOTE
The starter motor can turn when the transmission is in neutral.
Check the following items before troubleshooting the system.
- Main and sub fuses for possible blown condition
- Battery and starter motor cables for loose connection
- Battery discharged
Starter motor do not turn
1- 1. Check the starter relay switch for opera- "CLICK"

tion. You should hear the relay "CLICK" HEARD J 1-2. Apply battery voltage to the starter motor I
when tho starter switch button i, d.~ directly and check the operation.
pressed. (page 19-6)
TURN DO NOTTUAN
"CLICK " NOT HEARD
· Loose or poor con- . Faulty starter motor

tact in starter (page 19-3)
motor cable
· Faulty starter relay
switch (page 19-6)
ABNORMAL
2. Check the neutral indicator for function. Faulty neutral switch (page 20-51
• Loose or poor contact connector of the neutral
NORMAL switch
• Faulty ignition switch (page 20-6)
• Neutral indicator bulb faulty
• Faulty silicon rectifier (page 20-5)
3. Check the starter relay switch voltage (page I NO VOLTAGE

Faulty starter switch (page 20-6)
19-6) I • Open or short circuit in wire harness
BATTERY
VOLTAGE
4. Check the starter relay switch for continuity I ABNORMAL

• Faulty starter relay switch
(page 19-6) I
NORMAL
• Loose or poor contact at connector in the starter
relay switch
Starter motor turns engine slowly
Low specific gravity in battery
Excessive resistance in circuit
Binding in starter motor
Starter motor turns, but engine does not t urn

Faulty starter clutch (see section 10)
• Faulty starter reduction gears (sea section 101
Starter motor and engine turns. but engine does not st art
Faulty ignition system (see section 17)
Engine problems (see section 3)
- low compression
- Fouled spark plug
Faulty fuel system (see section 4)
19-2
,,r
1
;
,
1
STARTER MOTOR
STARTER SYSTEM
"
REMO VAL
: A
With the ignition switch OFf~ remove the negative cable at the
battuJ' bejou sefricing the s!artu mOlor.
Remove the fuel pump by removing the mounting bolt.

Remove the starter gear cever from the left side of the engine.
Remove the dowel pins and gasket .

Remove the starter idle gear by pulling out the gear shaft.
I
Remove the starter motor mounting bolts, shift the motor to
the right and pull it out of the frame .
NOTE
Do not force to pull the motor out, the cable is st ill connect -
,d.
Disconnect the cable.
INSPECTION After
Remove the two starter motor case screws and the front and
rear covers .
Oisassemble them .
NOTE
Record the number and location of shims lor correct as- /
sembly.
,,
, '
...1
(4 ) SHIMS (21 REAR COVER
19-3
STARTER SYSTEM
Inspect the brushes for damage and measure the brush length. ~ 1) BR~SH
SERV ICE LIM IT : 5.5 mm 10 .22 in )
Measure brush spring tension with a spring scale .
SERV ICE LIMIT : 140 9 (26 azl
J'l2iBRIUSH SPRING
Inspect the commutator bars for discoloration. Bars discolored

in pairs indicate grounded armature coils; in which case the
starter motor must be replaced .
Check for continuity between pairs of commutator bars; there

should be continuity .
Also , check for continuity between individual commutator

bars and the armature shaft: there should be no continuity .
19-4
STARTER SYSTEM
Check for continuity from the cable terminal to the motor case
and from the cable terminal to the brush wire. Replace the
starter motor if the cable terminal is not continuous to the
brush wire or if it is shorted to the motor case.
ASS EMBLY! INSTALLATION
., (1) CARBON BRUSHES
0_,,(3) SHIMS----{i
"
(2) ARMATURE COIL
(3 ) SH IMS
(7) REAR
COVER
"'
(6) LOCK ((I " ( ,) .)

WASHER \\J l-)
(5) RONT COVER
HOLDER PIN
Assemble the starter motor. Align the case notch with the
brush holder pin.
NOTE
• Install the shims in the recorded positions.
Install the front cover; do not to damage its dust seal.
-~
, (2) CASE
19-5
STARTER SYSTEM
Install the rear cover, aligning its slot with the brush holder pin.
(1) BRUSH HOLDER PIN
Install the starter motor in the reverse order of removal.
STARTER RELAY SWITCH

OPERATION INSPECTION
Remove the tool box (page 18-31.

Depress the starter switch button with the ignition ON.
The coil is normal if the starter relay switch clicKs.
11) STARTER SWITC H
VO LTAGE IN SPECTION
If the switch 'CLICK' is not heard, measure the voltage be-

tween the VI A (+) and Lg /R i-) wires of the relay connector.
Battery vollage should be indicated when the starter switch
button is depressed with the ignition switch ON and the trans -
mission in neutral.
Perform the following inspection if battery vol ta ge is indicated
between the VIR and Lg/R wires.
CONTINUITY INSPECTION
Connect an ohmmeter to ·the staner relay switch large termi-

nals.
Connect a fully charged 12 V battery positive wire to the start-

er relay switch VI R wire terminal and battery negative wire to
the Lg/R wire terminal.
Check for continuity between the starter relay switch termi·

nals.
There should be con tinuity while 12 V battery is connected to

the starter relay switch terminals. There should be no continui -
ty when the battery is disconnected.
19-6
MEMO
LIGHTS/SWITCHES
(2) I I SWITCH
MAIN FUSE (FOREMAN)

(1) OIL TEMPERATURE
I
(3) FUEL
PUMP FUEl
CUT
RELAY
BATTERY
(12) FAN MOTOR IS) BOX

CONTROL
:;r=o;a, NEUTRAL • SU B FUSES
UNIT (10) OIL TEMPER/miA', SWITCH • MAIN FUSE (FOUATRAX)
SENSOR
OIL COOLING SYSTEM OIAGRAM
(12) FAN MOTOR

CONTROL UNIT
(2) IGNITIO N
SWITe H (8) SUB ( 10) OIL TEMPERATURE
B,
rY'OB T' FUSES
'181 B,L SENSOR
R ~B'
(5) MAIN Fusi
IBI
BI~B'/Rt:.. Bu-Tub
(1 , )
(7) BATTERY (10) OIL

TEMPERATURE
1
INDICATOR
-L
20-0
20. LIGHTS/SWITCHES
SERVICE INFORMATION 20- 1 IGNITION SWITCH 20-6
TROUBLESHOOTING 20-2 HANDLEBAR SWITCH 20-6
HEADLIGHT 20-3 OIL TEMPERATURE SENSOR 20-7
FRONT ACCESSORY LIGHT/TAILLIGHT 20-4 FAN MOTOR CONTROL UNIT 20-7
INDICATOR LAMP 20-4 FUEL PUMP/FUEL CUT RELAY 20-B
NEUTRAL SWITCH/ REVERSE SWITCH 20-5 FUEL UNIT/METER (FOREMANI 20-9
SERVICE INFORMATION
GENERAL
• A continuity check can usually be made without removing the part from the vehicle by simply disconnecting the wires and
connecting a continuity tester or voltmeter to the terminals .
• When inspecting the oil cooling system, check the system components and lines step-by-step, according to the trouble-
shoot ing sequence on the next page.
SPECIFICATION
Headlight ,2V 60/ S0W

Taillight 12V 5W x 2
Neutral indicator 12V 3W
Reverse indicator 12V 3W
Oil temperature indicator 12V 3W
Accessory tight 12V 5W x 2 (FOURTRAXt
12V 25W x 2 (FOREMAN)
TORQUE
Oil temperature sensor 15 - 20 N·m 0.5 - 2.0 kg-m, 1 1- 1 5 ft-Ib)
20-1
LIGHTS/ SWITCHES
TROUBLESHOOTING
lig ht does not come on when light switch is turned on (E n-
gine is running)
Bulb burned out
Faulty switch
Wiring to that component has open circuit
Headlight beams do nOl shift when hi-Io switch is operated

Faulty dimmer switch
Bulb burned out
Wi ring to that component has open circuit
OIL COO LING SYSTEM
NOTE
When the ignition switch is turned on, the oil temperature warning indicator should come on for a few seconds then go off .
• After '87 : To prevent damage, the fan motor control unit w ill cut power to the motor if the motor slezes.
Cooling fan does not work
1. Perform the fan motor control unit voltage in- I ABNORMAL

spection (page 20-7). · Sub fuses fau lty.
NORMAL
I
·· Open or short circuit in wire harness.
Loose or poor contact in connectors.
2. Check the oil temperature sensor resistance

at the control unit connector between Bu and ABNORMAL
G wires. Resistance should be about 10 kfl · Loose or poor contact in connector
with the engine cold (25 " CI7 7 " F). ·· Open or short circuit in Bu wire.
Faulty oil temperature sensor (page 20-7) .
NORMAL
3. Disconnect the Lb and W wires from the con- ABNORMAL

trol unit and short them. Cooling fan motor
should turn with the ignition switch on .
·· Loose or poor contact in motor connectors.
Open or short circuit in Bu or G wires.
NORMAL
· Faulty fan motor.
Faulty control unit.
Cooling fan works, but oil temperature warning indicator does not come on .
Disconnect the Bu/R and G wires from the con -

trol unit and short them. f--------- Bulb fau lty.
The indicator should come on when the ignition INDICATOR Open or short circuit in wire harness.
switch is turned on. DOES NOT
COME ON
INDICATOR COMES ON
Loose or poor contac t in connector.
Faulty control unit.
20-2
LIGHTS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
\
FOURTRAX
Remove the upper and lower mounting screws. \ j1j1~
Remove the headlight from the case.
1
Disconnect the headlJght wire connector from the bulb.
FOREMAN
Remove the headlight case mounting bolts and case from the
bracket.
Remove the headlight from the case.
Disconnect the headlight connector.
111 (21 RUBBER COVER

Remove the rubber cover and unhook the holder spring.
Remove the bulb from the headlight.
Install the new bulb and hook the holder spring.
Install the rubber cover 85 shown.
Connect the wire connector to the bulb.

Install the headlight in the reverse order of removal.
CASE REMOVAL/ INSTALLATION (FOURTRAXI (11 HEADLIGHT

CASE
Remove the headlight and the headlight case mounting bolts.
Install the headlight case onto the brackets, aligning the marks
on the case with the dot on the brackets.
Install the headlight into the case.
20-3
LIGHTS/SWITCHES
FRONT ACCESSORY LIGHT ITAILLIGHT (1) FRONT ACCESSARY (2) TAILLIG HT
BULB RE PLAC EM EN T
Remove the bulb socket by turning it counterclockwise and

remove the bulb from the socket.
Install a new bulb into the socket and install the socket into the
case by turning it clockwise.
(FOURMAN ONLY)
Install the dust covers securely.
CASE REM OVA L/I NSTA LLA TI ON
Remove the bulb socket.

Remove the front accessory light case by removing the bolts
and collars.
Remove the taillight case by removing the nuts and collars.

0) I I CASE
Remove the taillight packing from the case.
(2) COLLAR
NOTE
The lens/case is a assembled part. If the lens is damaged.
\(0)0) ~
.~
replace it as a set.
Install the case in the reverse order of removal.
14 1
INDICATOR LAMP
BULB REPLACEME NT
Remove the handlebar cover (page 12-4).

Pull the bulb socket out of the indicator lamp housing and
remove the bulb.
Install a new bulb and push t he socket back into the housing.
Install t he handlebar cover (page 12-6).
20-4
LIGHTS/SWITCHES
NEUTRAL SWITCH/REVERSE SWITCH

REM OVAL
Remove the switch cover by removing two screws.

Disconnect the wire connectors from the switches.
INSPECTION
The neutral switch is functional if continuity exists only with

the transmission in neutral.
The reverse switch is functional if continuity exists only with

the transmission in reverse.
Connect the switch connectors (see below).

Disconnect the indicator connector, and check for continuity
between LglA terminal and ground, or between Gr terminal
and ground, in neutral or reverse positions. There should be
continuity.
If the neutral or reverse indicators do not come on, check the

indicator bulbs faulty.
If they Bre in good condition, replace the indicator wire with a
new one.
NOTE
Do not try to remove the rectifier from the indicator wire;
the y are an assembly.
INSTALLATION (2) REVERSE SWITCH
Connect the switch connecto rs according to the letter (on the

connector), "N" to neutral switch and "A" to reverse switch.
If thlJ nlJutral and reverse switch wire connections are

interchanged. the neutral indicator comes on when the trans-
mission is in reverse.
Install the switch cover in reverse order of removal.
20-5
LIGHTS/SWITCHES
IGNITION SWITCH
Remove the front fender (page 16- 11.
Disconnect the ignition switch wire connectors.
Check. for continuity between the ignition switch connectors
in each switch position .
Continuity should exist between the color coded wires as indi-
cated below.
FOURTRAX
COLOR BIIW G R BI RIBI P
OFF 0 <J
ON
FOREMAN
(2) LIGHTING SWITCH
COLOR R BI AIBI P
OFF
ON 0 <J 0 <J
HANDLEBAR SWITCH
The handlebar switch (lighting/ dimmer switches, engine stop
switch , starter switch) must be replaced as an assembly.
Remove the front fender Ipage 16- 11.
Disconnect the handlebar switch wire connectors.
Check continuity between the terminals. Continuity should
131 STA.RTE~~
exist between the color coded wire terminals as indicated
below .
ENGINE STOP SWITCH FOREMAN
FOURTRAX
COLOR G BIIW COLOR BUG BIIW
OFF 0 <J OFF
RUN RUN
LIGHTING SWITCH
FOURTRAX
COLOR Be BII Br W Bu
OFF
lo C <J
ON INI C
HI 0
STARTER SWITCH
LIGHTING/DIMMER SWITCHES
FOREMAN
SWITCH LIGHTING DIMMER COLOR Sl/ Sr YIR
COLOR SlIBr Be Bu W RELEASED
OFF Hi PUSHED
ON INI 0 :<'
lo <; <J
20-6
LIGHTS/SWITCHES
Oil TEMPERATURE SENSOR

REMOVAL
Drain the engine oillpage 2-2).

Remove the switch cover (page 20-5).
Disconnect the wires (After '87: the wire) from the oil temper-
ature sensor and remove the sensor from the right crankcase
cover.
INSPECTION
Suspend the oil temperature sensor in heated engine oi l to

check its operation. Do not let the thermometer or sensor
touch the pan, or false readings will result .
Connect ohmmeter probes across the terminals of the sensor 111 (2 ) OIL SENSOR
and measure the resistances .
TECHNICAL DATA
Temperature 25 ° C 10Q " C 170" C

(77"F) (212 ° F) (338 ° F)
Resistance 9.5 - 0.95- 209-
10.5 kU 1 .05 kO 231 n
Replace the sensor if the readings are out of the ranges as EN(;INE OIL
shown.
INSTALLATION
Instal! the temperature sensor with a new sealing washer in

the right crankcase and connect the wires.
TORQUE: 15-20 N·m (1.5- 2.0 kg-m , 11 - '5 ft·lb)
Install the switch cover (page 20-5).

Fill the crankcase w ith the recommended oil (page 2-2 ).
FAN MOTOR CONTROL UNIT

NOTE
Check the system components and lines, step-by-step, ac-
cording to the troubleshooting sequence on page 20-2.
VOLTAGE INSPECTION
Disconnect the fan motor control unit connectors and check

them for loose contact or corroded terminals .
Measure the voltage between connector terminals of the wire
harness side on the following chart.
ITEM TERMINAL SPECIFICATION

Battery-unit- motor line W (+ ) and G H
Battery-unit line BI/Br (+ ) and G H Battery voltage with the ignition switch ON .
Battery-indicator-unit line Bu/R (+ ) and G H
20-7
LIGHTS/SWITCHES
FUEL PUMP/ FUEL CUT RELAY
keep /lames or sparks away from the working area.

Wipe up the spilled gasoline at once.
NOTE
Make sure the battery is fully charged before making this in-
spection. The fuel pump will not operate correctly jf battery
voltage is below 10.5 volts.
(1) FUEL CUT RELAY

FUEL CUT RELAY INSPECTION
Remove the right side cover and connector case lid.
Disconnect the 4P connector from the cut relay, and turn the
ignition switch ON.
v
,. Measure the voltage between Bl/Sr 1After '86: 811G) (+) and
G {-I wires on the harness side.
Battery voltage should be indicated.
2. Check for voltage between Sf/Bu (+) and G (-) wires on the
harness side.
There should not be voltage.
3. Connect a jump wire between Bl / Sr (After '86: Sf/G) (+) and

SI/Bu wires of the harness side. (1) FUEL
Remove the seat, and measure the voltage between BI/Bu CUT
1+) and G 1-) wires of the fuel pump connectors on the har~ RELAY
ness side.
Battery voltage should be indicated.
4. Disconnect the jump wire and connect the fuel cut relay
connectors to the relay.
Start the engine.
Measure the voltage between BI/Bu (+) and G (-) wires of
the fuel pump connectors.
Battery voltage should be indicated. ~
~
(3) FUEL
PUMP (2) JUMP WIRE
CAUTION
• Be careful not /0 ground any of the terminals.
(2\ FUEL CUT
RELAY
FUE L PUMP INSPECTION
Connect a jump wire between the BllBr (Alter '86: BI/G) and
BI/Bu wires of the harness side connector.
BI/ Br
(After 'B6: BI/ G)
20-8
LIGHTS/SWITCHES
Remove the fuel tube from the carburetor and put the end into
a graduated beaker.
Turn the ignition switch ON for 5 seconds and then turn the
switch OFF.
Measure the amount of gasoline pumped into the beaker and
multiply it by 12.
STANDARD DELIVERY: 270 - 330 cc (9. ' - 11 .2 oz) per min-

ute .
Replace the fuel pump. if delivery is not within the specifica -

tion listed.
FUEl UNIT/METER (FOREMAN)

(1) FUEL METER
(2) FUSE (3) IGNITION SWITCH

BI'Br-<Y'-..o---tlf0-l~-,
Bu/W
(4) MAIN FUSE
WIG G
YIW
1 (5) BATTERY
FUEL UNIT INSPECTION (1) FUEL UN IT

FULL
Remove the fuel unit.
Measure the resistance between the fuel unit wire terminals
•
i~l
with the float at the upper (FULL) and lower (EMPTYj posi-
lions.
TERMINALS UPPER (FUll ) LOWER (EMPTY)

I ~ ~ l1\'J
,,@
WIG and YIW 23 - 43
390 - 7350
n 390-7350
23-430
EM;;! - - ( ) Y/W
WIG and Bu/W
Y/W and Bu/W 420 - 7800 420 - 7800 WIG
Bu/W
20-9
LIGHTS/SWITCHES
FUEL METER INSPE CTION
Connect the fuel unit wire connectors and turn the ignition
switch ON.
Inspection and Display of LEO (light Emitting Diode).
FLOAT POSITION Display of LED

UPPER (FULl) All LED'S (7) ON
LOWER (EMPTY) All lEO'S (7) OFF
If not so, check the fuel met er connectors f or loose contact Of

corroded terminals and check for open or short circuit between
the fuel unit and fuel meter.
REMO VA L
Remove the right side inner fender by removing the mounting

bolts (page 16· 2).
Disconnect the fuel meter wires.
Remove the fue l meter bv removing the fast eners.
20-10
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22. TECHNICAL FEATURES
DIFFERENTIAL 22-1 DC-COl SYSTEM (FOREMAN) 22-4
COOLING SYSTEM 22-3
DIFFERENTIAL
This vehicle uses Full Time 4 Wheel-Drive which improves off-road driveability and ability to ascend slopes. The f ront drive
system is equipped with differential gears to improve turning ability by reducing the steering load.
(4) OUT· PUT GEAR

DRIVE
111 DlFI'E",'NTIIAl~3! (2) LEADING 151 HAIILINI~

HOUSING SWINGAAM SWINGARM
(31 FULL I 4WD

DRIVE SHAFT
22-1
TECHNICAL FEATURES
A limited slip mechanisim is used in the front differential unit. This system is comprised of two sets of dutch discs and plates,
each tensioned by its own spring. one set for each front wheel. The use of conventional front differentials on fo ur wheel drive
vehicles tends to make them difficult to drive when one of the front wheels loses traction, This is because conventional
differentials transmit driving power to the wheel that has lost traction, causing the vehicle to turn to one side. With a limited-
slip differential, even though a wheel slips or is raised from the ground. the pinion gear and side gear are engaged by pressure
from the friction plates. A certain portion of torque from the engine is transmitted to the other wheel, that still has traction, to
prevent the slipping wheel from racing, This characteristic allows the speed of the raised or slipping wheel to be much t he
same as the wheel on the ground, which prevents the front of the vehicle from turning unintentionally. When a turn is initiated
by the rider, the clutches slip moderately, causing differences in torque distributed to the inside and outside wheels, and turn -
ing resistance is decreased.
(1) OIFF,REN1·'AL
12) 'MITFn SLIP DIFFERENTIAL
(3) AXLE <H,'FT
(4) SIDe
IS) PINION·'"
)7) CUJ1C:H
(6) CLUTCH 'o";C'I/Pl.A
22-2
TECHNICAL FEATURES
COOLING SYSTEM
In addition to the oil cooler, a control system is designed to improve engine performance in a wide range from low through
high speeds.
/'
/'
/
The fan control system is composed of an oil temperature sen-

sor, fan motor control unit, and oil temperature indicator.
When oil temperature goes over 1 10 -130 D C (270-306°F),
sensed by the oil temperature sensor, the fan motor operates
through the control unit.
When oil temperature goes over 170 - 1sooe (378-414°F),
the oil temperature indicator comes on through the control unit
and alerts that the oil tempe rature is rising critically high.
Afte r '8 7: (2) Oil TEMPERATURE

To prevent damage, the fan motor control unit will cut power INDICATOR
to the motor if it siezes. (1) FAN MOTOR CONTROL UNIT
(31 POWER
SOURCE
(4) OIL TEMPERATURE

SENSOR
(5) FAN MOTOR
22-3
TECHNICAL FEATURES
Fig . ,
DC·CDI SYSTEM (FOREMAN) ( 1 ) AC -COI (4) CAPACITOR (51 COl (6) SPARK
This model employs DC-COl system to improve the ignition

(2) EXCITER
,,...-- --- --:/
performance in the low engine speed range. (31
DESCRIPTION
,
On this system, the capacitor for the ignition is charged by the
.. "
battery instead of the exciter coil in the alternator which is
used on the current COl system (Fig. 1 J.
(91 (S) CONTROL

GENERATOR CIRCUIT
Fig . 2
This system enables a stabilized voltage, which is not affected (11 COMPARISON OF COl PERFORMANCE
by the engine speed, to be applied to the ignition coil (Fig. 21 (VI ".... (21 DC-COl
because the battery is used as a source of electricity. 220
,,
200
,,
150
100 ,,,
1 1/'" (31 AC -CDI
,
50 ~/
,, I I
1,000 2,000 3,000 (rpm)
Fig. 3
The voltage supplied from the battery is stepped up from 1 2 V (11 DC-CPI f41 DC-COl (5) CAPACITOR (6) IGNITION
to appro)(, 220 V by the booster circuit, then it is charged into (2) BATTERY r -~ ------ -COIL
the capacitor,
\r-=---+i
The signal from the pulse generator triggers the thyristor by
flowing the thyristor current from the control circuit.
,
...!...
When this occurs, the current charged in the capacitor flows
II
1
into the ignition coil primary circuit and the high tension cur-
rent flows from the secondary circuit to the spark plug (Fig. 3).
(101
PULSE =
(8) THYRISTOR PLUG
GENERATOR
Fig 4
After '87; 111 After '87;DC-C DI
This DC-C Ol system has the special system that the ignition
system is spark only when the engine is cranking by detecting
the alternator charging current.
(3) BOOSTER
CIRCUIT
(5) ALTERNATOR
22-4
TROUBLESHOOTING
Probable Cause
1 O. Test cylinder compression TOO l O W - - - - - - - - - - -__ • Valve stuck open

using a compression gauge Worn cylinder and piston rings
Leaking head gasket
NORMAL Improper valve timing
j Incorrect valve seat contact
11 . Check valve clearance INCORRECT--- - - -- - -_. Improper valve adjustment

Worn valve seat
CORRECT
I
12. Remove cylinder head cover VALVE TRAIN N O T - - - - - -_ Clogged oil passage
and inspect lubrication LUBRICATED PROPERLY Clogged oil filterl or oil filter screen
VALVE TRAIN LUBRICATED

PROPERLY
I
13. Check carburetor for clogging ClOGGEO-----------~•• Carburetor not serviced frequently
enough
NOT CLOGGED
POOR PERFORMANCE AT LOW AND IDLE SPEEDS

Probable Cause
1 . Check if air is leaking past LEAKING---- -- - - - _. Deteriorated insulator O-ring

carburetor insulator Loose carburetor
NOT LEAKING
I
2. Try spark test WEAK OR INTERMITTENT----~•• • Go to page 17-3
SPARK
GOOD SPARK
I
3. Check carburetor pilot screw INCQRRECT-- - - - - - -- -_. Improperly adjusted pilot screw
adjustment
CORRECT
I
4 . Check ignition timing and INCORRECT---------•• Improper valve clearance
valve clearance Improper ignition timing (Faulty COl
unit or pulse generator)
CORRECT
23-3
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEEDS

Probable Cause
, . Disconnect fuel tube at FUEL FLOW RESTAICTED-----•• • Lack of fuel in tank

carburetor Clogged fuel line
Clogged fuel tank cap breather
FUEL FLOWS FREELY hole/or tube
Clogged fuel v81ve
Faulty fuel pump/ or fuel cuI relay
J
2. Check ignition timing and INCORRECT----------_ •• • Improper valve clearance
valve clearance Faulty COl unit
faulty pulse generator
CORRECT Improper flywheel installation
I
3. Remove carburetor and CLOGGED----------- .. Clogged jets
check for clogged jet
NOT CLOGGED
I
4. Check valve timing INCORRECT----------_. Cam sprocket not installed properly
CORRECT
I
5. Check valve spring tension W E A K - - - - - - - - - - - - -•• faulty valve spring
NOT WEAKENED
POOR HANDLlNG----ch"k t;,e p'mu,.

Probable Cause
1. If steering is heavy----- - - - - -- -- - - - - - - - - -- - •• Steering stem nut too tight

Damaged steering lower stay bear-
ing
2. If either wheel is wo b bljng--------------------~•• Excessive wheel bearing play

Bent rim
Improperly inst alled wheel hub
Bent frame
Bent swingarm
3. If the vehicle pulls to one side - - - - - - - - - - - - - - - - - -_ •• Tire air pressure incorrect

Bent tie-rod
Incorrect tie-rod adjustment
Improper wheel alignment
Bent fra m e
23-4
23. TROUBLESHOOTI NG
ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH SPEEDS 23·4
HARD TO START 23· ' POOR HANDLING 23· 4
ENGINE LACKS POWER 23·2
POOR PERFORMANCE AT LOW
AND IDLE SPEEDS 23· 3
ENGINE DOES NOT START OR IS HARD TO START

Probable Cause
1. Check if fuel is getting to NO FUEL TO ---------~... No fuel in fuel tank

carburetor CARBURETOR Clogged fuel line or fuel filter
Clogged float valve
GETTING TO CARBURETOR Clogged fuel tank cap breather
hole /or tube
j
2. Try s park test WEAK OR NO SPAAK ------~.. •
Faulty fuel pump/or fuel cut relay
Go to page 17-3
GOOD SPARK
I
3. Test cylinder compression LOW COMPAESSION------~•• • low battery charge
Valve clearance too little
COMPRESSION NORMAL Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
Improper valve timing
4 . Start by following normal ENGINE STARTS BUT------~. · Starter valve stuck closed or
starting procedure SOON STOPS damaged
Faulty choke cable
ENGINE DOES NOT START Improperly adjusted pilot screw
Air leaking past carburetor insulator
Improper ignition timing (COl unit or
j pulse generator faulty )

Fuel/air mixture too lean
5. Remove spark plug WET PlUGi ----------~.. • Carburetor flooded

Starter valve stuck open or
damaged
T
Fuel/air mixture too rich
Air cleaner dirty
Improperly adjusted pilot screw
6. Start with choke applied
23-1
TROUBLESHOOTING
ENGINE LACKS POWER

Probable Cause
1. Raise wheels off ground and WHEEl DOES NOT SPIN •• Brake dragging
spin by hand FREELY Worn or damaged wheel bearing
Wheel bearing needs lubrication
WHEEL SPINS FREELY faulty final gear
j Faulty differential gear
2 . Check tire pressure with the gauge PRESSURE TOO LOW •• Punctured tire
Faulty tire valve
PRESSURE NORMAL
3. ChiCk for slipping clutch CLUTC H SLIPS •• Weak clutch spring

Worn clutch discs/ plates
NORMAL Warped clutch discs/ plates
t
4. Lightly accelerate engine ENGINE SPEED NOT •• Fuel/air mixture too rich or lean
INCREASED SUFFICIENTLY Clogged air cleaner
ENGINE SPEED INCREASED Restricted fuel line
Clogged fuel tank cap breather
holelor tube
Clogged muffler
5.RJo," 0;"""
check oil level
g.ug. "d OIL LEVEL INCORRECT •• Oil level too high
Oil level too low
Contaminated oil
CORRECT
j
6. Check if engine overheats OVERHEAT ED •• Excessive carbon build-up in com -
bustion chamber
NOT OVERHEATED Use of improper quality of fuel
I .
Clutch slipping
Fuel/ air mixture too lean
7 _ Accelerate or run at high speed ENGINE KNOCKS •• Worn piston and cylinder
Fuel/air mixture too lean
ENGINE DOES NOT KNOCK Use of improper grade of fuel
Excessive carbon build-up in com-
bustion chamber
Ignition timing too advanced
(Faulty COl unit or pulse generator]
8. Check ignition timing INCORRECT •• Faulty COl unit

Faulty pulse generator
CORRECT Improper flywheel installation
t
9. Remove spark plug FOULED OR DISCOLORED •• Plug not serviced frequently enough
Use of plug with improper heat
NOT FOULED OR range
DISCOLORED
23-2
24. INDEX
Air Cleaner Case ............................................. . 4-5 Accessory Light/Taill ight ................ . 20-4
Element ...................... . 3-4 Brake .... .. ....... .. 13-3
Alternator/Starter Clutch/Gearshift Linkage ......... , 0- 1 Front Differential Installation ............................. 15-13
Alternator ................................................ 10-6,17·5 Removal .............................................. . , 5-3
Charging Coil ........... ... ....... .......... .......... , 8-4 Front Fender ... 16-1
Battery/Charging System .... .......... .......... .......... 18-' Shock Absorber ... .. ................ 12- 19
Battery ....... ,.... ... ..... ..... .. 18-3 Wheel ...... 12 -7
Brakes ........... 13·' Front/Rear Bumpers ........................................ . , 6-1
Brake Fluid 3-7 Carriers (Foreman) ............ .................... . 16-7
Shoes ............ . 3-8 Fuel System . . . 4- 1
Shoes/Wheel Cylinder/Adjuster Filter ............ . 3-3
Assembly ... 13-8 Line ..................................................... . 3-3
System . 3-8 Pump ................................................... . 4 -4
Breather Tube . 3-5 Pump/Fuel Cut Relay ......... .. 20-8
Bumpers , Fenders, Carriers .............................. . 16- 1 Tank ............................ . 4-3
Cable & Harness Routing ................................. . 1-9 Unit/Meter (Foreman ) ............................ . 20-9
Camshaft Removal ......................................... . 7-5 Gearshift Linkage ............................................ . 10-10
Installation ............................................ . 7- 13 General Information ........................................ . 1-1
Carburetor Assembly ....................................... . 4 - 12 Safety .............................. ........... ........ . 1-1
Choke .................................................. . 3-4 Handlebar .............. ...... . ........ .... . 12·4
Disassembly .......................................... . 4-9 Switch ................................................. . 20-6
Idle Speed ............................................ . 3-7 Headlight ....................................................... . 20-3
Installation ................. 4- 14 High A ltitude Adjustment 4 ·16
Removal ..................... 4-8 Ignition System 17-1
Case Bearing And Oil Seal Replacement .... 15·8, , 5- 16 Coil 17-4
COl Unit System Inspection 17-4 Switch .. 20-6
Centrifugal Clutch 9-4 Timing .................................................. , 7·6
Change Clutch ... 9-8 Indicator Lamp ................................................ 20·4
Li f ter Mechanism ... 9-12 Kick Starter ........... ..................... .................... 9-20
Charging System ........ ......................... 18-4 Knuckle/Knuckle Holder/Drive Shaft 12-14
Clutch/Oil Pump/Kick Starter ............................. 9-1 Left Crankcase Cover Installation .. .. ... 10·13
Clutch System ................................................ 3-10 Removal ... 10-4
Cooling System ................ .. 6-1, 22-3 Ughts/Switches 20-1
Fan ... ........... .. .. .. ............... 6-3 LUbrication ..... 2- 1
Crankcase/Crankshaft/Transmission. 11-1 Points .. 2-4
Assembly. 11-13 Maintenance ... 3 -1
Separation ............................................ . 11-4 Schedule ... .. 3-2
Crankshaft/Balancer ........................................ . 11-5 Master Cylinder .. .. 13·11
Cylinder HeadlValves ..................................... . 7- 1 Model Identification 1 -2
Cylinder/Piston ............................................... . 8- 1 Neutral Switch/Reverse Switch 20-5
Cylinder. . ................................ . 8-2 Nuts. Bolts, Fasteners .................................... . 3-"
Compression ............. .. ...... .. 3-7 Oil Cooler/Oil H oses 6-2
Head Removal .............. . 7-6 Filter Screen 9-24
Assembly ............................................. . 7-11 Pump/Primary Drive Gear 9·16
Cover Assembly/lnstatiation .. . 7-' 5 Temperature Sensor ... 20-7
Cylinder Head Cover Removal/Disassembly 7-3 Output Gear ... l' -1 4
Installation 7-12 Pilot Screw Adjustment. 4 -16
DC-COl System (Foreman) .. .. 22-4 Pinion Gear Installation .................................. .. 15-9
Differential ............................................... . 22-1 Removal ............................................... . 15-7
Differential/Final Drive Oil ................................ . 2-3 Piston ....................................... ................... . . 8-3
Engine Removel/lnstallation .............................. . 5- 1 Piston/Cylinder Installation 8-4
Installation . .. .. ..... ..... . 5-7 Pulse Generator .. , 7-5
Engine Oil & Filter Change .................... .. 2-2 Rear Wheel/Suspension. 14- 1
Level .... 2-2 Axle/Wheel Bearings .. 14-4
Engine Removal ............... .. 5-3 Brake ..... .............................................. . 13-13
Fan Motor Control Unit ......... .. 20-7 Brake Pedal .......................................... . 13·18
16-4
g
Final Drive Assembly .. . , 5-'7 Fender ...... ... ......... .............................. .
Disassembly .... . 15-' 3 Shock Absorber ..................................... . 14-7
Installation ........................ . 15-22 Wheel .. 14-3
Removal ................................................ 15-' 3 Regulator/ Rectifier .. ......... ... . . 18-4
Front Differential/ Final Drive 15-' Reverse Lock Mechanism ................................ . 9-'6
Front Wheel/Suspension/Steering ............. ... 12- 1 System ............................ .... . 3-10
24-1
INDEX
Right Crankcase Cover Bearing/Oil Seall Lubricati on ......................... . 2~ 1

Follower Cam ............... . 9-14 Rear Wheel/Suspension ...... . 14- 2
Installation . 9-24 Starter System ............................ .. 19-2
Removal 9~3 Valve Clearance 3~5
Service Information Guide Replacement ....................... ....... .. 7~B
Alternator/Starter Clutch/Gearshift Seat Inspection/Refacing ................. .. . .. .. . 7~9
Linkage.. . .................................. . 10-1 Wheels/Tires ......................... . 3-12

Battery/Charging System. 18- 1 Wiring Diagrams ....... .. ..... .. .. .. .. ... .. .. ..... .. .. ....... . 21·'
Brakes .. . .............................. . 13-1
Clutch/Oil Pump/Kick Starter ........ . 9~1
Cooling System ................. . 6~ 1
Crankcase/CrankshaftfT fa nsmission 11-1

Cylinder HeadlValves ..... 7~ 1
Cylinder/Piston .... B~ 1
Engine Removal/Installation ..................... . 5~2
Front Differential/Final Drive .................... . 15~ t

Front Wheel/Suspension/Steering ... . 12-2
Fuel System ................... , ....... . 4~ 1
Ignition System .............. . 17-2

Lights/ Switches .................. . 20-1
Lubrication 2~ 1
Maintenance . ................... 3·'

Rear Wheel/Suspension ........ ...........'4-'
Starter System ....................... 1 9-'
Service Rules ................................... 1- 1
Skid Plate. Guard Plate IAfter '86:) .................... 3·13
Spark Arrester Cleaning ........................ ........... 3- 1 1
Plug ..................................... 3-5
Specifications ......................... ' -3
Starter System ............ .......................... 19- 1
Clutch .......................................... 10-8
Motor .................................................. . 19-3
Reduction Gear ................... . 10-2
Relay Switch ... 19-6
Steering Shaft Holder Bearing .......... ................. 3-'2
Stem ... .. .................................... 12·25
System .......................................... 3·1 2
Suspension ... .......................................... 3-11
Swingarm .............................................. 12·21. , 4-9
System Diagram ........................... .... 17-0, 18-0. , 9-0
Technical Features ............................... 22-'
Throttle Housing ... .. ............... .. 12-6
Operation .......................... . 3~3
Tie Rod ................................ ..... ................ . 12- 12
Tires ......................................................... . 12-8
Tools ....................................................... . 1 ~7
Torque Values ............................ . 1 ~5
Transmission ................. .. 11·8
Troubleshooting
Alternator/ Starter Clutch/Gearshift
Linkage ......... ...................................... . 10·'
Battery/ Charging System .............. . 18-2
Brakes. .. ................. . 13-2
Clutch/Oil Pump/Kick Starter .................. .. 9~2
Crankcase/ Cran kshaft/T r ansm ission 1 t -3
Cylinder HeadIValves... . ................... .. 7~2
Cylinder/Piston... . ... ....... ................... . B~ 1
Front Differential/Final Drive ........ .. '5·2

Front Wheel/Suspension/ Steering 12-3
Fuel System ................................... . 4 ~2
Ignition System . 17-3
Lights/Switches. 20-2
24-2 13021

10258826-Honda Fourtrax 350 Service Manual Repair 1986-1987 Trx350

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10258826-Honda Fourtrax 350 Service Manual Repair 1986-1987 Trx350

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...

If you don't know the sou rce of the trouble.

BUMPERS, FENDERS, CARRIERS

-' BATTERY/ CHARGING SYSTEM

(5) The carburetor identification number is on the left side

DRIVE TRAIN Clutch Wet multi-plate, semi-automatic

STANDARD TORQUE VALUES

5 mm bolt, nut 4.5 - 6 (0.45-0.6, 3-4) 5 mm screw 3 .5-5 (0.35 - 0.5, 2 - 41

DESCRIPTION TOOL NUMBER ALTERNATE TOOL REF. SEC.

DESCRIPTION TOOL NUMBER ALTERNATE TOOL REF. SEC.

Pinion holder 07924-HAOODOO Must be modified pinion holder (4) 15

DESCRIPTION TOOL NUMBER ALTERNATE TOOL REF. SEC.

Valve adjusting wrench, lax 12 mm 07708 - 0030200 or equivalent commercailly available 3

CABLE & HARNESS ROUTING

• A loose wire, harness or cable can be a safety hazard. After

• Secure wires and wire harnesses to the frame with their

• Route harnesses so they afe neither pulled taut nor have

• Protect wires and harnesses with electrical tape or tubing if

• Do not use a wire or harness with a broken insulation.

• Keep wire harnesses away from the exhaust pipes and

• Be sure grommets are seated in their grooves properly.

• After clamping, check each harness to be certain that it

• Do not bend or twist control cables.

j 1) FRONT BRI'~E HOSE BRAKE CABLE

(14) IGNITION '"",TCH-

) fAN MOTOR CONTROL UNIT

(101 BRAKE HOSE

(22) IGNITION COIL AFTER '86 :

(21) FAN MOTOR CONTROL UNIT

(3) BREATHER TUBES

(5) REAR BRAKE

(12) REAR BRAKE

'86, '87: After ' S7: (8 ) IGNITION SWITCH

(1) ALTERNATOR WIRE

(3) CABLE CLlP

(131 CABLE GROUND

(12) BRAKE PEI)AL

(16) STARTER MOTOR

111) cor'NECn)R BOX

(2Q) REGULA TORI

(1) FUEL CAP

(6) CARBURETOR BRIEA'rHER TUBE

(12) CR,'NK:CASE (11) CA"BU 'RETOF no) DRIVE

(2) REAR BRAKE

~~====::1:7) AEAR BRAKE BREATHER TUBE

FUEL UNIT WIRE

(1) COOLING FAN

(6) Aher '87:

lS) FUSE CASE

(12) STARTER RELAY

(3) Oil COOLER

(1) OIL FILTER SCREEN

• Refer to section 6 for oil cooter and cooling fan services .

Engine oil recommendation Use Honda 4-stroke oil or equivalent.

Other viscosities shown in the chart may be

Engine oil drain bolt '86, '87: 15 ~ 25Nom(1.5 ~ 2 . 5kg-m, 11 ~ 18ft-lbl

ENGINE OIL LEVEL

ENGINE OIL & FILTER CHANGE

Remove the oil filler cap and drain bolt.

Fill the crankcase with re commended oil (page 2-')'

Install the oil filler cap/dipstick.

DIFFERENTIAL/ FINAL DRIVE OIL

Place the vehicle on level surface.