Honda Cb900 F Hornet 02-03 Service Manual Eng by Mosue

A Few Words About Safety Service Information ‘The service and repair information contained in this manual is intended for use by qualified, professional technicians. Atempting service or repairs without the proper training, tools, and equipment could cause injury to you oF others. It could also damage the vehicle or create an unsafe condition « ‘This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some proce: dures require the use of specially designed tools and dedicated equioment. Any person whe intends to use a replacement pert, service procedure or a too! that is not recommended by Honda, must determine the risks to their personel safety and the safe operation of the vehicle. Ifyou need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly reo: ‘ommend that you do not use replacement parts of inferior quality. q For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others, A WARNING Improper service or repairs can create an unsafe condition that can cause your customer or others « to be seriously hurt or killed For Your Safety Because this menual is intended for the professional service techri- cian, we do not provide warnings about many basic shop safety prac- tices (e.9., Hot parts — wear gloves). If you have not received shop sefety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Follow the procedures and precautions in this manual and athor service materials caroiully A WARNING Failure to properly follow instructions and precau- tlons can cause you to be seriously hurt or killed. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable haz- ard that can arise in performing service and repair procedures. Only | Follow the procedures and precautions in this you can decide whether or not you should perform a given task. manual carefully. Important Safety Precautions using safety equipmant. When performing any service task, be especially careful of the following: + Read all of the instructions before you begin, and make sure you have the tools, the replacement or repsir parts, and the skills required to perform the tasks safely and completely. + Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dril, grind, pry or work ‘around pressurized air or liquide, and eprings or othor stored-onergy components. if there ie any doubt, put on eye protection, + Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cute, Before you grab something that looks like it can hurt you, stop and put on gloves. + Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the veticle, either with a hoist or 2 jack, make sure that itis always securely supported. Use jack stands. ‘Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: + Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. + Burns from hot perts or coolant, Let the engine and exhaust system cool before working in those areas. + Injury from moving part. the instruction ts you to run the engine, be sure your hands, ingers and cating are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibilty of a fire or explosion, be careful when working around gasoline or batteries. + Use only @ nonflammable solvent, not gasoline, to clean parts. + Never drain or store gasoline in an open container. ¢ + Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts,HOW TO USE THIS MANUAL ‘This srvice manual dsoribes the sence procedures forthe CBBO0E Follow he Maintenance Schedule (Sesion 2) recommendations to ensure that the vice is in peak operatng contin Prrforming te frst scheauled maintennce is very important. It compen Sictins 1 and apy tothe hola matorevela. Stton 2 illustrates orcs Aires fer removalistalision of companeats that may be required 1 be. form eevee cesribed in he folowing sens. Steins # though 18 describe parts ef the motoreee, grouped according Fd the section youwant this page then turn othe ble ofcontets on "Nos sections start wth an asserbiy or system ilustraton sane indore tin and teuseshooting for the Section. "The tubservent pages give talc procedure Hf you don't know the sour of the trouble, go to section 22, ‘Your safety, and the safy of thers. s vervimpotant. To helpyou make ‘maton thoughout this manus Of couree isnt prota! or possible ‘You must use you! own goad judgement. ‘You fingimporant ser information i 8 vary offormieluting +"Setey Latte on the venice + Setey Messages ~ preceded by a safety let symbol A. and or of ‘Thee signal words mean FREE 3. son iow instructions POE en egasmmssrions + Inswetions how to serves this ohci corey and safely ‘you ead this manual, you vl ie inermatin {oTeE, symbol. Te purpose ofthis message Your vesicle ater propery rte environment. is prceded by 9 revert damage 10 ‘ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS ‘AND SPECIFICATIONS INCLUDED IN THIS PUBLICA- ‘TION ARE BASED ON THE LATEST PRODUCT INFOR- MATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH. OUT NOTICE AND WITHOUT INCURRING ANY ‘OBLIGATION WHATEVER, NO PART OF THIS PUBLI- CATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PER- ‘SONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, CONTENTS GENERAL INFORMATION & ] ERAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE Ei LUBRICATION SYSTEM £ 7 {Sfeqsanened Fuel injection & [coounssrsrem [enanerenovauinstauanion J [_AremvaronsTarren cure AU) CRANKCASE/TRANSMISSION j47 a 14 HYDRAULIC BRAKE ENGINE AND DRIVE TRAIN HASSIS | BATTERY/CHARGING SYSTEM IGNITION SYSTEM [17 ELECTRIC STARTER 118 LIGHTS/METERS/SWITCHES [19 ELECTRICAL MOTOR SCOOTERS OR ATVS. Honda Motor Co. Ltd. ‘SERVICE PUBLICATION OFFICE Date of esue: December 2007 © Honda Motor Co., Lt. WIRING DIAGRAMS Ey ‘TROUBLESHOOTING ElSYMBOLS ‘The symbo's used throughout this manual show specific service procedures. If supplementary information is required par- taining to these symbols, it will be explained specifically in the text without the use of the symbols. Replace the partis) with new one(s) before assembly. hid a ® Use the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent Use molybdenum disulfide grease (containing more than 3% malyadenum disulfide, NUGI #2 or equivalent. Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A Multi-purpose I4-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide peste (containing more than 40% molyodenum disullide, NLGI #2 or ‘equivalent. Example: Molylote® G-n Paste manufactured by Dow Corning U.S.A Honda Moly 60(U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use sifcone grease. Apply @ locking agent. Use a medium strength locking agent unless otherwise specified, Apply Use DOT 4 brake fluid. Use the recommanded brake fluid unless otherwise sp feeeh bd Use fork or suspension fluid.1. GENERAL INFORMATION SERVICE RULES 1 LUBRICATION & SEAL POINTS 118 MODEL IDENTIFICATION 12 CABLE & HARNESS ROUTING 1:22 A ‘SPECIFICATIONS 13 EMISSION CONTROL SYSTEMS 1-35 TORQUE VALUES 1-12 EMISSION CONTROL INFORMATION TOOLS 1-17 LABELS 1-38 SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don’t meet Honds's design specifications may cause damage to the motorcycle. 2, Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with Enalish fasteners, 4. Install new gaskets, O-rings, cotter pins, and lork plates when reassembling. 5. When tightening bolts or nuts, begin with the larger digmeter or inner bok first. Then tighten to the specified torque diagonally in incremental stops unless a particular eaquence ie epecified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces betore reassembly, ymaly, check all parte for proper installation and operation. lecrical wires as shown on pages 1-22 through 1-32, Cable and Harness Routing, 1-1GENERAL INFORMATION MODEL IDENTIFICATION VEHICLE IDENTIFIVATION NUMBER (VIN) The Vehicle Identification Number (VIN) is located Con the left side of the frame near the steering head. \/t/ Ae (Gy ENGINE SERIAL NUMBER ‘Tho engine serial number is stamped on the right side of the upper crankcase. ‘The frame serial numberis stamped on the right si cf the steering head, THROTTLE BODY IDENTIFICATION NUMBER ‘COLOR LABEL The throttle body identification number is stamped. onthe intake side of the throttle body as shown. ‘The color labelis attached as shown. When orderi color-coded perts, always specity the designated color code.GENERAL INFORMATION SPECIFICATIONS > GENERAL DIMENSIONS: FRAME ENGINE Tem ‘Overail length ‘Overall width ‘Overall neight Wheelbase ‘Seat height Footpeg height Ground clearance Dry weight Except Californie type) California type Curb weight Except Californie type! California type Maximum weight eapscity Frame type Front suspension Front axle travel Rear suspension Rear axle travel Front tire size Rear tire size Front tie brand Roar tire brand Front brake Rear brake Caster angle Trail length Fuel tank capacity Cylinder arrangement Bore and etroke Displacement Compression ratio Valve train Intake valve opens —-—at 1 mm closes—| (0.04 in) lit Exnaust valve opens closes Lubrication system Oil pump type Cooling system Aicfiltration Engine dry weight Firing order SPECIFICATIONS. 2128 mm 168.7 in) 750 mm (285 in) 4,085 mm (42.7 in) 1,460 mm (657.5 in) 795 mm {31.3 in) 345 mm (136 in) 445 mm (6. in} 194 kg (428 Ibs) 185 kg (430 Ibs) 218 ka (481 Ibs) 219 kg (483 Ibs) 174 kg (384 Ibs) Diamond Telescopic fork 109 mm (4.3 in) ‘Swingarm 4128 mm (4,7 ind 120/70 ZR 17 (SEW), 120/70 ZR 17 NIC (58W) 180/85 2R 17 (73W), 180/85 ZR 17 NUC (73W) BTSGF RADIAL N (Bridgestone) “TXA5 (Michatin) BTSBR RADIAL G (Bridgestone) “TXQS (Michelin) Hydraulic double diss Hydraulic single dise 25° 98 mm (3.9in) 19.0 liter (502 US gal, 4.18 Imp gal) 4 cylinders in-line, inclined 30' from vertical 71.0 X.58.0 mm (2.80 X 228 in) 919 cm? (56.1 curin) 08:1 Chain driven, DOHC. 10° BTDC 30° ABDC 35° BBOC B'ATOC Forced pressure and wet sump Trochoid Liquid cooled Paper element 68 kg (150 lbs) 4224-3 | 1-3GENERAL INFORMATION GENERAL (Cont'd) Tem ‘CARBURATION | Type Throttle bore DRIVE TRAIN | Clutch system Transmission Primary reduction Final reduction Gear ratio Gearshitt pattern ELECTRICAL | Ignition system Starting system Charging system Lighting system SPECIFICATIONS Rogulator/recttier Clutch oporation syste | PGM-Fi (Programmed Fu Injection? 36mm (1.4in) Multi-plate, wet Coble operating Constant mesh, 6-speeds 1.52 (76/50) 2.888 (43/16) 2.788 (36/13) 2.000 (26/13) 1.600 (24/16) 1.368 (26/19) 1.227 (27/22) 1.130 (26/23) Left foot operated return system, 1-N-2-3- 4-5-6 ‘Compucer-controted digital transistorized with elecvic advance Electric starter motor Triple phase output alternator SCR shorteditriple phase, full wave rectification BatteryGENERAL INFORMATION y LUBRICATION SYSTEM Unit: mm (in) Engine oll eapacity filter change isassembly 3.5 liter (8.7 US at, 3.1 Imp ath I STANDARD SERVICE LIMIT liter (88 US gt, 32 Imp gt (4.6 US at, 39 Imp at) Recommended engine oil il pressure at oll pressure switch Gil pump rotor Tip clearance Pro Honda GN4 or HP4 (without molybdenum additives) 4stroke oll [USA & Canada), or Honda 4-stroke oil (Canada only), ‘or an equivalent motor oll API service classification SG or Higher ‘except oils labeled as energy conserving ‘on the API service label. JASO 7903 standard MA Viscosity: SAE 100-40 a (5.0 kaflem?, 71 psi) at 0 min feprny(BOTG/T76F) 0.15 (0.006) 0.20 (0.008) Body clearance Side clearance | FUEL SYSTEM (Programmed Fuel Injection) Idle speed he TEM ‘SPECIFICATIONS Throttle body identifcation | Except California type Gasac number California typ Go348 Starter valve vacuum differance — 2664 Pa (20 mm Ha) Base throttie valve for synchronization No2 4,200 = 100 min* (rpm) Tarote grip tree play 2-4 mm (1/16 -3/16 in) Cam pulse generator peak voltage (at 20°C/68'F) intake air temperature sensor resistance (at 20°088F) 14k Engine coolant temperature sensor resistance lat 20°C/68F) 23-26 ki Fuel injector resistance (at 20C/68F) 11.1-12.39 PAIR solenoi Ive resistance (at 20°C/68°F) "| 20-249 0.7 V minimum Fel pressure ate 0.7 minimum 7200-250 mm Hg ‘949 kPa (9.5 kgf/em’, 50 psi) Fuel pump flow (at 12 V)_ £256 cm (8.7 US oz, 9. Imp 02) minimum/10 seconds. 1-5GENERAL INFORMATION ; COOLING SvSTEM TEM | Radiator and engine Reserve tank : relief pressure Begin to open Fully open | Valve tit | Coolant capacity Radiator ca Thermostat Recommended antifreeze ‘Standard coolant concentration SPECIFICATIONS Biter (9.98 US a, 282 Imp liter 1.95 US gt 70 Imp a 108-197 kPa(1.1 = 1.tkafem?, 16-20 ps 064°C (176189 7) 35 G0 8 rm (0.3 in) minimum Pro Honda Coolant or an equivalent high quality ethylene aly: col antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines 50 - 50% mixture with soft water Unit: mm (in) - CYLINDER HEAD/VALVES Tem ‘STANDARD SERVICE LIMIT Teresa areen 7.276 kPa (130 kalem? 185 psi = ‘at 350 min (rpm) Vave clearance IN | 0.16 0.03 (0.008 + 0.001) = “EX | 0.25 + 0.03 (0010 + 0.001) — Camshaft | Camlobe height IN | 36,040 ~ 36.280 (1.419 - 1.428) 36.01 (1.42), EX | 35.800 ~ 36,040 (1.409 - 1.419) 3571.41) | Aunout ex — 0.05 (0.002), Oil clearance (0.020 ~ 0.062 (0.008 - 0.0028) 0.10 (0.004) Valve Valve liter 0.0. 25,978 — 25.983 (1.0228 - 1.0233) 25.97 (1.022) Valve lifter bore I.D. | 26.070 - 26.026 (1.0240 - 1.0246) 26.04 (1.025) Vawve, Valve stem 0.0. IN | 4.475 - 4400 (0.1762 -0.1768) 4465 (0.1758) pare oie EX | 4.465 ~ 4.480 (0.1758 - 0.1764) 4.455 00.1784) | | Valve guide 1.0. INEX | 4.500 - 4512 (0.1772 - 0.1776) 4540 (0.1787) ‘Stem-to-guide clearance IN | 0.010 - 0.037 (0.0004 - 0.0015) [0075 (0.0030) | Ex | 0.020 - 0.047 (0.0008 ~ 0.0019) [0.085 (0.0023) | | Valve guide projection above | IN| 145-147 (057 -0.58) t _— | evlinder head EX | 148- 15.0 (0.58 0.59) valve seat wickh INEX | 0.90~ 1,10 (0.035 - 0,043) 1.5 (0.08) Valve spring free length IN| 4091160 ‘40,08 (1.578) ex | 409/161) [40.08 (1.578) Cylinder heed warpage = [0.10 (0004)GENERAL INFORMATION Starter driven gear bossO.D. 151.699 51.718 [2.0354 - 2.0361) > CLUTCH/GEARSHIFT LINKAGE Moe mn i rem STANDARD SERVICE LIMIT ‘Clutch lever free play —_ [10-20 (ae 1416) = Guteh Spring free length | 46.8 (192) 7508) Disethiciness | 292-3.08 (0115-0121) 2.6 (0.10) | [eevee pe 020 (0018) Clute outer guide 1D. 24.994 250004 (0.9840 - 0.9844) 25,01 (0.985) 0D. 34.975 34991 (1.3770 - 1.3776) 34.97 (1.377) | Mainshaft 0.D. at clutch outer guide 24.980 - 24.993 (0.9835 - 0.9840) 24,95 (0.983) | Shiftfork, | LD. 42,000 12.021 (0.4724 — 0.4733) [2.03 (0.74) ‘fork ehan Claw thickness 5.93 ~ 6.00 (0.233- 0.236) 5.9 (0.23) | ‘Shift fork shaft O.D. [11.957 - 11.968 (0.4707 ~ 0.4712) 11.95 (0.870) Unit mem Gn) > ALTERNATOR/STARTER CLUTCH TEM STANDARD SERVICE LiMrr 51.684 (2.0348) ; CRANKCASE/PISTON/CYLINDER Unit: men fin) Piston 0.D. measurement point rem STANDARD SERVICE Liarr vlinder AD, 71000-71016 2.7953 ~2.7963) 71.10 2796) - - 10.10 (0.004) lerpage _ | 0.08 (0.002) | Fiston, piston _Platon mark direction ke C sings Piston 0.0. 70.965 - 70985 (2.7989 - 2.7847) 7080 (278%) 15 mm (0.6 in) from bottom of skirt Connecting rod-to-piston pin clearance I Crankpin oll clearance I Pieton pin bore 1D. 17.002 17008 0.6694 0.6886) 1763 10870) iston pin OD. 16.993 17.000 (0.6630 ~ 0.6683) 16.98 (0.869) Piston piston pin cance | 1002 - 0.015 (00001 - 06006) —= Piston sing-to-ing | Top 0.990 - 0.086 (00012 - 0.0026) 0.08 (0.008) arooveclesrance Second 0015 0.045 (00006-00018) ~~ [ Piston ing end gop |Top 028-028 (0011-0015) —~=~S*«i 0.02 Second "| 0.40 ~ 0.55 (0.018 ~ 0.022) 0.7 0.03) | Oil ‘side rai) (02-07 (001 -9.03) 0810.08 | to-piston clearance 7 0.015 ~ 0.050 (0.0006 - 0.0020) __| _ Conreting rod small erd 1.0. 17.016 - 17084 (0.6699 - 0.6706) 17.08 (0871) 0.016 - 0.041 (0.0006 - 0.0016) 0.030 - 0.082 (0.0012 - 0.0020) 0.06 (0.002)GENERAL INFORMATION a _ CRANKSHAFT/TRANSMISSION one neniny Tem STANDARD SERVICE LMT Crankshaft Side clearance 10.08 ~ 0.20 (0.002 - 0.008) | 0.30 (0.012) Runout — 0.30(0012) | Main journal oil clearance 0.017 - 0.035 (0.0007 — 0.0014) 0.04 (0.002) Transmission GearlD. | MB, MB 28,000 28.021 (1.1024 1.1032) 28.04 (1.104) cr | 24,000 ~ 24.021 (0.9449 - 0.9547) 2404 (0.946) (02.3.4 | 31.000-31.025 (12205-12215) «31.04 11.2221 RaneUn 27.959 ~ 77.960 (1.1007 - 1.1016) 27.96 (1.100) 30,985 ~ 30.980 (1.2187 - 1.2197) ‘093 (1.216) [30.950 — 30.975 (1.2185 — 1.2195) 9093 (1.218) Bushing 1D. 24.965 26.008 (0.9857 - 0.9945) 2802 (0.985) 27.985 ~ 28.006 (1.1018 - 1.1026) 2802 (1.103) Geato-bushing 01020-0062 1 foo (0008) ceeraree ~ | 0.11 (0.004) 0.025 - 0.975 (0.0010 - 0.11 (0.004) | Mainshaft OD. 2496 (0.983) | [Clutch outer guide | 24.980 24.999 (08635- 0.8640) 2496 (0.983) Counterheft 0.0." 2 [anger = 27.960 (1.1011 1.1016) 2788 200 Bushing-to-shaft M5. 0.008 — 0.039 (0.0002 - 0.0015) | 0.08 (0.003) clesieres a “| 0.006 — 0.039 (0.0002 - 0.0015) (0.08 (0.003)GENERAL INFORMATION Wheel balance weight ~ FRONT WHEEL/SUSPENSION/STEERING pet TEM STANDARD ‘SERVICE LIMIT Minimum tio Weed depth = 15 (008) Cold tire pressure | Driver ‘only a 250 kPa (2.50 kgf/cm’, 36 psi) —_— Diver and passenger 250 KPa (2.50 kgtlen?, 36 psi = Tele ranot 2 021000 Wheel im ranout | Radia = 2.0(0.08) axial 2.00.0 609 (2102) max Weal lanes aol ve hala Fork Spring free length 6.7 (10.89) Tube runout ~ | 0.20 (0.008) | Recommended frk full Bro Honda Suspension Fuld S58 = Fluid level 155 (6.1) = | Fluid capacity 463 = 25 om? (15.7 = 0.08 US 02, —— _ 16.30.03 Imo) Steering head bearing pre-load 110 =15 Nem (1.01.5 koh > REAR WHEEL/SUSPENSION ts STANDARD SERVICE LIMIT = 2.00.08) [oaks preccure | Goran 280 Pa (290 igen? 4 pil = [ovivar and pesonger [2201re 220 Kgten!. BATTERY/CHARGING SYSTEM — ITEM | capa ‘Current leakage Battery SPECIFICATIONS 12-86 Ah 1.2 mA max. Votage 20687) | Fully charged 13 |_Needs charging 32 Below 12.30 1ZA5- 10h 50ATh [0:38 kW25,000 min” (rpen) 01-108 Spark plug NGK SPECIFICATIONS. (CRAEH-9 (Standaré) / CR9EH-9 (For high speed running) ‘Spark plug gap Ignition coil peak voltage Ignition pulse generator peak voltage Ignition timing (“F* mark) U24FERS (Standard) / U27FERS (For high running| 8 mm (0.03, 100 V minimum 0.7 minimum 8 BTOCat idle 1-10GENERAL INFORMATION voltage 80 120°C ECT sensor resistration = - ELECTRIC STARTER Une oat et TEM STANDARD SERVICE LMT toe aaa aes Tasexe - LIGHTS/METERS/SWITCHES TEM SPECIFICATIONS | Bubs Headlight | Hi 12V-60 W Lo 1V-55W Brake/tail light - 12V- 215 WX2 Turn signal ight Front av -2978 W X2 eer ~ tav-2sw License ih 12-5 instrument ight TaV-1.7 WX8 Tt T2V-1.7WX2 - ——! LED LED Oil pressure indicator - ‘LED PGM-Fl warning indicator - LeD Fas aban Tpcaoe c 60 Fuse Main fuse 7 30A POMFlfuse 20A [Sub fuse 20AX1, 10AX4 108 V minimum 21-262 a2 076k 1-11GENERAL INFORMATION ee TORQUE VALUES ToRQUE TORQUE FASTENER TYPE Num (hehe BAAD FASTENER TYPE Nem (kgf, Ib) ' mm hex bolt and nut 3105, 36) Smmserew 4(0.4,29) 6 mm hex bolt and nut 1011.0,7) | Smmscrew 9(0.9,65) 8 mm hex boll and nut 22,22, 18) Ommfange bolt mm nese, 1011.0, 7) 10mm hex bolt and nut 34135, 25) small flange) 12mm hex bolt and nut 54165, 40) mmm flange bolt (mm head, 12102,8) large flange) ‘Smmflange bolt (10 mm head) and nut 12(1.2,9) ‘8mm flange bolt and nut 26 (27,20) 10 mm flange bolt and nut 39 (40,29) + Torque specifications listed below are for important fasteners. * Others should be tiahtaned to standara torque values listed above, NOTES: 1. Apply sealant tothe threads 2. Applya locking agent tothe threads. 2. Stak. 4. Apply oil tothe threads and flange surface. 5. Unut 6. ALOC boltiscrew: replace with a new one. 7. Apply grease to the thresds, 8. Apply molybdenum disulfide oil tothe threads and seating surface 8. cr bot y ENGINE 7 THREAD TORQUE shed OTF |_DIA. mm) Nem (kam, tee) REMARKS MAINTENANCE: —f Spark plug 4 10 12(1.2.9) “Timing hole cap 1 45 18(1.8,13) —-NOTET Engine oil fiterearvidge 1 20 26(27,20) NOTES LUBRICATION sySTEM: | Cil main gallery sealing bott 20mm) 1 20 29(3.0,22) NOTE2 pump cover bolt 1 6 8108,58) NOTES Cooler bot filter boss) 1 2 64(65,47) NOTES FUEL SYSTEM (Programmed Fuel Injection): ECT (Engine Coolant Tempersturelthermo sensor 1 oy 23(23,17) Throtte body insulator band serew 8 5 ‘See page 1-14 Starter valve lock nut 4 10 200.18.1.3) Starter valve cable stay screw 4 3 1.008, 07) Pressure regulator mounting hott 2 6 10(1.0,7) COOLING SYSTEM: ‘Vater pump cover fange bolt 2 ‘ 12012,0) NOTES ENGINE MOUNTIN Drive sprocket special bolt 1 10 5416.5, 40) 1-12y ENGINE (Cont'd) GENERAL INFORMATION THREAD ‘TORQUE neEM QTY DIA. mm) Nem (kgfrm, tbttt) | REMARKS ‘CYLINDER HEAD/VALVES: Cylinder head mounting bolwasher 10 3 49(4.9,35) | NOTES Camshaft holder flange bolt 20 6 121.2.) NOTE 4 Cylinder head cover bolt 6 6 10.0.7) Breather plate flange bolt 3 6 12(1.2,9) NOTE 2,9 PAIR reed valve cover SH bolt a 6 121129) NOTE 9 Cam sprocket flange bolt 4 7 20(2.0,14) | NOTE2 Cam pulee goneretor rotor flange bolt 2 6 12.(1.2,9) NoTE 2 Cylinder head stud bolt (exhaust pipe stud bolt) 8 8 See page 1-14 (LUTCH/GEARSHIFT LINKAGE: Clutch center lock nut 1 2 128 (131,95) | NOTE 3,4 Clutch spring dott 5 6 1211.29) Oil pump driven sprocket bolt 1 6 15(1.5,11) | NOTE2 Shift drum center socket bolt 1 8 23(2.3,17) | NOTE2 Shift drum stopper arm pivot bolt 1 6 32(1.2.9) Gearshift spindle return spring 1 8 22(2.2, 16) | ALTERNATOR/STARTER CLUTCH: Altemator stator socket bolt 4 6 mn2s | Starter clutch outer socket bolt 6 8 16(1.6,12) | NoTE2 Flywheel flange bolt 1 10 103(105, 76) | NOTE 4 Starter wire clamp flange bolt 1 6 10(1.0,7) NOTE 9 (CRANKCASE/TRANSMISSION: ‘Mainshatt bearing set plate bolt 2 6 12(0.2.9) Nore 2 Gearshift drum bearingjfork shaft set bolt 2 6 3211.2.) NOTE 2 Crankcase bolt (Main journal) 10 8 27(28,20) | NOTES Crankcase bot 1 10 39.4.0, 28) Grankcase bolt 4 6 721.2.) Crankcase bok 2 8 2412.4, 17) (CRANKSHAFT/PISTON/CYLINDER: ‘Connecting rod nut a 8 34(3.5,25) | NOTEA IGNITION SYSTEI Ignition pulse generator rotor cover bolt 6 ® son | Ignition pulse generator rotor special bolt 1 10 59(6.0,43) | ELECTRIC STARTER, Starter motor terminal nut 1 6 w29 | UGHTS/METERS/SWITCHES: Oil pressure switch 1 Pr 18 121.2.) NoTE1 Oil pressure switch wire terminal boltwasher 1 4 20.2, 1.4) Neutral switch 1 40 1211.29) 1-13GENERAL INFORMATION Ineulstor clamp (Throttle body side): 721mm (03 + 0.06 in) > <+ Insulator clamp (Cylinder head side): 7£ 11mm (0.3 + 0.04 in) Exhaust pipe stud bolt: 42.5 = 05 mm (1.67 = 0.02 in} 1-14FRAME GENERAL INFORMATION eM FRAME BODY PANELS/EXHAUST SYSTEM: Exheust pipe joint flange nut Exhaust pipe mounting nut Muffler mounting flange bolt Mufler band flange boit FUEL SYSTEM [Programmed Fuel Injection); Fuel tube banjo bolt (fuel tank side) Fuel tube sealing nut (throttle body side) Fuel pump mounting nut FUEL PUMP - Bae gl fo =I Ve \ COOLING SYSTEM: Cooling fan mounting nut Fan motor mounting nut ENGINE MOUNTING: Front engine hanger boltinut Rear upper engine hanger boltnut Rear lower engine hanger boltinut Gear shift linkage bolt FRONT WHEEL/SUSPENSION/STEERING: Handlebar weight mounting screw Front brake disc bolt Front axle bolt Front axle holder flange bolt Front brake hose clamp flange bolt (left front) Front brake hose clamp flange bolt (right front) Fork socket bolt Fork bolt Fork top bridge pinch socket bolt Fork botiom bridge pinch flange bolt Steering bearing adjusting nut Steering beating adjusting nut lock nut Steering stem nut Front brake hose clamp bolt (steering stem) ‘THREAD DIA. (mm) 2 10 10 @gaaeazoo TORQUE [Nem (kgf+m, IDF) 20 (2.0, 14) 27 (2.8, 20) 27 (2.8, 20) 27 (2.8, 20) 22 (2.2, 16) 22 (2.2, 16) 1211.2, 9) 3027, 20) 5 (05,36) 50 (6.1, 37) 50 (5.1, 37), 50 (6.1, 37), 2012.0,14) 10(1.0,7) 20 12.0, 14) 59 (6.0, 43) 22 12.2, 16) 12(1.2,9) 12112.9) 2012.0, 14), 222.2, 16) 222.2, 16) 39 (4.0, 29) 25 2.5, 18) 103 (10.5, 76) 10(1.0,7) REMARKS NOTE 2 ‘See page 7-10 NOTE 6 NOTE 6 NOTE 2 Seepage 13-23 1-15GENERAL INFORMATION FRAME (Cont'd) rem REAR WHEEL/SUSPENSION: Rear brake diss bolt Final driven sprocket nut Rear axle nut Rear shock absorber upper mounting bolt Roar shock absorber upper mounting nut Drive chain slider flange bolt Swingarm pivot nut HYDRAULIC BRAKE: Front master cylinder reservoir cep screw Front brake lever pivot bolt Front brake lever pivot nut Front brake light switch screw Front master cylinder mounting bolt Front brate caliper assembly torx bolt Front brate caliper mounting flange bolt Roar mastor eylindor push rod lock nut Rear masier cylinder mounting bolt Reer brake caliper bracket bolt Rear brake caliper pin bolt Pad pin Pad pin plug Brake hose oil bolt Brake caliper bleeder valve Step holder mounting bolt Rear master cylinder hose joint serew UGHTS/METERS/SWITCHES: Side stand ewiteh bolt Ignition switch mounting bot Fon motor ewiteh OTHERS: Side stand pivot bolt Side stand pivot lock nut THREAD DIA. (mam) a 2 18 10 10 6 8 10 10 TORQUE Nem (kgfem, Ibfft) 243,30) 108 (11.0, 80) 93 (9.5, 68), 4243, 31) 42 (43,30) 9(09,6.5) 9319.5, 69) 1(0.1,0.7) 110.1,0.7) 6 (0.6, 4.3) 1(0.1,0.7) 12112, 9) 3233, 24) 30 (8.1, 22), 7117, 12) 10(1.9,7) 2323, 17) 21 (28, 20) Wt, 12) 3(0.3,2.2) 34.3.5, 25) 6 (0.6,4.3) 27 (28, 20) 10 (1.9.7) 10119, 7) 25 (2.5, 18) 1811.8, 13) 10(19,7) 39 (4.0, 28) REMARKS NOTE 6 NOTES NTE 5 NoTEs NOTES NoTE 2 NOTES NOTES NOTE 1 1-16GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available. 2. Alternative to 3, Newly designed tool. 4. Not evalleble in U.S.A DESCRIPTION TOOL NUMBER | REMARKS |_ REF. SEC. Fuel pressure gauge (07406-0040003 | NOTE 2: 07406-0040002 5 Oil pressure gauge set 07506-3000000 NOTE 1 4 Oil pressure gauge attachment 07510-MJ10100 | NOTE1 4 Clutch center holder 0724-0050002 NOTE 1 9 Flywheel holder 07725-0040000 NOTE? 10 Rotor puller 0733-0020001 NOTE 2: 07933-39500 10 Attacment, 32 X 35 mm 0746-0010100, 9,14 Attachment, 37 X 40 mm 07746-01020, 9,14 Attacnment, 42 X 47 mm 0746-01030 15,14 Attachment, 52 X 85 mm 07746-0010400 1“ Attachment, 28 X 30 mm 07746-1870100, 4 Attachment, 22 X 24mm 07746-0010800, 4 Inner driver C 0746-0030100 n Attachment, 25 mm .D. 0746-0030200 12 Outer driver, 37mm o7ziD-mswo200 4 Pilot, 17 mm 07746-0040400 9,14 Pilot, 20 mm (07746-0040500 13,14 Pilot, 35 mm 0746-0040800, 3 Plot, 28 mm (07746-0081100 | 44 Bearing remover shaft ‘07GGD-0010100 13,14 Bearing remover head, 20 mm 07746-0050600, 13,14 Driver (07743-0010000, 9,13, 14 Valve spring compressor (07757-00100 8 Valve seat cutter NOTE 1 |e ‘Seat cutter, 27.5 mm (48° IN/EX) (07760-0010200 Flat cutter, 27 mm (32° EX) (07780-0013300, Flat cutter, 30 mm (32° IN} (07780-0012200 Interior cutter, 24mm (60"INEX) -—_07780-0010600 Cutter holder, 4.6 mm (9781-0010600 | Snap ring pliers 07914-SAS0001 16 Steering stem socket 07916-3710101 | NOTE 2: 079163710100 18 Ball race remover sat (07953-10000 6 “‘Attachment, 40 em (07953-M10100 = Driver shaft (07953-MJ10200 Ball race remover, 40 x 246L (07953-4250002 Ball race remover, 44.5 mm (07946-3710500 Stooring stom driver (07946-Mi300000 2 Fork seal driver weight 07947-KA50100 B Fork seal driver attechmant 07048-40200 a Valve spring compressor attachment 07959-KM30107, 8 Oil fiter wrench O7HAA-PJ70100 a Peak voltage adaptor (O7HGJ-0020100 5,17, 19 8 (U.S.A only) Teppst hole protector O7HNG-MR70002 | Drive chain toot set O7HNH-MR10103-| NOTES: O7HMH-MR1010B or =| 3 O7HMH-MR010C (U.S.A only) Valve guide diver O7HMD-MLoo101 | 8 Valve guide reamer, 4.508 mm O7HNH-MLOOIOT | 8 Compression gauge attachment O7RN.-MYs0100 «| NOTE 1 8 Inspection adaptor 07XMZ-MBWO101 20 ECM test harness ‘O7¥MZ-cO10100 | Two required 5 Yalve guide driver ‘0743-0020000 8 Driver shaft B 07964-00200 2 Christie battery chrger Mcro12/2 U.S.A only 7 1-17GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS ‘Crankcase mating surface Liquid sealant — - (Three Bone 12078 or | equivalent) | 10-15 mm (0.4— 0.6 in) Oil pressure switch threads Do not apply sealant to the thread heed 9-4 mm (0.1 ~ 0.2 in) 0 Ignition pulse generator cover bolt threads ‘Apply sealant tothe thread head 6.5 simm Marked “ 1-18GENERAL INFORMATION - ENGINE (Cont'd) LOCATION MATERIAL REMARKS. Ignition pulse generator grommet Sealant Crankcase mating surface ECT (engine coolant temperature sensor) threads. Coating width: 6.5 « 1mm. Cam pulse generator rotor bolt threads Lower crankcase sealing bolt threads Cylinder head sealing holt threads AC generator bolt threads Cylinder head semi-circular cut-out APPLIED POSITION | Main journal bearing surface - | Molybdenum disulfide | Piston pin slicing surface | oil mixture of V2 Connecting rod bearing surface | engine oil and 1/2 Connecting rod small end inner surface molybdenum disulfide Crankshaft thrust surface | grease Camshaft lobessjournals and thrust surface Valve stem (valve guide sliding surface) Valve lifter outer sliding surface i} Clutch outer/primary driven goat sliding surface Clutch outer guide sliding surface M34, C5, C8 shifter geer (shift fork grooves) l Starter reduction gear shaft outer surface | Piston ring sliding area Engine oil Oil strainer pecking Clutch disc surface Starter one-way clutch sliding surface Connecting rod nut threads Flywheel bolt threads end seating surface Main journal 8 mm bolt threads and seating surface (after removing anti-rust oil additive) Clutch center lock nut threads Oil filter cartridge threads and O-ring Camshatt holder bolt threads and seating surface Cam chain tensioner, tensioner collar seating surface Oil cooler center bolt threads Each gear tooth and rotating surface Each bearing Each O-ring | Other rotating ares and sliding surface 7 1-19GENERAL INFORMATION r ENGINE (Cont'd) LocaTiON MATERIAL REMARKS Timing hole cap threads Multi-purpose grease Each oil seal lip Lower crankzase sealing bolt threa Locking agent Cylinder head cover breather plate bolt threads —- Coating width: 6.5 = 1mm Cam pulse generator rotor bolt threads ‘Starter one-way clutch outer bolt threads sump driven eprocket bolt throade ‘Shift drum bearing set plate bolt threads Mainshaft bearing set plate bolt threads ‘Cam sprocket bolt threads Shift drum center bolt threads Spindle plate tightening bolt threads Oil filter boss threads 1-20GENERAL INFORMATION > FRAME LOCATION MATERIAL REMARKS Seat catch hook sliding area Front wheel dust seal lips Rear wheel dust seal lips Clutch lever pivot bolt sliding area Rear brake pedal pivot sliding area Gearshift pedal pivot Side stand pivot Steering head bearing sliding surface Steering head dust seal lips ‘Swingarm pivot bearings Swingarm pivot dust seal ips Shock absorber needle bearings Shock absorber dust seal lips Throtile cable A, B outer inside Clutch cable outer inside Handlebar grip rubber inside Steering bearing adjustment nut threads Front brake lever-to-master piston contacting area Front brake lever pivot Rear master brake raster piston-to-push rod contacting area Brake caliper dust seals Rear brake caliper boot inside Rear brake coliper pin boot inside Brake master piston and cups Brake caliper piston and piston seals Fork cap O-ring | Fork dust seat ips Rear brake reservoir hose joint screw threads Front brake caliper assembly bolt threads Rear brake caliper pin bolt threads Front fork socket bolt threads 1d il 8 Multi-purpose grease Cable lubricant Honda bond A, Honda Hand Grip Cement (US.A. only or equivalent) Engine oil Silicone grease DOT & brake fluid Pro Honda Suspension Fluid 85-8 Locking agent 1-21GENERAL INFORMATION CABLE & HARNESS ROUTING COMBINATION METER 9P COMBINATION METER SP (WHITE) CONNECTOR: (BLACK) CONNECTOR RIGHT HANDLEBAR wren a BLU) Swarcs 9? (aROWN) CONNECTOR CONNECTOR erin Saree ieee eet —__| { ™~. ee an seporrs camass sau smnRei Sree crue Geane arn Ha pier ieerTuR enum Soe 1-22GENERAL INFORMATION IGNITION coIL, CLUTCH casLé FRONT BRAKE HOSE ‘THROTTLE POSITION SENSOR MAIN WIRE HARNESS. FRONT BRAKE HOSE CLUTCH WIRE CABLE 1-23GENERAL INFORMATION BARO SENSOR WIRE CLUTCH WIRE IGNITION cot, INTAKE AIR DUCT CONTROL FUEL PRESSURE/REGULATOR Reena cam PULSE GENERATOR ‘THROTTLE POSITION SENSOR 3° CONNECTOR . 1-24GENERAL INFORMATION SIPHON TUBE MAIN WIRE HARNESS ECT SENSOR FRAME GROUND OIL PRESSURE wie BAND SWITCH WIRE CRANK PULSE GENERATOR WIRE 1-25GENERAL INFORMATION BARO SENSOR WIRE ‘CAM PULSE GENERATOR WIRE INTAKE AIR DUCT CONTROL SOLENOID VALVE BANK ANGLE SENSOR WIRE ‘THROTTLE SENSOR WIRE INTAKE AIR TEMPERATURE (IAT) SENSOR WIRE mae REGULATORMECTIFIER WIRE VEHICLE SPEED SENSOR WIRE ALTERNATOR WIRE NEUTRAL SWITCH WIRE SIDE STAND SWITCH WIRE 1-26GENERAL INFORMATION FUSE BOX MAIN 208 SUB 20AX2 BATTERY POSITIVE(4)CABLI MAIN WIRE HARNESS ‘STARTER RELAY SWITCH WIRE TOAX4 IGNITION PULSE GENERATOR WIRE OIL PRESSURE SWITCH WIRE MAIN FUSE 308 REAR BRAKE LIGHT SWITCH WIRE ‘STARTER MOTOR WIRE REAR BRAKE HOSE 1-27GENERAL INFORMATION eee se MAP SENSOR 3P (GRAY) i CONNECTOR INTAKE AIR DUCT conTRoL = | /\ SOLENOID VALVE aT SENSOR PAIR SOLENOID VALVE 2° (NATURAL) CONNECTOR FRAME GROUND IsniTiON Pt GENERATO! GIL PRESSURE SWITCH 1-28GENERAL INFORMATION INJECTOR NOz INJECTOR NOS INJECTOR NOS MAP SENSOR INJECTOR NOT INTAKE Ain DUCT CONTROL |\\ ‘SOLENOID VALVE (MAIN WIRE HARNESS THROTTLE POSITION SENSOR WIRE FUEL TANK AIR, VENT TUBE TUBE 1-29GENERAL INFORMATION FAN MOTOR 2P CONNECTOR, UPPER RADIATOR HOSE ECT SENSOR. SIPHON TUBE WATER HOSE OIL COOLER WATER HOSE OIL COOLER WATER HOSE ‘1 COOLER WATER HOSE OL FILTER CARTRIDGE lL COOLER 1-30GENERAL INFORMATION REAR MASTER CYLINDER RESERVOIR CUP REAR BRAKE LIGHT SWITCH WIRE REAR MASTER CYLINDER REAR BRAKE CALIPER BRAKE HOSE 1-31GENERAL INFORMATION SERVICE CHECK EM CONNECTOR STARTER RELAY SWITCH WIRE ‘MAIN FUSE 30, AGAVE FUSE BOX. Gian noes FAN CONTROL RELAY ~ Fon CUT RELAY *SUBFUSE 204 x2 + ENGINE STOP RELAY * 1-32GENERAL INFORMATION California type only No.4 TUBE (Cenister-to-EVAP purge control solenoid valve 1-33GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS ‘The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very Important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but iti toxic Honda Motor Co., Ltd. utiizes lean jection settings as well as other systems, to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-ty gas is returned to the combustion chamber through the air cleaner and throttle body. ‘THROTTLE BODY AIR'CLEANER HOUSING ao FRESH AIR em iowa cas 1-35GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) ‘The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission contrcl system is separate from the crankcase emission control system. ‘The exhaust emission control system consists of @ secondary air supaly system thet introduces filtered air into the exhaust {gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Puleo Secondary Air Injection} control valve. ‘This charge of freeh air promotes burning of the unbumed exhaust gases and changes @ considereble amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. ‘The reed valve prevents reverse air flow through the system. The PAIR control valve is operated by the solenoid valve. The ‘solenoid valve is controlies by the PGI-FI unit, and the fresh air passage is openediciosed according to the running condition (ECTAAT/TPIMAP sensor and engine revolution). No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended. PAIR CONTROL VALVE THROTTLE BODY PAIR CHECK VALVE AIR CLEANER HOUSING EXHAUST PoRT << Fresh aR em tsusr cas 1-36GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) ‘This mode! complies with California Air Resources Board evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it ie obsoroed and stored wh the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAP cenister is drawn into the engine through the throttle body. ‘THROTTLE BODY FUEL TANK <= FRESH AIR Furl varon = EVAP CANISTER EVAP PURGE CONTROL SOLENOID VALE NOISE EMISSION CONTROL SYSTEM. ‘TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing there- of (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or deliv- ery to the ultimate purchaser or while it is in use: (2) the use of the vehicle after such device or element of design hae been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baffies, header pipes or any other component which conducts exhaust geses. 2. Removal of, or puncturing of any part of the intake system. 43. Lack of proper maintenance. 4, Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those specified by the manufacturer. 1-37GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLY) 1-38 ‘An Emission Control Information Label is located on the main frame as shown. It gives base tune-up spec: fications. Tho fuel tank must be lifted up to read it Refer to page 315 for fuel tank opening. VACUUM HOSE ROUTING DIAGRAM LABEL (CALIFORNIA TYPE ONLY) ‘The Vacuum Hose Routing Diagram Label is on the main frame as shown The fuel tank must be lifted up to read it. Refer to page 3-18 for fuel tenk opening. EMISSION CONTROL, INFORMATION LABELS ” CANADA TYPE ONLY VACUUM HOSE ROUT- ING DIAGRAM LABEL Vacuum Hose Routing Diagram Engine famiyaanx00 20K ‘Calforia verteFRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS FUEL TANK REAR COWL GRAB RAIL REAR FENDER A AIR CLEANER HOUSING SIDE COVER REAR FENDER 8 SIDE COVER 2-02. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS 20 REAR COWL 23 SERVICE INFORMATION 241 FRONT FENDER 23 TROUBLESHOOTING 241 REAR FENDER A 24 SEAT 22 REAR FENDER B 24 | 2 SIDE COVER 22 MUFFLER/EXHAUST PIPE 25 | AIR CLEANER HOUSING SIDE COVER 2.2 | SERVICE INFORMATION GENERAL + Work in @ well ventilated ares. Smoking oF allowing flames or sperks in the work area or where gest cause a fire or explosion. + This section covers removal end installation of the body panels and exhaust system. Serious burns may result ifthe exhaust sysiem is not allowed to cool before components are removed or serviced. + Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. ne Is stored can TORQUE VALUES Exhaust pipe joint flange nut 20 Nem (2.0 kgfem, 14 Ibfeft) Exhaust pipe mounting bot 27 Nem (2.8 kgfem, 20 Ife) Exhaust pipe band bolt 27 Nem (2.8 kgfor, 20 Ibftt) ‘Muffler band flange bolt 27 Nem (2.8 kgfer, 20 Ibftt) ‘Muffler mounting bolt 27 Nem (2.8 kafom, 20 Ibett) TROUBLESHOOTING Excessive exhaust noise + Broken exhaust system + Exhaust gas leak Poor performance + Deformed exhaust eystom + Exhaust gas leak + Clogged muffler 2-1FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Unhook tho sot with the ignition key. Full the seat beck and remove it INSTALLATION Align the seat hooks with the frame hooks and push the seat forward Push the seat down until it locks. SIDE COVER REMOVAL Remove the seat (page 2-2). Remove the side cover bolt. Remove the front tab from the fuel tank and remove the rear tab from the grommet of the frame. Remove the side cover, Installation is in the reverse order of removal. AIR CLEANER HOUSING SIDE COVER REMOVAL/INSTALLATION Remove the socket bolts and air cleaner housing side Installation Is in the reverse order of removal. SEAT SIDE COVER AIR CLEANER HOUSING SIDE COVER sockeT BOLTSFRAME/BODY PANELS/EXHAUST SYSTEM. REAR COWL as REMOVAL/INSTALLATION Lt Remove the four socket bolts and grab rail Remove the two trim clips and socket bolts. Remove the rear cowl by pulling it beck. Installation isin the reverse order of removal. ‘TRIM CLIPS FRONT FENDER FRONT FENDER FLANGE BOLTS REMOVAL/INSTALLATION Remove the brake hose clamp bolts end reflectors Remove the front fender mounting socket bols/nuts ‘and flange bolts, Remove the front fender. Installation is in the reverse order of removal. SOCKET BOLTSFRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER A REMOVAL/INSTALLATION ‘SOCKET BOLT Remove the rear cow! (page 2-3) Romove the following: =RJL tur signal light 2P connector. — License light 2P connector. Remove the socket boltsinuts and flange bolts. Remove the rear fender A, Installation is in the reverse order of removal. connectors REAR FENDER A REAR FENDER B REMOVAL/INSTALLATION See SwiTcH FUSEBOX RELAY Remove the rear fender A (see upper). Remove the following: Rear shock absorber reserve tank ~Stareer relay switch —Fuse box Do notlet te | ~Fan control relay PaMmevicn —Fuel cut relay uniténgire con ~Engine stop relay oj oduiecms—Tur signal relay rang free —PGN-FV/IGN unit/Engine control module(ECM) RESERVE Remove the socket bolts and flange bolts. TANK Remove the rear fender 8 from the frame. Instaliation is in the reverse order of removel. REAR FENDER 8 SOCKET BOLT 2-4FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER/EXHAUST PIPE MUFFLER MUFFLER MOUNT REMOVAL: BOLTWASHER Remove the rear cowl (page 2:3). MUFFLER BAND BOLT Remove the socket bolt and remove the front mutfler protector by pulling itforward. Loosen the muffler band bolt Remove the muffler mounting bolt and washer, Remove the muffer. FRONT MUFFLER Pareae SOCKET BOLT DISASSEMBLY /ASSEMBLY REAR MUFFLER PROTECTOR & casker sockér sour MoUNT BoLt 2-5FRAME/BODY PANELS/EXHAUST SYSTEM clearance ofthe rule protector and rear toner 8 1s equalon beth I you remove the ioe _swingatm (eter 0 ‘section 14. De not damage the water hoses INSTALLATION Install the muffler and loosely tighten the muffler mounting botta/wachor. Tighten the muffler mounting bolts first, then tighten the muffler band bolts to the specified torque. TORQUE: Muffler mounting bolt: 27 Nem (28 kgf+m, 20 Ibf-ft) Muffler band bolt: 27 Nem (28 kofom, 20 Ibftt) Recheck the clearance of the muffler and protector. Install the front muffler prote:tor and tighten the sock- ‘ot bolt securely Intell the rear cow! (page 23). EXHAUST PIPE REMOVAL Remove the mutfler (page 25). Romove the two radiator mounting bolts. Remove the rediator guide from the frame and move. the radiator forward. Loosen the exhaust pipe band bolt and exhaust pipe mounting bolts/nuts PROTECTOR SOCKET BOLT MUFFLER MOUNT MUFFLER BAND BOLTWASHER pour — ~ aL act murrten (Cs Wes FRONT MUFFLER” As EXHAUST PIPE, BAND BOLT 2-6FRAME/BODY PANELS/EXHAUST SYSTEM Do not damage the swingarm by the exnaust removing the the exhaust pe ‘gaskets with new Do not damage by the exis joint oe when ‘nstaling the Remove the exhaust pipe joint nuts, exhaust pipe ‘mounting bolt, washer and nut. Remove the exhaust pipe and gaskets. INSTALLATION Install the new exhaust pipe gasketsand exhaust joint pipe gasket Instell the exhoust pipe and loosely tighten the exhaust pipe joirt nuts, exhaust pipe mounting bolts, washers and nuts, Install the muttier (page 2). Tighten the boltinut to the specified torque as follows. TORQUE: 1. Exhaust pipe joint nut: 20 Nem (20 kgf-m, 14 IbE-) 2. Exhaust pipe band bott: 27 Nem (2.8 kglom, 20 ttt) 3. Exhaust pipe mount boit/nut: 27 Nem (28kgtm, 20 Ibe) Recheck the clearance of the muffler end protector (page 24) Inctall the radiator to the frame. Install and tighten the radiator mounting bolts securely WASHER, JOINT NUT EXHAUST PIPE MOUNT BOLT/NUT ExHausT pipe ‘is BAND BOLT FADIATOR y3. MAINTENANCE SERVICE INFORMATION 34 DRIVE CHAIN 3-16 MAINTENANCE SCHEDULE 33 DRIVE CHAIN SLIDER 3-20 FUEL LINE 3-8 BRAKE FLUID 3-20 THROTTLE OPERATION 3-4 BRAKE PAD WEAR 3-21 CHOKE OPERATION 35 BRAKE SYSTEM 3-21 AIR CLEANER 35 BRAKE LIGHT SWITCH 3-22 CRANKCASE BREATHER 3-6 HEADLIGHT AIM 3-22 SPARK PLUG 3-6 CLUTCH SYSTEM 3-23 VALVE CLEARANCE 37 SIDE STAND 3.28 ENGINE OIL/OIL FILTER 312 SUSPENSION 3-26 ENGINE IDLE SPEED 3-18 NUTS, BOLTS, FASTENERS. 3-25 RADIATOR COOLANT 3.13 WHEELS/TIRES 3-25 COOLING SYSTEM 3-14 STEERING HEAD BEARINGS 3-26 SECONDARY AIR SUPPLYSYSTEM 3-15 EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) 3.15 SERVICE INFORMATION GENERAL + Place the motoroycle on a level ground before starting any work. + Gasoline is extremely flammable ands explosive under certain conditions. + Work in a well ventilated area, Smoking or allowing flames or sparks in the workares or where the gasoline Is stored can cause @ fre of explosion. + Ifthe engine must be running to do some work, make sure the areais woll ventilated. Never run the engine inn enclosed + The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. 3-1MAINTENANCE a esse SPECIFICATIONS rem SPECIFICATIONS Thai gi ree play _ ‘nm (118376 in) 7 7 ‘Sparkplug =| NGK ____ CRREH-9 STANDARD) CRIEH-9 (HIGH SPEED) | DENSO ~| U2FERD ISTANDARD) _ U27FERS (HIGH SPEED) Sparkpluggep—SSSS~*« 080 03-008) 7 Valve clearance: IN 0.18 003 mm (0.006 = 0.001 in) = 0.25 = 0.03 mm (0.010 = 0.001 in) Engine oil capacity | After draining 3.5 liter (8.7 US qi, 3.1 Imp atl ___| After draining/oilfiter change ___3.6liter (3.8 US qt, 3.2 Imp qt) | Recommended engine oi Pro Honda GNé or HP4 (without molybdenum additives) iroke oil (USA & Canad), or Honda 4-stroke oil (Canada only), or an equivalent motor oil API service classification SG or Higher except oils labeled as energy conserving on the API service label. JASO 7303 siandard MA Viscosity: SAE 10WV-40 1,200 = 100 min’ itp) 30-40 mm (1.2-1.6 in) bors : 10 = 20 mm (3/8 - 19/16 in} Glutch lever free play Tire size 120770 ZR 17 (58W), 120/70 ZR 17M/C (58W) 1086 2817 09), 10966 zn 7 M/CBW) Teband Wiieene STS6F RADIAN = | TEER RADIAL G within 1x8 - L [er Fs Teaiiemas | Biber [ont | ani avis os Fuar | 2904Pa [2.90¥atem, «2 pai rer and ainanow | Font] 260 Fa 0 tant 96 pa ~ Zz | [Rear | 250 era 2.0 ato 2p a J Tina re Wed depth Front | 1.8 mm 10.06) For | 2.0 mm (0.08in) TORQUE VALUES Tining bole ep 1B Nem (1.8m, 1 186A) Apply ares othe thence Sputtpue 12Nm (12 kgm, 8 bet Espa aoa over ae Toke (10 kee, ey Engine oll drain toe 28 Nim (.0 gem, 2216 Cran oe cai ZeNem (27 kgf, Z0IKEA Apply clean engine ol tothe O-ring Ber cae me Sener gh esIbe) Oona Driv grok pele bot Senor igh, S01 Dien rout 408 Nem (110 kg, 8 BF) TOOLS itt wrench a7waa-psror00 Sine chain ol orn 3MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. I: nepoct and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace, A: Adjust. L: Lubricate. ‘The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require ‘more technical information and tools. Consult their authorized Honda dealer. FREQUENCY | WHIGHEV- | ©) ODOMETER READING INOTE = hes = —_ FRET” | aaparea [aa] 8 [a6 a5] ae| SS pear re = whe _[Rutante to eloarenbselsels = CTHRGTTLE OPERATION ich | CHOKE OPERATION I t 1 2 AIR CLEANER I = 2 1 Grawccase BEATER El eanceue E>) VALVE CLEARANCE I aL a = EO — + 5 ENGINE OIL FILTER " g * ENGINE IDLE SPEED Et esoune svete [SECONDARY Ain SUPPLY SYSTEM * | controt SYSTEM DRIVE CHAN z | BRAKE SYSTEM E [= (aoa ben Siren 2+) WeaouichT an E 2 cuten sverew = 5 Sioe stan 87) susrenson @ + | NUTS, BOLTS, FASTENERS a: 3 ama * Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechani: cally qualified. Inthe interest of safety, we recommend thet items be serviced only by an authorized Honda dealer. NOTES: 1. At higher odometer readings, repeat at the frequency interval Service more frequently if the motorcycle is ridden in unusually wet or dusty areas. 1 sablished here, 2 3. Service more frequently ifthe motorcycle is ridden often at full throttle or in the rain. 4 5 California type only. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires meshan- ical ski 3-3MAINTENANCE FUEL LINE Remove the side covers (page 2-2). Loosen the fuel tank mounting boly/nut ‘Move the fuel tank back. Do not amove Open and support the front end of the fusl tank using the mantenance a auitable supper ae chown, Check the fuel lines for deterioration, damage or leakage Replace the fuel line if necaseary. Inetal the fuel tank in the reverse order of removal THROTTLE OPERATION Check for smooth throitle grip full opening and avto- ‘matic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is ot smooth, Measure the free play at the throttle grip flange. FREE PLAY: 2~ 4 mm (1/16 ~ 1/8 in) BOLTS WASHERSMAINTENANCE ‘Throttle grip free play canbe adjusted at either end of, the throttle cable. ADJUSTER Minor adjustment are made with the upper adjuster. Adjust the free play by loosening the lock nut end turing the adjuster. Major adjustments are made with the lower adjuster. (Open and support the front end of the fuel tank (page 3-4), ‘Acjust the free play by loosening the lock nut and tuming the adjuster. After adjustment, tighten the lock nut securely Recheck the throttle operation. Replace any damaged parts, ifnecessary. CHOKE OPERATION Check for smooth opening and closing of the choke knob. Check the choke cable and replace them if they are deteriorates, kinked or damaged. Lubricate the choke cable, if throttle operation is not smooth. AIR CLEANER Remove the left side cover (page 22). VARIABLE INTARE WY oe@) aR conTROL isconnect the variable intake air control { Mt @)) SACU TUBE ‘out tube from the ir cleaner housing cover WY U4 LY Remove the screws and air cleaner housing cover. Remove and check the air cleaner element in accor~ dance with the maintenance schedule (page 3-3). /CHou8ine cover SCREWS’ 35MAINTENANCE Clean the air cleener element using compressed air anytime it is excessively diny or damage. Install the removed parts in the reveres order of moval. CRANKCASE BREATHER Remove the side cover (page 2-2) Disconnect and clean the drain tube. Connect the drain tube, SPARK PLUG REMOVAL Coen around the Open and supportthe front end of the fuel tank snark pug bases (page 3-4), wih compressed Remove the radiator fram the frame boss by ai befor remor moving it to the right, then move the radiator forward ng srdbe 270 page Ret no 92ers Disconnect the ignition coil connectors. ‘ne combustion Remove the spark plug using a spark plug wrench or Thameer fl equivalent tool. Inspect or replace as described in the maintonaneo schedule. INSPECTION Cheek the following and replace if nevessary (recom ‘mended spark plug: page 32), + Insulator for damage + Electrodes for wear + Burning condition, coloration INSULATOR SIDE ELECTRODEMAINTENANCE REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or spark plug aleaner. Check the gap between the center and side electiodes with ewiretype fecler geuge. lfnecessary, acjust the gap by bending the side elec: trodes carefully ‘SPARK PLUG GAP: 0.8 - 0.9 mm (0.03 - 0.04 in} Reinstall the spark plugs in the cylinder head ané hhand tighten, then torque to specification. TORQUE: 12 Nem (1.2 kgm, 9 thf) REPLACING A SPARK PLUG ‘Set the plug to specificetion with a wire-type feeler ‘gauge (see above). Install and hand tighten the new spark plug, then tighten it about 1/2 turn after the sealing washer contacts the seat of the plug hole. Inetall the radiator onto the frame bose (page 2-6). VALVE CLEARANCE Inspect ond aust the valve clear engine 6 cols (hetow 25°C957 INSPECTION ‘Open and eupport the frent ond of the fuel tank (page 3-4). Remove the cylinder head cover (page 8-4) Remove the cam chain tensioner titer sealing bolt and sealing washer. Turn the cam chain tensioner lier shaft fully and secure it using the tensioner stopper tool (Rafer to page &7), 0.8-0.9mm 10.03 - 0.04 in} soir — scaunc Washi STOPFER TOOLMAINTENANCE Record the ctay- ‘ance foreach valve for refer ‘ence shire sebcton i adust- ment is equred. Remove the timing hole cep and O-ting, Turn the crankshaft clockwise, align the “T” mark on the ignition pulse generator rotor with the index mark fon the right erankcase cover. The timing marks "IN" and “EX") on the cam sprock- cts must be flush with the cylinder head surface and facing outward as shown, Hf the timing marks on the cam sprocket facing inward, turn the crankshaft clockwise one full turn (360°) and realign the timing marks with the cylinder head surface so they are facing outward, (0.3 INTAKE VALV Insert the feeler gauge between the valve liter and | VES No.1 INTAKE VALVES thecam lobe. Check the valve clearance for the No.1 and No eylinder intake vaives using a fealer gauge. VALVE CLEARANCE: IN: 0.18 = 0.03 mmm (0.006 = 0.001 in)MAINTENANCE ‘Turn the crankshaft clockwise 1/2 turn (180°), align the index tine on the igrition pulse go’ its facing up 2s shown. cor the cos ‘nce foreach Check the valve clearance for the No.2 and No.é cylin- vole ferrefer der exhaust valves using « fevler gauge. ence in shin selection i aguet " sloton Vedur! VALVE CLEARANCE: EX: 0.25 = 0.03 mm (0.010 = 0.001 in) ‘Turn the crankshaft clockwise 1/2 turn (180), align the “T" mark on the ignition pulse generator rotor with the index mark on the right crankcase cover. Fecord the cleat Check the valve clearance for the No.2 andNNo.4 cylin. | NO.4 INTAKE VALVES ance‘or esc der intake valves using a feeler gauge. | NO.2 INTAKE VALVES valve for reer cocci, VALVE CLEARANCE: okcion ads INE 0.16 = 0.03 mm (0.006 = 0,001 in)MAINTENANCE Record the cleer ‘ence for each valve for rfer- ‘ence n shin selection i aust: ‘ment is required, Turn the crankshaft clockwise 1/2 turn (180, align the index line on the ignition pulse generetor rotor so that, itis facing up as shown. Check the valve clearance for the No.1 and No.3 eylinder exhaust valves using a feeler gauge. VALVE CLEARANCE: EX: 0.25 = 0.03 mm (0.010 = 0.001 in) ADJUSTMENT Remove the cemshaft (page 8-6). Remove the valve lifters and shims. + Shim may stick to the inside of the valve lifter. Do VALVE LIFTER ‘ot allow the shims to fall into the crankcase. Mark all valve lifters and shims to ensure correct reassembly in their orginal locations. ‘The valve lifter can be easily removed with a valve lapping tool or magnet. ‘The shims cen be easity removed with a tweezers or a magnet, Clean the valve shim contact area in the vaive lifter with compressed air 3-10MAINTENANCE ‘Shey-ve aiterent sin theknesses xe avaible fom 1200 mm to 2800 mn in ines of 0.925 stale shims ‘and vave titers their origin! ‘Measure the shim thickness and record it. Calculate the new shim thickness using the equation below. Aw(B-C)+D New shim thickness Recorded valve clearance ‘Specified valve clearance Old shim thickness goer ‘+ Make sure of the correct shim thickness by measuring the shim by micrometer. + Reface the valve seat if carbon deposit result ina calculated dimension of over 2.800 mm. Install the newly selected shim on the valve retainer. Apply molybdenum disulfide oll to the vaive lifters. Install the vaive liters into the valve lifter holes. Install the camshaft (page 23). Rotate the camshafts by rotating the crankshaft clockwise several times. Recheck the valve clearance. Remove the eam chain tensioner stopper tool. Install the new sealing w: tensioner lifter sealing bol ‘Tighten the bolt securely. ‘end com chain Install the removed parts in the reverse order of removal. SHIM ©oO 1.80 mm 1.825mm 1.85 mm © 1.875 mm STOPPER TOOL © ‘CAM CHAIN TENSIONER LIFTER BouT aot (@Og% @D Lang? 5 WASHER —MAINTENANCE ENGINE OIL/OIL FILTER Other viscositns chart may be average tempore ture in your rdeg aren is within the incited range. Chenge the engine ol with the engine warm {and the motorey= ‘leon tee ground to essere compete ‘raining 3-12 OIL LEVEL INSPECTION Start the engine and letitidie for 2 - 3 minutes. Turn off the engine and support the motorcycle level surfece, Check the oil level through the inspection window. Ifthe level is below the lowe. line, remove the oil filler cap and fl the crankcase with recommended oll up to the upper level line. Remove the ol filler cap, Fill the recommended engine oll up to the upper leva line, RECOMMENDED ENGINE OL: Pro Honda GN4 or HPé (without molybdenum additives) 4stroke oil (USA & Canada, or Honda ‘stroke oll (Canada oni}, or an equivalent motor oil API service classification SG or Higher except oils labeled as energy conserving on the API service label. ‘JASO T903 standard MA Viscosity: SAE 10W-49 Reinstall the filler cap. ENGINE OIL & FILTER CHANGE Warm up the engine. Stop the engine ard remove the oll filer cap. Remove the drain bolt, drain the oil completely Check that the sealing washer on the drain bolt is in ‘9006 condition, and replace if necessary. Install nd tighten the drain bolt. TORQUE: 29 Nem (3.0 kgfom, 22 loft) Remove and diecard the oil filter cartridge using the special tool Tool: i fiter wrench o7Haa-Ps70100 INSPECTION ‘WINDOW. 5 CARTRIDGE. UY py ty‘Apply clean engine oil to the new oll fer O-ring. Install the new oil iter and tighten it to the specified torque. Too: Oil filter wrench (OTHAA-PS70100 ‘TORQUE: 26 Nem (2.7 kgfem, 20 Ibfft) Fill the crankcase with recommended engine ol. lL caPacrTY: 3.5 liter (3.7 US qt, 3.1 Imp qu) after draining 3.6 liter (3.8 US gt, 3.2 Imp qt) after drainingfitter change Install the oil filer cap. Star the engine and let it idle for 2 to 3 minutes. Stop the engine and rechack the ail level. ‘Make sure there are no oil leaks. ENGINE IDLE SPEED ‘Open and support the front end of fuel tank (page 3-4). + Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. + The engine must be warm for accurate idle speed inzpection and adjustment. Werm up the engine for about ten minutes. Turn the throttle stop screw as required to obtein the specified idle speed. IDLE SPEED: 1,200 + 100 min” (rem) RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" and “LOWER” level lines. MAINTENANCE OIL FILTER CARTRIDGE THROTTLE STOP SCREW. LOWER LEVEL LINE 3-13MAINTENANCE HH necessary, add recommended coolant. RESERVE TANK RECOMMENDED ANTIFREEZE: Pro Honda Coolant or an equivalent high quality ‘ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. Remove the reserve tonk filer cap and fill to the “UPPER” level line with a 50/50 mixture of distilled water and antifreeze. Reinstall the filler cap. COOLING SYSTEM Remove the lower cowl and inner helf cow! (page 2-4). Check the radistor air passages for clogging or damage. Straighten bert fins, and remove insects, mud or ‘other obstructions with compressed air or low water pressure. Replace the radiator ifthe air flow is restricted over ‘more than 20% of the radiating surface. Inspect the radiator hoses for cracks or deterioration, ‘and replace if necessary. ‘Check the tightness of all hose clamps and fasteners, MADITORTOSE A a 3-14SECONDARY AIR SUPPLY SYSTEM tine neses show ‘any signs of heat ‘amage, inspect the PUR check vate in he PAIFL raed valve cover ror damage, + This model ie equipped with @ builtin sscondary air supply system. The pulse secondary air supply system is located on the cylinder head cover. + The secondary air supply system introduces filtered air Into exhaust gases in the exhaust port. The s2c- ondary airis drawn into the exhaust port whenever ‘there is negative pressure pulse in the exhaust sys~ tem, This charged secondary air promotes burning of the unburned extaust gases and chenges a con- siderable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water. Check the PAIR (pulse secondary air injection) tubes between the PAIR control solenoid valve and cylinder head cover for deterioration, damage oF loose connections. Make sure that the hoses are not cracked Check the air suction hose between the air cleaner housing and PAIR cortrol solenoid valve for deterioration, damage or loose connections, Mate sure that the hoses ara not kinked, pinched or cracked, EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) Check the evaporative emission (EVAP) canister for cracks or damage. MAINTENANCE PAIR REED VALVE Cl EXHAUST PORT CYLINDER HEAD COVER PAIR CONTROL VALVE AIR SUCTION HOSE No.4 TUBE (Canister-to-EVAP purge control solenoid valve) No.1 TUBE (Fuel tank- t0-Canister) 3-15MAINTENANCE Check the tubes between the fuel tank, EVAP canister, EVAP purge control valve and throttle body for deteri- ‘ration, damage or loose connections. Also check that the tubes are not kinked or pinched. Refer to the Vacvurn Hose Routing Diagram Label and Cable & Hamess Routing [page 1-27) for tube conne tions and routing, Check the air suction hose between the air cleaner housing and PAIR contro} solenoid valve for det ration, damage or loose connections. Make sure that the hoses are not kinked, pinched or ‘racked. DRIVE CHAIN over inspect and ‘adjust the dive ‘hain whi the ‘engines running, DRIVE CHAIN SLACK INSPECTION ‘Tur the ignition switch OFF, place the motorcycle on ite side stand and shift tho tranemission into neutral Check the slack in the drive chain lower run midway between the sprockets. CHAIN SLACK: 30 ~ 40 mm (12 - 1.6 in} NOTICE Excessive chain slack, 50 mm (2.0 in} or more, may damage the frame. ADJUSTMENT Loosen the rear axle nut. ‘Turn both adjusting bolts until the correct drive chain slack is obtained. Make sure the index marks on both adjusting plate are aligned with the end of the swingarm. Tighten the rear axle nut to the specified torque. ‘TORQUE: 83 Nem (95 kgi+m, 69 Ibift) Recheck the drive chain slack and free wheel rotation, Lubricate the drive chain with #80 — 90 gear oil or drive chain lubricant designed specifically for use with O-ring chains. Wipe off the oxcose oil or chain lubricant. Check he crive chain wear indicator label attached on, the left drive chain adjusting plate. I the swingarm index mark reaches the red zone of ‘the indicator latel, replace the drive chain with @ new cone (page 3-21) No.4 TUBE (EVAP purge control solenoid valve-to-Canister) THroTTie Booy PURGE TUBE INDICATOR LABEL 3-16CLEANING AND LUBRICATION Clean the chain with non-flammable or high flash point solvent and wine it éry. Be sure the chain has dried completely before lubricating Inspect the drive chain for possible damage or wear, Roplace any chain thet hes damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing @ new chain on badly worn sprockets will cause the new chain to wear quickly Inspect and replece sprocket as necessary. Lubricate the drive chain with #80 — 90 gear oil or drive chain lubricant designed specifically for use with O-ring chains. Wipe off the excess oil or chain lubricant. SPROCKET INSPECTION Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary. Never use anew drive chain on wom sprockets. Both chain end sprockets must be in good condition, or the new replacement chain will wear rapidly. Check the attaching tolts and nuts on the drive end driven sprockets. I any are loose, torque them. 40 Ib) Driven sprocket nut: 108 Nem (11.0 kghm, 80 Ibfett) MAINTENANCE NON-FLANMAGLE OR HIGH FLASH POINT SOLVENT CLEAN LUBRICATE #80 -90 GEAR OIL OR DRIVE CHAIN LUBRICANT 3-17MAINTENANCE When using the special ta, fok low fe menutac turer's instruction. Include the mas ter link ten you ‘count the five ‘hain inks REPLACEMENT This motorzycie uses a drive chain with a staked master link Loosen the drive chain (page 2-16). ‘Assemble the special tool as shown. ToL: Drive chain tool set (O7HMH-MR10103 Locate the crimped pin ends of the master Ink from the outside of the chain, and remove the link with the drive chain tool set. TooL: Drive chain tool eet O7HMH-MR10103, Fomove the drive chain. Remove the excess drive chain links from the new diive chain with the drive chain tool set. ‘STANDARD LINKS: 114 links REPLACEMENT CHAIN: DID: DIDSOVAS-114LE RK: RKSOHFOZS—114LE DRIVE CHAIN TOOL SET > <— MASTER LINE DRIVE CHAIN TOOL SET 3-18MAINTENANCE Never reuse the old drive chain, master fink, master link plate and O-rings. o-RINGS PLATE Assemble the new master link, O-rings and plete. ‘Assemble and set the drive chain tool set. TOOL: Drive chain tool set o7HMH-M 10103, MASTER LINK Insert the master Make sure that the master link pins are installed link trom the properly. DRIVE CHAIN TOOL SET lrside cf he drive Measure the master link pin length projected from the ‘hain and install plate. the plate with the ‘entiation mark outide, ‘STANDARD LENGTH DID: 1.15 ~ 1.55 mm (0.065 ~ 0.081 in} RK: 1.2 ~ 1.4 mm (0.05 ~0.06 in) ‘Stake the master ink pit Acrive chain with Make sure that the pins are staked properly by mea- clp-b0e master guring the diameter of the staked area using a slide Ink must not Be Caliper, ‘sed. DIAMETER OF THE STAKED AREA: DID: 5.50 ~ 5.80 mm (0.217 ~ 0228 In) | RK: 5.55 ~5.85 mm (0.219 ~ 0230 in) Aftar otaking, chook tho stoked area of the master link for cracks. H there is any cracking, replace the master fink, O- rings and plete, coop No Goon CRACKED 3-19MAINTENANCE DRIVE CHAIN GUIDE PLATE INSPECTION Remove the crive sprocket cover and guide plate. (Check the drive chain guide plate for wear or damage and replace if necessary. BRAKE FLUID 3-20 NOTE: + Do not mix different types of fluid, as they are not ‘compatible with each other, + Do not allow foreign material to enter the system when filling the reservoir. + Avoid spilling fluid on painted, plactie or rubber Parts. Place a rag over these parts whenever the system is serviced. When the fluid level is low, check the brake pads for wear see next page). & low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper pieton ie puchod out, and thia eccounte for a low reservoir level. Ifthe brake pads are not worn and the fluid level is low, check entire system for leaks (see next page. FRONT BRAKE ‘Turn the handlebar ¢0 that the reservoir ie level and check the front brake fluid reservoir level. I the lovel io near the lower level line, check the brake pad wear (see below). REAR BRAKE Place the motorcycle on a level surface, and support it in an upright position. Check the rear brate fiuid reservoir level. Hf the level is near the lower level line, check the brake pad weat (see below). WEAR OR DAMAGE GUIDE PLATE LOWER LEVEL LINEMAINTENANCE BRAKE PAD WEAR WEAR INDICATOR FRONT BRAKE PADS Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of the wear limit groove. Rofer to page 18-7 for brake pad replacement. REAR BRAKE PADS Check the brake pad for wear. | Replace the brake pads if either pad is worn to the bottom of the wear limit groove. Fefer to page 18-5 for brake pad replacement. WEAR INDICATOR BRAKE SYSTEM BRAKE HOSE, INSPECTION Fiemly apply the brake lever or pedsl, and check that no air has entered the system. If the lover or podal fools soft or spongy when operat- ‘ed, bleed the air from the system. Inspect the brake hose and fittings for deterioration, {cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. | Refer to page 15:5 for brake bleeding procedures. BRAKE LEVER ADJUSTMENT ‘The distance between the top of the brake lever and the grip can be adjusted by turning the adjuster. ‘ADJUSTER 3-21The frore brats light switch does ot requis acustmere Adjust the hee. fight beam as ‘spectied ty local ‘ows and reguttions MAINTENANCE eS Sw—h BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height is obtained, BRAKE LIGHT SWITCH ‘Adjust the braks light switch so that the breke light comes on just prior to the brake actually being engaged. Ii the fight fails to come on, adjust the ewitch eo that the light comes on at the proper time, Hold the switch body and turn the adjuster. Do not turn the switch body. HEADLIGHT AIM Prace the motorcycle on a level surface. ‘Adjust the headlight beam vertically by loosening the headlight mount bots. Adjust the headlight beam horizontally by turning the horizontal beam adjusting screw. ‘Aclociwiee rotation moves the beom toward the right, side of the rider, PUSH ROD i BRAKE LIGHT SWITCH Se HORIZONTAL BEAM ADJUSTING SCREW 3-22CLUTCH SYSTEM Measure the clutch lever free play at the end of the ‘lutch lever. FREE PLAY 10 - 20 mm (3/8 ~ 13/16 in) Minor adjustments are made using the upper adjuster at the clutch lever. Loosen the lack nut and turn the adjuster. NOTICE The adjuster may bo damaged itit ie positioned too far out, leaving minimal thread engagement. If the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn Tighten the lock nut and make @ major adjustment as described below. Major adjustments are performed at the clutch arm, Loosen the lock nut and turn the adjusting nut to adjust free play. Hold the adjusting nut securely while tightening the lock nut Hf proper free play cannot be obtained, of the clutch slips during a test ride, disassemble and inspect the clutch (c0@ setion 9). MAINTENANCE 10 20 mm (3/8 ~ 13/16 in) LOCK NUT apjyster LOCK NUT ADJUSTING NUT 3-23MAINTENANCE SIDE STAND ‘Suppor the motorcycle on a level surface. Check the side stand spring for damage or loss of tension, ‘Check the side stand assembly for freedom of move- ‘ment and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system: ~ Sit astride the motorcycle and raise the side stand. ~ Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squezzed = Move the side stan full down, ~ The engine should stop as the side stand is lowered I there is a problem with the system, check the side stand switch (section 19) SUSPENSION Lease, woin or cemaged suspen sion pets impair motoreetestabik- ‘ard control, FRONT SUSPENSION INSPECTION Check the action of the forks by compressing the front suspension several times. Check the entire fork assembly for signe of leaks, damage or loose fasteners. Replace damaged components thet cannot be repaired. Tighten all nuts and bolts (page 1-19). Refer to section 13 for fork service. REAR SUSPENSION INSPECTION Check the action of the shock absorber by compressing it several times. (Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components that cannot be repaired Tighten all nute and belts (page 1-12), Place the motorcycle on a work stand or box to raise the reer wheel off the ground and support the motorcycle securely. Check for worn swingarm bearings by grabbing the swingarm and attempting to move the Wheel side to side. Replace the bearings if any loose- ness is noted SIDE STAND SWITCH ‘SIDE STAND SWITCH 3-24MAINTENANCE Refer to section 16 for shack absorber and swingarm service. REAR SUSPENSION ADJUSTMENT ‘SPRING PRE-LOAD ADJUSTER Spring preload can be adjusted by turning the adjuster using a pin spanner. NUTS, BOLTS, FASTENERS (Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-12). Check that all safety clips, hose clamps and cable stays are in place and properly secured. WHEELS/TIRES NOTICE Tire preseure should be checked when the tires are COLD. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FRONT REAR Tire pressure kre kgiem®, psp | 250(2.50,36) | 290 (2.90, 42) wei 120770 2R 17 | 160/552R 17 (saw) (730) 120770 ZR 17 | 180552 17 Micissw) | Myc (T3Wi ‘tie Bridgestone BTS6F RADIAL NBTSSR RADIAL G, bland tf + Open or short circuit in Pink and PinkAWhite wire + Loose or poor contacts on the ECM connector Out of range ee + Open or snort circuit in Green/Orange wire + Loose or poor contacts on the ECM connector Voltage exists [____veieg? on «Replace the ECM with a new one, and inspect it again 5-17FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 8 BLINKS (TP SENSOR) ‘Tun the ignition switch OFF, 1 Disconnect the TP sersor $P connector. ‘Check for loose or poor contact on the TP sensor connector. TP SENSOR CONNECTOR ‘Connect the TP sensor connecter. Place the motoreycle on its side stand. Stet the engine and check that the MIL blinks. ‘TP SENSOR CONNECTOR Y spins No blinks + Loose er poor contact on the TP sensor connector ‘Tum the ignition switch OFF, Disconnect the TP sensor 3° connector ‘Turn the ignition switch ON. ‘Measure the voltege between the wire harness side connector terminal and ground, Connection: Yellow/Red (+) ~ Ground (-) Standard: 4.75 -525 V Voltage exists — Out of range na > + Open oF shor circuit in the Yellow/Red wire + Loose or pocr contact on the ECM connector+ of the wire harness side, Connection: Red/Yellow (+) - Green/Orange (-) Stondard: 4.75 - 5.25 V Measure the voltage at the TP sensor terminals FUEL SYSTEM (Programmed Fuel injection) ‘ Our ofrange 8° > . Open or short circuit in Green/Orenge wire 1 [S0e0 or poor contact on the ECM connectors ¥ vottage existe ‘Turn the ignition ewitch OFF Disconnect the ECM 22P connectors. Check for continuity between the TP sensor con- nectar terminal of the wire harness side and Connection: Red/ Yellow (+) ~Ground (-) ‘Standard: No continuity No continuity Contin |_Sontinutty = « short circuit in Red’Yellow wireFUEL SYSTEM (Programmed Fuel Injection) t Connect the test harness to the ECM connec- ECU TEST HARNESS oN Check for continuity between the test harness terminal and the TP sensor connector terminal. Connection: Red/Yellow ~ B9 ‘Standard: Continuity ¥ continuity Connect the TP sensor 3P connector. TP SENSOR CONNECTOR “Turn the ignition switch ON, Measure the voltage at the test harness termi: nals. Connection: 88 (+) ~ A22 (-) Standard: *0.4 ~ 06 V (throttle fully closed) "42 ~ 48 V [throttle fully open) No continuity. Norenet + Open circuit in Red/Veliow wire + Replace the ECM with a new one, and inspect it again Out of range Sai tS i cnnor 5-20FUEL SYSTEM (Programmed Fu Injection’ ‘A.oltage marked * refers to the value whan the voltage reading at the TP seneor OP connector (page &19) shows 5 V. When the reading shows otter than § V, derive a voltage at the test hamess as follows: Inthe case of @ voltage of 475 Vat the TP sensor 3P connector: 04X 475/5.0= 0.38 V 0.0X 4.75/5.0= 0.57 V Thus, the solution is “038 ~ 0.67 V" with the throttle fully closed, Replace 0.4 and 0.8 with 4.2 and 4.8 respectively, in the above equations to determine the throttle fully open range. 5-21FUEL SYSTEM (Program Fuel Injection) PGM-FI MIL 9 BLINKS (IAT SENSOR) ‘Turn the ignition switch OFF 1 Disconnect the IAT sensor 2P connecter, Check for loose or poor contact on the IAT sensor connector. aT SENSOR CONNECTOR Connect the IAT sensor 2P connecior. Place the motorcycle on its side stand. “Turn the ignition switch ON. Check that the MIL blinks, 9 blinks Turn the ignition switch OFF. Disconnect the IAT sensor 2P connector. Measure the resistance st the IAT sonsor (at 20 Standard: 1-4 Normal “Turn the ignition switch ON, | No blinks + Loose or poor contact on the IAT sensor connector Abnormal + Faulty IAT sersor 5-22t Moasure the voltage botwoen the terminals of the wire harness side. Connsetion: Gray/Blue (+] ~ Ground (-) Standard: 4.75 5.25 V Tienes Measure the voltage between the terminals of the wire harness side. Gray/Blue (+] ~ Green/Orange (-) Standard: 4.75 ~5.25 V FUEL SYSTEM (Programmed Fuel Injection) Out o 78°. Open oF shor cireut in Gray/Blue wise + Loose or poor contact on the ECM connectors, ut of rang Out of 78. Open oF short circuit in Green/Orange wire + Loose or poor contact on the ECM connectors. Voltage e * Replace the ECM with a new one, and inspect it again 5-23FUEL SYSTEM (Programmed Fut tion) PGM-Fi MIL 11 BLINKS (VEHICLE SPEED SENSOR) Turn the ignition switch OFF. Disconnect the vehicle speed sensor 3P connec- Check for loose or poor contact on the vehicle speed sensor connector. spr eD SENSOR CONNECTOR Connect the vehicle speed sensor 3P connector. Start the engine. Ride the motoreyele and keep the engine rev mare than 5,000 min" (rpm) about 20 seconds Put the side stand down, and check that the MIL blinks. | Yt bins Tuln the ignition switch OFF 1 Disconnect the vehicle speed sensor 3P connector. ‘Tuin the igntion switen ON. ‘Measure the voltage at the wire harness side connector. Voltage exists No blinks: Out of range + Open or short + Loose or poor contact on the vehicle speed sensor connector + Open or shor cireult In Black wire of the engine sub-harness ult in Black/Brown wire of the main wire harness: 5-24t Connect the speed sensor 3P connector. ‘SPEED SENSOR _42)_ CONNECTOR Disconnect the ECM connectors. Connect the test harness to the wire herness connectors. ECU TEST HARNESS ‘Support the motorcycle securely and place the rear whee! off the ground, Shift the transmission into gear. Measure the voltage at the test harness termi- ale with the ignition ewiteh is ON while slowly turning the rear wheel by hand. CONNECTION: Pink/Greon (4) ~ Ground (+ STANDARD: Repeat 0to 5V Abnormal FUEL SYSTEM (Programmed Fuel Injection) + Open or short circuit in Pink/Green wire of the main wire hamess Format [hoot Replace the ECM with 2 new one, and inspect it again 5-25FUEL SYSTEM (Programmed Fuel Injection) PGM-Fi MIL 12 BLINKS (No.1 INJECTOR) Turn the ignition switch OFF. ati Disconnect the No.1 injector 2F connector, Check for loose or poor contact on the No.1 injector 2P connector. INJECTOR INsecTOR CONNECTOR Connect the No.1 injector 2P connector. Place the motorcycle on ite side stand, ‘Tum the ignition switch ON. Check that the MIL blinks ¥ 2 bins ‘Turn the ignition switch OFF. Disconnect the No.1 injecior 2° connector and measure the resistance of the No.1 injector. Connection: Black/White (+) ~ Pink) Standard: 13.0-14.4 (20/68) Normal 5-26 No blink. + Loose or poor contact on the No.1 injector connec tor Abnormal . + Faulty No.1 injectorFUEL SYSTEM (Programmed Fuel Injection) ' Check for continuity between the No.1 injector and ground. Connecti Black/White (+) ~ Ground -) Standard: No continuity Ne continuity ‘Turn the ignition awitch ON. Measure the voltage between the No.1 injector ‘connector of the wire harness side and ground. Connecti Black/White (+) - Ground (-) Standard: Battery voltage Y vottage exists ‘Turn the ignition switch OFF Connect the No.1 injector connector. Continuity Out of range + Faulty No.! injector + Open or short circuit in BlacWWhite wire 5-27FUEL SYSTEM (Program: Disconnect the ECM connectors. Connect the test hamess to the connectors, = ecu TestHaRness figs (7 ~ Ses ire harness y a Measure the resistance at the test harness terminals, | e Connection: A13 (-) ~ B2 (+) Standard: 9-15 (20°C/68'F) t Normal — Check for continuity between the test harness ‘and groune. termins Connection: A13 (+)- Ground (-) Standard: No continuity Out of range Continuity No continuity *+ Open circuit in BlackWhite and/or Pink/Yellow wire + Shor circuit in Pini/Yellow wire {____. « epiace the £¢M with a new one, and inspect it again 5-28FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 13 BLINKS (No.2 INJECTOR) ‘Turn the ignition switch OFF. ean nae Disconnect the No.2 injector 2° connector. Check for joose or poor contact on the No.2 injector 2P connector. INJECTOR insecTOR CONNECTOR Connect the No.2 injector 2P connactor, Piace the motorcycle on its side stand. Turn the ignition switch ON. Check that the MIL blinks. {shine Turn the ignition switch OFF. Disconnect the No.2 injector 2P connector and. ‘measure the resistance of the No. injector. Connection: Black/White (+) - Pink/Blue (-) Standard: 11.1- 123 20°C/6 * Normal No blinks + Loose of poor contact on the No.2 injector connec: tor Abnormal + Faulty No.2 injector 5-29FUEL SYSTEM ( Continui (Check for continuity between the No.2 injector —2™PHY 5. Fauity No.2 injector and ground. Black/White (+) ~ Ground (-) ‘Standard: No continuity TN conta Hs hae Sean is ft peer aerial Connection: Black/White (+) - Ground (+) Standard: Battery voltage Volt ‘Turn the ignition switch OFF Connect the No2 injector connector.FUEL SYSTEM (Programmed Fuel Injection) t Disconnect the ECM connectors. Connect the test harness to the wire harness connectors. ECUTESTHARNESS a? i Measure the resistance at the test harness terminals, Connection: A2 (-) ~ B2 (x) Standard: 9-15 20'C/68'F) Normal Check for continuity between the test harness terminal and ground. fran Out of FaNGe «Open cirut in BlackiWhite andor Pink/Blue wire Continuity ee ink/Blue wire No continuity {___ Replace the ECM with a new one, and inspect it again 5-31FUEL SYSTEM (Pros PGM-FI MIL 14 BLINKS (No.3 INJECTOR) Turn the ignition switch OFF. 1 Disconnect the No injector 2P connector. ‘Check for loose or poor contact on the No.3 | injector 2P connector. S inuectoR Nw ae Ws) INJECTOR CONNECTOR, ———_ Connect the No. Place the motorcycle on its side stand. Turn the ignition switch ON, Check that the MIL blinks. [item Turn the ignition switeh OFF, Disconnect the No3 injector 2P connector and ‘measure the resistance of the No.3 injector Connection: Black/White (+) ~ Pink/ Standard: 130-144 (20°C/68') mmed Fuel Injection) Normal 5-32 + Loose or poor contact on the No.3 injector connec tor + Faulty No.3 injectorFUEL SYSTEM (Programmed Fuel Injection) y Check for continuity between the No.3 injector and ground. Black/White (+) ~ Ground (-| Standard: No continuity aaa ‘Turn the ignition switch ON. Measure the votage between the No.3 injector ‘connector of the wire harness side and ground. Black/White (+) - Ground (-) Standard: Battery voltage ¥ Votige exists ‘Turn the ignition switch OFF. Connect the No injector connector. Continuity ~ + Faulty No.3 injector ut of range. + Open or short circuit in Black White wireFUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM connectors. Connect the test harness to the wire harness connectors. ECU TEST HARNESS L_Out of range: Measure the resistance at the test harness terminals *+ Open circuit in Black/White andlor Pink/Gresn wire Connection: A12 (-)~ B2 (+) Standard:3-15 (20°C/68'F) Y Norma Ree Continuity Check for continuity between the test harness |-——"""""_» «short circuit in PinkiGreen wire ermine! end ground. Connection: A12 - Ground ‘Standard: No continuity "No continuity + Replace the ECM with a new one, and inspect it again 5-34FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 15 BLINKS (No.4 INJECTOR) ‘urn the ignition switch OFF ] Se Disconnect the No.¢ injector 2° connector, | Check for loose or poor contact on the No.t | injector 2° connector. INJECTOR INsecTOR CONNECTOR No blinke Connect the No. injactor 2° connector. RRR Le + Loose oF poor contact on the No.! injector Piace the motorcycle on its side stand, connector Turn the ignition switch ON. Chock that the MIL blinks, 15 blinks Abnormal Turn the ignition switch OFF Abnormal ie «Faulty No injactor Disconnect the No.4 injector 2P connector end measure the resistance of the No.4 injector. Connectio Black/White (+) ~ Pink/Black (-) Standard: 13.0~ 14.4 (20°C /68'F) 5-35‘Check for continuity between the No.4 injector and ground. Connection: Black/White (+) ~ Ground (-) ‘Standard: No continuity ¥ No continuity Turn the ignition switch ON. Measure the voltage between the No.4 injector connector of the wire harness side and ground, Q Connection: Black/White (+) ~ Ground (-) Standard: Battery voltage ‘Turn the ignition switch OFF. Connect the No.4 injector connector. 5-36 Continuity Out of range + Faulty No. injector + Open or short circuit in Black/White wireFUEL SYSTEM (Programmed Fuel Injection) al Disconnect the ECM connectors. Connect the tesi harness to the wire harness connectors, Meseace theirometarGelai mates kamwass | —CULOUTANGO go caeauitin Black/White sndjer Pink/Black wire’ terminals. 3 Connection: A12 (-) - B2 (+) Standard: 9-15 (20'C/88'F) 1__Continuit ‘Check for continuity between the test harness [Short circuit in Pink/Black wire terminal and ground. Connection: A12 - Ground Standard: No continuity No continuity {__ = + Replace the ECM with anew one, and inspect it again 5-37FUEL SYSTEM (Programmed Fuel Injection) PGM-Fi MIL 18 BLINKS (CAM PULSE GENERATOR) ‘Tum the Ignition switch OFF 1 Disconnect the cam pulse generator 2° connector. CEheck for loose or poor contect on the cam pulse generator 2° connector. CAMPULSE AV OL Generator CONNECTOR No blinks Connect the cam pulse generator 2P connector, + Locse ot poor contact on the cam pulse generator 2P connector Place the motorcycle on its side stand ‘Turn the starter motor more than 10 seconds ‘and then check that the MiL Buin. 18 inks Tura the ignition switch OFF and the engine stop switch OFF Disconnect the cam pulse generator 2° connector. | Continu Check the continuity between the cam pulse -——-~“""Y_» . Fauity cam pulse generator genorater connector terminal and ground, Connection: White/Yellow ~ Ground, ‘Standard: No continuity | No continuity 5-38FUEL SYSTEM (Programmed Fuel Injection) -—_}__=. Out of range Crank the engine with the starter motor, and ————“"# » . Fautty cam pulse generator measure the cam pulse generator peak voltage atthe cam pulse generator 2P connector. Connection: Gray (+)~ White/Yellow Standard: 0.7 V minimum (20°C/68) ¥ Normal Connect the cam pulse generstor 2P connector, Disconnect the ECM connectors. Connert the test harness to ECM connectars. ECU TEST HARNESS Out of range Crank the engine with the starter motor, and ——“° 8°, . Goon circuit in White/Yellow andior Gray wire measure the cam pulse generator peak voltage atthe test harness terminals. Connection: B11 (+) - Ground (-) Standard: 0.7 V minimum (20°C/63) ia CNet Replace the ECM with a now one, and ispectit again. 5-39FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 19 BLINKS (IGNITION PULSE GENERATOR) Turn the ignition switch OFF. HP Disconnect the ignition pulse generator 2P connector. Check for loose or poor contact on the ignition | pulse generator 2P connector. IGNITION PULSE GENERATOR CONNECTOR Connect the ignition pulse generator 2° 1 + Loose or poor contact on the ignition pulse gener- connector. stor 2P connector Place the motorcycle on its side stand. “Turn the starter motor moro than 10 seconds and then check that the MIL blinks. ¥19 blinks Turn the ignition switch OFF and the engine stop switch OFF Disconnect the ignition pulse generator 2° connector. IGNITION Pulse "A GENERATOR CONNECTOR = _, Abnormal Check the continuity between the ignition pulse ——APHOFMA . Fauity ignition pulse generator generator connector terminal and ground. No continuity 5-40¥ Crank the engine with the starter motor, and ‘measure the ignition pulse generator peak voltage at the ignition pulse generator 2° connector, Connection: Yellow |) ~ Yellow/White |) Standard: 0.7 V minimum (20°C/68'F) Tnemal Connect the igrition pulse generator 2P connector. Digconnect the ECM connectors. Connect the test harness to ECM connectors, ECU TEST HARNESS measure the ignition pi age at the test harness terminals. Connection: B11 (+) - Ground (-) ‘Standard: 0.7 V minimum (20°C/68F) FUEL SYSTEM (Programmed Fuel Injection) Out of range Ss» « Faulty ignition pulse genorator Out of range: + Open circuit in White/Yellow wire + Open circuit in Yellow wieo Normal > - heplave the Ect with a new one, and inspect it ‘again. 5-41FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 20 BLINKS (E?-PROM) ‘Turn the ignition switch OFF. 1 Disconnect the ECM connectors. Check for loase or poor contact of the ECM con: nectors. Connect the ECM connectors. Short the service check connector with ajumper wire (page 5:6). ‘Turn the ignition switch ON and check that the MIL blinks. connector (page 5-6). SERVICE CHECK | CONNECTOR, a \c | ——" JUMPER WIRE Loewe ___ ‘Turn the ignition switch ON and check that the MIL blinks. 20 biinks 120 blinks LSB Le Reset the sell-diagnosis memory data (page 67). Excapt 20 blinks, oe ‘Turn the ignition switch ON and check that the MiL blinks. L Excopt 20 biinke + Replace the ECM Blinks Remove the jumper wire from the service check + No problem 5-42beret Turn the ignition switch OFF, eS ‘Shortthe service check connector with e jumper wire (page 5-6) Turn the ignition switch ON and check the MIL blinks. 20 blinks Reset the self-diagnosis memory data (page 5-7) Turn the ignition switch ON and check the ML. blinks. FUEL SYSTEM (Programmed Fuel Injection) + No problem Excopt 20 blinks + No problem 20 blinks Cie gs opiace the ECM 5-43FUEL SYSTEM (Programmed Fuel Injection) FUEL LINE INSPECTION | NEGATIVE CABLE FUEL PRESSURE INSPECTION [NOTICE | + Before disconnecting fuel tubes, release the fuel pressure by loosening the service check bolt at the fuel tank. * Always replace the sealing washers when the ser- Viee check bolt ie removed or loosened. BATTERY Open and support the front end of the fuel tank (page 3-4), Remove the air cleaner housing side cover (page 2-2). Unhook the battery cover retainers, then open the battery cover Disconnect the battery negative cable from the battery terminal Disconnect the pressure regulater vacuum tube and prmererrmerree plug the vacuum tube. Cover the fuel hose sesling nut with a rag or shop towel ‘Slowly loosen the fuel hose sealing nut and catch the remaining fuel using a approved gasoline container,FUEL SYSTEM (Programmed Fuel Injection) Remove the fuel tube sealing nut. Install the special nut (Honda Genuine part) end attach the fusl pressure gauge. Special nut: Part No. 90201-90A-003, TOOL: Fuel pressure gauge 07406-00402 (07406-04003 ‘SPECIAL NUT Connest the battery negative cble. (SSS Start the engine. PRESSURE GAUGE Read the fuel pressure at idle speed. Dp IDLE SPEED: 1,200 = 100 min” (rpm) STANDARD: 343 kPa (3.5 kgf/em?, 50 psil If the fuel pressure is higher than specified, inspect ‘the following: ~ Pinched or clogged fuel return hose ~ Pressure regulator ~ Fuel pump (page 5-47) If the fuel pressure is ower than specified, inepect the following: = Fuel line leaking = Clogged fuel fiter = Pressure regulator = Fuel pump (page 5-47) Awys replace After inspection, remove the ful pressure gauge and the sesing wash reinstall and tighten the fuel hose sealing nut using srwhon the fos! the new sealing washer. ‘al saaing nut is removed ar loosened, TORQUE: 22 Nem (2.2 kgfom, 10 IDF) Connect the pressure regulator vacuum tube. Install the removed parts in the reverse order of romovel © VACUUM TUBE 5-45FUEL SYSTEM (Programmed Fuel Injection) FUEL FLOW INSPECTION FUEL CUT RELAY Remove the svat (page 2-2) Open and eupport the front end of the fuel tank (page 3-15). Disconnect the fuel cut relay connector. aon Jump the Brown and Black/White wire terminals of Chock he wre the wire harness side using a jumper wir ‘olor when you select te * When the fuel return hose is disconnected, gasoline ‘ue! will spill out from the hose. Use an approved gaso- cute, line container to drain the gasoline. + Wipe off spilled gasoline. Disconnect the fuel return hose at the fuel tank, plug the fuel tank inlet joint. Turn the ignition switch ON for 10 seconds. ‘Measure the smount of fuel flow. ‘Amount of fuel flow: 256 cm? (8.7 US oz, 8.0 Imp 02) minimum 10 seconds at 12 V Ifthe fue! flow is less than specified, inspect the followine: = Pinched or clogged fuel hose and fuel return hose ~ Clogged fuel filter ~ Pressure regulator ~ Fuel pump page 5-47) After inspection, connect the fuel return hose. Start the engine and check for leaks. 5-46FUEL SYSTEM (Programmed Fuel Injection) FUEL PUMP INSPECTION ‘Turn the ignition switch ON and confirm that the fuel pump operstes for a few seconds. the fuel pump does not operate, inspect as follows: (Open and support the front end of the fuel tank (page 3-18) Disconnect the fuel purnp 3P connector. ‘Turn the ignition switch ON and measure the voltage between the terminals. Connection: Brown (+) ~ Green (-) ‘There should be battery voltage for a few seconds. Ithere is battery voltage, replace the fuel pump. H there ie no battery voltage, inepeet the following: = Main fuse 304 = Sub fuse 10 ~ Engine stop switch (page 19-19) = Fuel cut relay (page 5-48) = Engine stop relay (page 5-76) = Bank angle sensor (page 5-75) ~ ECM (page 5-76) REMOVAL NOTE: + Before disconnecting the fuel hose, release the fuel pressure by loosening the fuel hose sealing nut at the throttle body. + Always replace the sealing washers when the fuel hose sealing nut is removed or loosened, Romove the fuel tank (page 5-49). Remove the fuel pump mounting nuts. Remove the fuel pump assembly and packing, PACKINGFUEL SYSTEM (Programmed Fuel Injection) Note the direction ‘ofthe fa! fer De not damage the fue revere Avays repisce packing with a FUEL CUT RELAY Check he wire 00" when yor soles the fue cut ‘ley 5-48 FUEL FILTER REPLACEMENT Disconnect the fuel tubes from the fuel filter. Remove the screws and fuel filter. Install the fue! fiterin the reverse order of removal, FUEL FILTER INSTALLATION Place new packing onto the fuel tank. Install the fuel pump, being careful not to damage the fuel pump wire, {stall and tighten the fuel pump mounting nuts in the sequence shown, ‘TORQUE: 12 Nem (1.2 kgfom, 9 Ibfft) INSPECTION Remove the rear cow! (page 2-3). Disconnect t the fuel cut rela jal cut relay 4P connector, romoveFUEL SYSTEM (Programmed Fuel Injection) ‘Connect the chmmeterto the fuel cut relay connector terminals. CONNECTION: Black/White— Brown Connect the 12V battery to the fellowing fuel cut relay ‘connector terminals. ‘CONNECTION: ;rown/Black ~ Black/White There should be continuity only when the 12V battery is connected. If there is no continuity when the 12V battery is connected, replace the fuel cut relay. FUEL TANK Do net remove the maintenance vite bol yet REMOVAL Remove the side cover (page 22). Loosen the fuel tank mounting kolt/nut. Slide the fuel tank to the backward. Open the front end of the fuel tank and support it Using a suitable support. Tighten the fuel tank mounting boltinut to the specified torque. TORQUE: 12 Nem (1.2 kgfem, 9 Ibtt) Release the fuel pressure (page 5-44) Dieconnsct the fusl tank sir vent hose and overflow tube. Remove the {uel hose sealing nut and sealing washers, then disconnect the fuel hose (page 5-44). NoTE: + Do not apply excessive force to the fuel pipe. + Always hold the fuel pipe nut while removing the fuel hose sealing nut. Temporarily install the 12 X 30 mm bolt (pitch 1.25) andssealing washers tothe fuel hose banjo, then tight en the sealing nut. FUEL CUT RELAY BATTERY BottNuT FUEL TANK ‘SEALING NUT/WASHERS 5-49FUEL SYSTEM (Programmed Fuel Injection) Remove the following: vel tank over flow hose Zp) FUEL RETURN HOSE ~ fuel tank air vent hose = fuel pump/reserve sensor 3P connector Clamp the the fuel rotuen hose, Disconnect the fuel return hose at the pressure regulater. Remove the bolt and maintenance wire. Close the fuel tank. Remove the ‘uel tank mounting balt/nut and fusl tank. Paes fea pei asi NOTICE Do not damage the fuel tank. Disconnect he uel return tube trom the fuel pump. Remove the fuel hose banjo bolt and sealing washers, then remove the fuel hose from the fuel pump. Refer to page 5-47 for fuel pump removal 5-50FUEL SYSTEM (Programmed Fuel Injection) FUEL TANK 22Nem (2.2 kat, 16 Ibieft) Connect the fuel hose to the fuel pump witn new sealing washers. Install and tighten the fuel hose banjo boltto the specified torque. TORQUE: 22 Nem (2.2 kgf+m, 16 Ibfft) Connect the fuel return hose to the fuel pump. Align the fue! hose eyelet joint wth the stopper on the fue pur Install the fuel tané onto the frame. Loosely install the fuel tank mounting botv/nut. ‘Support the front end of the fuel tank. Va —~ sotFUEL SYSTEM (Programmed Fuel Injection) Install the following: fuel tank over flow hose = fuel tank air vent hose = fuel pumpireserve sensor 3P connector FUEL RETURN HOSE Connect the fuel return tube to the pressure regulator. Connect the fuel pumpireserve sensor 3P (Black) connector. I and tighten the fuel tank maintenance bolt. Suppor the front end of the fuel tank. Connect the fue! hose banjo to the throttle body with, new aesling washers. While pushing the fuel hose banjo stopper to the throttle body, install and tighten the sealing nut to the specified torque. SEALING NUT Nore: + Do not apply excessive force to the fuel pipe. * Always hold the fuel pipe nut while tightening the fuel hose sealing nut. TORQUE: 22 Nem (2.2 kgfim, 16 Ibf-t) Remove the supporting tool and closo the fuel tank Slide the fuel tank forward and install the fuel tank stay to the frame rubber. Tighten the fuel tank mounting bolwnut to the speei- fied torque. TORQUE: 12 Nem (1.2 kgfom, 9 Ife) Install the side cover (page 2-2) 5-52FUEL SYSTEM (Programmed Fuel Injection) AIR CLEANER HOUSING REMOVAL Remove the throttie cables from the right handleber ‘switch housing (page 13-3). Remove the following: fuel tank (page 5-49) air cleaner element (page 3-5) Remove the vacuum tubes from the intake air duct ‘control solenoid val Disconnect the intake air duct control solenoid valve 2P connector. Disconnect the cam pulse generetor 2° connecior. Disconnect the crankcase breather tube from the air cleaner housing CCarifornia type only: Disconnect the No.5 tube trom the five way joint, Disconnect the fuel injector BP connector. Disconnect the No 4 fuel injector 2P connector. Remove the starter valve knob stay bolt. eee TF CONNECTOR FUEL INJECTOR [BP CONNECTOR 5-53FUEL SYSTEM (Programmed Fuel Injection) Remove the IAT sensor 2P connector. 2P CONNECTOR Remove the air cleaner housing mounting bolt. ? Loosen the insulator band screws {cylinder heac side). Disconnect the throttle body from the cylinder head, Remove the air cleaner housingithrottie body from the left side of the frame. NOTE: Seal the cylinder head inteke ports with tape or @ clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed DISASSEMBLY VACUUM TUBE Remove the vacuum tube from the one-way valve. the screws from the air cleaner housing and the housing, SCREWS 5-54FUEL SYSTEM (Programmed Fuel Injection) Remove the air funnel mounting screws, then remove the air funnels. AIR FUNNELS Remove the air cleaner housing. ASSEMBLY Check the rubber seals for damage and replace if necessary. Chock the rubber coals (air cleaner housing mating surface side) for damage and replace if necessary. RUBBER SEALS: Check the rubber seals (sir cleaner housing mating surface side) for damage and replace if necessary. EnRELEES Insill the air leener housing onto the throttle body. Install the air funnels in their proper locations. Inetall snd tighten the air funnel mounting screws securely. ‘Assemble the air cleaner housing halves. He Install and tighten the screws securely SEEFUEL SYSTEM (Programmed Fuel jection) Connect the vacuum tube to the one-way valve, VACUUM TUBE ‘Connect the erankcaso bré cleaner housing, thor tubs to the Connect the PAIR control valve air suction tube and, Intake vacuum tubes to the air cleaner housing. Connect the MAP sensor connector and vacuum tube. INSTALLATION Install the air cleaner housingithrotie body from the lef side of the frame. Tighten the cylinder head side insulator band so that the insulator band distance is 4 = 1 mm (0.2 = 0.04 in). Install the IAT sensor 2P connector. instal the air cleaner housing mounting bolt. BP ONNETR BOLT Install and tighten the by-starter vaive knob stay bolt. 5-56FUEL SYSTEM (Programmed Fuel Injection) Connect the fuel injector 8 connector. Connect the No.4 fuel injector 2P connector. Connect the crankcase br cleaner housing. ther tube to the air Install the vacuum tubes to the intake air duct control solenoid valve. Connect the intake air duct control solenoid valve 2P connestor. Connect the eam pulse generator 2P connector. Install the following cleaner element (page 3-5) = fue! tant (page 5-51), Connect the throttle cables to the throttle pipe (page 13-9), 5-57FUEL SYSTEM (Programmed Fuel Injection) THROTTLE BODY REMOVAL NOTE: + Before disconnecting the fuel hose, release the fuel pressure by loosening the service check bolt. + Always replace the sealing washer when the service ‘hack bolt is removed ar loosened. DISASSEMBLY SUB-HARNESS Remove the throttle body sub-harneee from the TP Fiefer 0 e80® (Thiottle position) sensor. 554 fe: 7018! Disconnect the fuel injector connector from the ‘ofthe throttle eye throttle body. Disconnect the vacuum tubes from the throttle body. ‘VACUUM TUBES. 0 notsnae the Loosen the insulator band serews and remove the throtie vave fom insulators from the throttle body. Tull open to fal close ster the aro cable has been removed. It may cause Incerect le eperaton, Disconnect the throttle cable ends from the throttle drum, 5-58FUEL SYSTEM (Programmed Fuel Injection) NOTICE + Do not damage the throitle body. It may cause incorrect throttle and idle valve synchronization. + The throtte body is factory pre-set. Do not disessemble in a way other than shown in this manual. + Do not locsen or tighten the white painted bolts and screws of the throttle body. Loosening or tightening them can cause throttie and idle valve synchronization failure. ‘ToP VIEW: 10 Nem (1.0 kgfem, 7 Ibftt) be WHITE PAINTED REAR VIEW: 10 Nem (1.0 kgfem, 7 bf) 1 Nem (0.09 kgf+m, 0.7 IbFft) 5.Nem (0.5 kgftm, 3.6 lof) 5-59FUEL SYSTEM (Programmed Fuel Injection) RIGHT SIDE VIEW: CALIFORNIA TYPE ONLY: EvAP PURGE. CONTROL VAWE WHITE PAINTED THROTTLE BODY VACUUM TUBE ROUTING VACUUM TUBES (California type only) 6 TUBE JOINT (California type only) 5-60ASSEMBLY Connect the throttie cable ends to the throttle drum, Check the inaulator band angle. Install the insulators onto the throttle body. BAND SCREWS Tighten the throttle body side insulator band so that the inaulator band distance ie 7 + 11mm (03 + 0.04 in) Tat mim 10.3 = 0.04 in) Apply oil to the insulator inside surfaces for ease of al throitle body installation, o Connect the vacuum tube to the throttle body. = SUB-HARNESS 5-61FUEL SYSTEM (Programmed Fuel Injection) Route the throttle body sub-harness properly 7 and connect the injector connectors and TP sensor SUB-HARNESS connector Install the throttle body to the air cleener case = \page 5-85). INJECTOR INSPECTION Start the engine and lett idle. Confirm the Injector operating sounds with a sounding rod or stethoscope. Ifthe injector does not operate, replace the injector. REMOVAL Remove the throttle body (page 6.58. Remove the bolts and fuel rail assembly, Remove the injectors from the fuel ral ST RAT ASSEETy INSULATORFUEL SYSTEM (Programmed Fuel Injection) Remove the O-rings INSTALLATION oe oplace the 0. Apply ail to the new O-rings. ings with rew Install the new O-rings and being careful not to dam- onesasaset age the O-ring, INJECTOR ™ FUEL RAIL ASSEMBLY Install the fuel injectors into the fuel ral, being caretul not to damage the O-rings. Install the fust rail assembly onto the throttle body, being careful not to damage the O-rings. Install and tighten the fuel rail mounting bolts to the specified torque. TORQUE: 12 Nem (1.2 kgfem, 9 ft) Install the throttle body (page 666). PRESSURE REGULATOR REMOVAL/INSTALLATION NOTE: Do not apply excessive force to the fuel ral. PRESSURE REGULATOR Hold the fue! rail secutoly, remove the preseure regulator mounting bolts, then remove the pressure regulator.FUEL SYSTEM (Programmed Fuel Injection) Disconnect the vacuum tube from the pressure ap OFING |” PRESSURE REGULATOR regulator. @ Install a new O-ring into the pressure regulator body. Install the pressure regulator onto the fuel pipe. Connect the vacuum tube to the pressure regulator. Hold the fuel pipe securely, tighten the pressure regu» PRESSURE REGULATOR lator mounting bolts to the specified toraue. TORQUE: 10 Nem (1.0 kgfem, 7 tof) STARTER VALVE CABLE/THROTTLE STARTER VAIVE CABLE STOP CONTROL KNOB CONTROL KNOB REMOVAL Donottwn Remove the cable stay mounting screws. the torte stop control knob, Remove the starter vaive cable end from the link arm, Remove thee: le stay/throttle stop control knob. INSTALLATION Connect the starter valve cable end to the link arm. CONTROL KNOB Inscall the starter vaive cable to the cable stay and tighten the cable stay mounting screws securely. ‘CABLE STAY 5-64FUEL SYSTEM (Programmed Fuel Injection) STARTER VALVE DISASSEMBLY STARTER VALE Remove the fuel ail and injectors (page 5-62). Turn each starter valve adjusting seew in, counting the number of turns unti it seats lightly Record the number of turne. STARTER VALVE ARM Romave the at knod (pege 5:62). tr valve eablethrattle stop cantral Remove the starter valve aim screws and starter valve arm, VALVE ARMS: LINK ARM LINK ARM Remove the screws and link arm. Romove the starter valve chat and three collars.Loosen the lock nut and remove the starter valve assembly. STARTER VALVES Pig FUEL RAIL. 0 ot apply com Clean the starter mercially avalabie ‘carbureror clear e'5 to theinsie ‘ere, whichis ‘molybdenum. Ive bypass using compressed air. ASSEMBLY VACUUM TUBES: PRESSURE REGULATOR 41 Nem (0.09 kafem, 0.7 IbfeR) en X THROTTLE STOP. CONTROL NoB Sage = i" 8 INJECTOR ‘STARTER VALVE BY-STARTER VALVE ee conraat Nos INSULATOR 5-66FUEL SYSTEM (Programmed Fuel Injection) Chock the starter valve and spring for damage. " ‘STARTER VALVE Install the starter valve assembly into the valve hole. ea Tighten the starter valve lock nut to the specified torque. STARTER VALVE TORQUE: 2 Nem (0.18 kgfem, 1.3 Ibfft) Install the starter valve shaft and three collars. COLLARS ‘SHAFT LINK ARM. LINK ARM Install the link arm to the starter valve shaft and tighten the mounting screws to the specified torque. TORQUE: 1 Nem (0.09 kgfm, 07 Ib) 5-67FUEL SYSTEM (Programmed Fuel Injection) STARTER VALVE ARM ; Install the starter valve arms onto the starter valves. Install and tighten the starter valve arm mounting screws to the specified torque. TORQUE: 1 Nem (0.09 kgfm, 0.7 Ibf-t) Install the sterter valve cable/throttle stop control nob (page 5-64) ‘Turn the starter valve serew until it seats lightly, thon back it out as noted during removal, Install the throttle body (page 566). STARTER VALVE SYNCHRONIZATION Nore: + Synchronize the starter valve with the engine at the hhormal operating temperature and with the transmission in neuttal . + Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change. ‘Open and support the front end of fuel tank (page 2-18) Remove the No.1 and Nowt vacuum tubes from the thrattle body. VACUUM TUBES Connect the tubes to the vacuum gauge. WRELUM GAUGE Connect the tachometer. 5-68Disconnect the PAIR air suction hoses from the reed valve covers and plug the cover. Start the engine end adjust the idle speed IDLE SPEED: 1,200 = 100 min* (rpm) The No2 stater Adjust each intake vacuum pressure with the No.2 \alve cannot be cylinder. adusted itis the aso starr vave Remove the plugs and connect the PAIR air suction hoses to the reed valve covers. Adjust the idle speed if the idle speed differs from the ‘spotified speod. IDLE SPEED: 1,200 = 100 min" (epm) Remove the vacuum gauge from the vacuum tubes. Connect the pressure regulator vacuum tubes to the Sway Connect the No.1 and No.4 cylinder vacuum tube to the throttle body. 5-69FUEL SYSTEM (Programmed Fuel Injection) MAP SENSOR OUTPUT VOLTAGE INSPECTION Connect the test harness to the ECM (nage $8. Measure the voltage at the test harnese torminale (page &9). CONNECTION: 87 (+) ~ Bt (-) STANDARD. 2.7-3.1V ‘The MAP sensor output voltage (above) is measured under the standerd atmosphere (1 atm = 1,020 hPa). The MAP sensor output voltage is affected by the di tance above sea level, because the output voltage is ‘changed by atmosphere. Check the sea level measurement and be sure thatthe ‘measured voltage falls within the specified value. MAP SENSOR REMOVAL/INSTALLA- TION Remove the fuel nk (page 8-<9) Disconnect the MAP sensor connector. Disconnect the vacuum tube from the MAP sensor. Remove the air cleaner housing (page 5-53). Remove the screw and MAP sersor from the air cleaner housing, Installation is in the reverse order of removal 5-70 20 1s issn 13300) 4380) (0) een CONNECTOR MaP SENSORIAT SENSOR ECT SENSOR Replace the ECT ‘engine is aid Aways replace a oaling washer with anew ene FUEL SYSTEM (Programmed Fuel Injection) REMOVAL/INSTALLATION Open and support the front end of the fuel tank (page 3-4), Disconnect the IAT sensor connector. Remove the screws and IAT sensor from the air clean or housing cover. Check the O-ring for damage and replace if necessary. TAT SENSOR Installation is in the reverse order of removal. REMOVAL/INSTALLATION Drain the coolant from the system (page 6-5). Remove the thermostat (page 6-6). Disconnect the ECT sensor connector from the Remove the ECT sensor and G teal Ga navaeniane ‘ a A ne ee sanemase ip. ¥ Y TORQUE: 23 Nem (2.3 kgf, 17 IF) cw * Connect the ECT sensor connector. Fill the cooling system with recommended coolent (page 6-5), 5-71EL SYSTEM (Programmed Fuel Injection) CAM PULSE GENERATOR 2P CONNECTOR REMOVAL/INSTALLATION Open and support the front end of fuel tank. (page 24). Disconnect the cam pulse generator 2P connector. Remove the bolt and cam pulse generator from the ‘cylinder head, ‘CAM PULSE GENERATOR Install the new O-ring onto the cam pulse generator. Install the cam pulse generator into the cylinder head, Install and tighten the mounting bott securely. P oang Al burs Route the cam pulse generator wire properly, connect =n the 2P connector. Install the removed parts in the reverse order of romoval. 5-72FUEL SYSTEM (Programmed Fuel Injection) TP SENSOR INSPECTION ECU TEST HARNESS Remove the rear cowl (page 23) Disconnect the ECM 22P (Black) and 22P (Light aray) connectors, CChack the connector for loose ar corroded terminals, Connect the ECU test harness between the ECM and mein wire harnese, TooL: ECU test hamess o7yMz-0010100 (two required) 1. INPUT VOLTAGE INSPECTION Tum the ignition switch ON and measure and record the input voltage at the test hamess terminals using @ digital multimeter. ‘CONNECTION: BI (+! —A22 (-) Standard: 4.55.5 V If me measurement is out of specification, check the following: = Loose connection of the ECM mutti-connector = Open circuit in wire harness 2. OUTPUT VOLTAGE INSPECTION WITH THROTTLE FULLY OPEN, ‘Turn the ignition switch ON and measure and record the output voltage at the test harness terminals. ‘CONNECTIOF BI (+) ~ B9 (~) MEASURING CONDITION: At throttle fully open 3, OUTPUT VOLTAGE INSPECTION WITH THROTTLE FULLY CLOSED Turn the ignition ewiteh ON end measure and record the output voltage with the throttle fully closed. ‘CONNECTION: BA (+) ~B9(-) MEASURING CONDITION: {At throttle fully closed 5-73FUEL SYSTEM (Programmed Fuel Injection) 4. CALCULATE RESULT COMPARISON Compare the measurement to the result ofthe following calculation. With the throtle fully open: Measured input voltage X 0.824= Vo The sensor ig normal ifthe measurement output voltage measured in step 2s within 10% of Vo. With the throttle fully closed: Measured input voltage X 0.1 = Ve ‘The sensor Is normal ifthe throttle closed output vore- age measured in step 3is within 10% of Ve. Using an analog meter, check that the needle of the voltmeter swings slowly when the throttle is opened oradually, CONTINUITY INSPECTION Open and support the front end of fuel tank (page 3-41, Disconnect the ECM 22P (Light gray) connector and the TP sensor 3P connector, Check for continuity between the wire harness and 1P sensor. If there is no continuity, check for an open or short circuit in the wire hamess. BANK ANGLE SENSOR Do rot disconnect he tank angie dining inspect INSPECTION Support the motorcycle on 2 level surface. Remove the rear cow! (page 2-3). Turn the ignition switch ON and measure the voltage betwoen the following terminale of tho bank angio sensor connector with the connector connected. 2P CONNECTOR TERMINAL ‘STANDARD White (4)- Green) | Battery voltage Red/Green |+) ~ Green o-1v Turn the ignition switch OFF. Remove the screws, washers, nuts and bank angle h NUTS BANK ANGLE'SENSOR 5-74FUEL SYSTEM (Programmed Fuel Injection) Paco the bank angle sanscr horizontal as shown, and. turn the ignition switch ON, Tati sR ieee rnM eR MOREA 2 eee nF | oe Inline the bank angle teneor wproximatly 60 | NORMAL teporximatohT@h 60° BANK ANGLE POSITION degrees to the left or right with the ignition switch | POSITION ON. ‘The bank angle sensor ie normal if the engine stop relay clicks and power supply is open. If you repeat this test, first turn the ignition switch eo OFF, then turn the ignition switch ON. (approximately) REMOVAL/INSTALLATION Disconnect the bank angle sensor 3P (Green) connector. Remove the two screws, nuts and bank angle sensor. Install the tank angle sensor with Installation is in the reverse order of removal its "UP" mark ‘acing up. Tighten the mounting screws securely. ENGINE STOP RELAY ENGINE STOP RELAY INSPECTION Check the wire olor when you select the engine slop rey, Disconnect the engine stop relay 4P connector.FUEL SYSTEM (Programmed Fuel Injection) Connect the chmmeter to the engine stop relay connector terminals. CONNECTION: Red/White - Black/White Connect the 12 V battery to the fellowing engine etop relay connecter terminals. CONNECTION: Red/Orange - Black There should be continuity only when the 12 V battery Is connected, If there is no continuity when the 12 V battery is connected, replace the engine stop relay. ECM (ENGINE CONTROL MODULE) REMOVAL/INSTALLATION Remove the rear cowl (page 2-2). Disconnect the ECM 22P (Black) end 22P (Light gray) connectors. POWER/GROUND LINE INSPECTION ECU test harness o7vmz-0010100 {two required) GROUND LINE Check for continuity between the ECM test hainess connector AS terminal and ground, between the A20 terminal and ground, and between the A12 terminal and ground. There should te continuity at all times. If there ie no continuity, check for an open circuit in Green/Pink wire and Green wire. POWER INPUT LINE Turn the ignition switch ON with the engine stop ‘switch in the RUN position, Measure the voltage between the ECM test hamess connector B6 terminal (+) anc ground. There should be battery voltage. If there is no voltage. check for an open circuit in BlackWhite wire between the ECM and bank angle sensor/rolay. Ifthe wire is OX, check for the bank angie sensor/telay (page 5-76). ENGINE STOP RELAY BATTERY CONNECTORS 22P (BLACK) CONNECTOR pet 22? (LIGHT GRAY) CONNECTOR 5-76FUEL SYSTEM (Programmed Fuel Injection) PAIR SOLENOID VALVE REMOVAL/INSTALLATION 2P CONNECTOR Romove the air cleaner housing (page 5-60). Disconnect the PAIR solencid valve 2P (Black) connector. Disconnect the PAIR air suction hose and air injection hoses. Remove the bolt and PAIR solenold valve. AIR INJECTION HOSES Installation isin the reverse order of removal. INSPECTION ®) e) Remove the PAIR solencid valve. wy (Check that air flows (A) to (B) only when the 12 V battery is connected to the PAIR solenoid valve terminals PAIR SOLENOID (Check the resistance between the terminals of the VALVE PAIR solenoid valve. STANDARD: 20-24 (20°C/68'F) 5-77FUEL SYSTEM (Programmed Fuel Injection) EVAPORATIVE EMISSION CONTROL No.1 TUBE (Fuel tank-to-Canister) SYSTEM (California type only) Note: + Refer to the Vacuum Hose Routing Diegram and Cable & Harness Routing ipage 1-33) for the tube ‘connections and routing. EVAPORATIVE EMISSION (EVAP) CANISTER REMOVAL/INSTALLATION Disconnect the No.1 and No.4 tube from the EVAP canister and remove them from the clemp. Remove the bolts, nuts and the EVAP canister from the bracket Install the EVAP canister in the reverse ordor of removal. No.3 TUBE (Drain) No.2 TUBE (Open air-to-Canister) EVAP PURGE CONTROL SOLENOID VALVE REMOVALJINSTALLATION Disconnect the No.4 and No tubes from the EVAP. urge control solenoid valve. Remove the bolts, nuts and solenoid valve from the stay. Disconnect the 2P connector from the ¢olenoid valve, Install the solenoid valve in the reverse order of removal. INSPECTION Remove the solenoid valve. Check air flow from tube fitting (A) {input port) to tube fiting (B) (output port) Air should not flow out. Connect the 12 V battery to the solenoid valve ‘connector, CONNECTION: Battery (+) ~ Black/White terminal Battery (+) ~ Yellow/Black terminal Air should flow when the battery is connected.COOLING SYSTEM SYSTEM FLOW PATTERN UPPER RADIATORHOSE —gipon TUBE RADIATOR LOWER RADIATOR HOSE6. COOLING SYSTEM ‘SYSTEM FLOW PATTERN 60 THERMOSTAT 66 SERVICE INFORMATION 61 RADIATOR 67 TROUBLESHOOTING 62 WATER PUMP 612 | SYSTEM TESTING 63 RADIATOR RESERVE TANK 615 | COOLANT REPLACEMENT 64 SERVICE INFORMATION GENERAL A WARNING LS. Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radietor cool down before removing the radiator cap. + Ifany coolant gets in your eyes, rinse them with water and consult a doctor immediately, + Hfany coolant is swallowed, induce vomiting, gargle and consult a physician immediately. + ifany coolant gets on your skin or clothes, rinse thoroughly with plenty of water. _ NOTICE Using coolant with silicate inhibitors may cause premature wear of water pump seais or bloctage of radiator passages. Using tap water may couse engine damage. + Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. + All cooling system services ean be done with the engine in the frame. + Avoid spilling coolant on painted surfaces, + After servicing the system, check for leaks with a cooling system tester + Refer to section 19 for fan motor relay and coolant tomporature senor inspection.COOLING SYSTEM SPECIFICATIONS rem IFCATIONS: Coolant capacity Radiator and engine “42 liter (838 US qt, 2.82 Imp at) q Reserve tank 08 liter (085 US gt, 0.70 Imp at) Radiator eap rel Thermostat 108 ~ 137 kPa (1.1 ~ 1.4 kgflem, 1 0-88 C (176-183) 95°C (203 F) 8mm (03 Pro Honda Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection ini specifically recommended for use in aluminum engines 208i) Recommended antifreeze Standard coolant concentration 5018 0% mixture with sof water TORQUE VALUES \Water pump cover flange bolt 12Nem (1.2 kghem, 8 IBF) CT bolt ‘Thermostat cover flange bolt 12Nem (1.2 kgfem, 9 Ibfft) CT bolt ECTitnermo sensor 23 Nem (2.3 kgfer, 17 lett Cooling fan mounting aut 3.Nem (0.27 kafem, 2.01bf+R) Apply a locking agent to the threads Fan motor mounting nut, 5 Nem (0.5 kgfem, 3.6 lft) TROUBLESHOOTING Engine temperature too high Coolant leak + Fauity temperature gauge or ECTithermo sensor + Faulty water pump machanical coal + Thermostat stuck closed + Deteriorated O-rings + Fauity radiater cap + Faulty radiator cap. + Insufficient coolant + Damaged ot deteriorated cylinder head gasket + Passages blocked in radiator, hoses or water jecket + Loose hose connection or clamp + Airin system + Demaged or deteriorated hose + Faulty ecoling fan motor + Faulty fan motor relay + Fauity water pump Engine temperature too low + Fauity temperature gauge or ECTithetmo sensor + Thermostat stuck open + Faulty cooling fan motor relayCOOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Open and support the front end of fuel tank (page 3-4), Remove the radiator cap. Test the coolant gravity using # hyciometsr tsee Q HYOROMETER below for “Coolant gravity chart”) fe For maximum corrosion protection, a 50-50% solu- — tion of etnylnne glycol and ditlled water it recom: mended (page 6), took for eonteminttion and replace the coolant i eos. COOLANT GRAVITY CHART Coolant temperature C (F) 0 5 10 1% 2 2 30 35 4 45 50 Coolant ratio 2) 1) (60) G8) (G8) G8) Gs) (4) tt) (22) 5 1.091.008 1.008.006 1.007.006 1.06 3.008.001 a0 0se7 10 1.081.017 1.017 1.016 1.016 1.014 1.013 1.011.000 |1.007*.005 6 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.078.016 1014 1.012 0 98.086 .0841.089 18.088 .008|3.027 [3.028.281.0210 5 1.45 1044/1013 1.042 1.040 1.038 1036 1.034 1.001.020 +07] 30 1.053 1.052 1.051 1.047 1.046 1.088 1.043 1.081 1.098 1.035 1.032 3 1.063 1.052 1060 1.058 1056 1.054 1052 1.049 1.088 1049 1040 I 40.072 1.070 1.0681. 1.084 1.082 1059) 1.056 1.059 1.050 1.007 © ‘00 1.076 72 coo ua| ee ar ec 082.000] 07.074 |3.074|-one 06.0. 5 1.095 1.088 1.061.066 1.065 1.082 |1.079 1.076 1.073 1.070.087] 60 1.10 1.086 1.065 1.082 1.066 1.086 1.085.060 1.077 1076 +071COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (see previous pagel seairg suraces. Prossure test the radiator Replace the radiator cap if it does not hold pressure, oF if rol proseure is too high or too low. Itmust hole specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108 ~ 137 kPa (1.1 ~ 1.4 kgt/em’, 16 ~ 20 psi) Pressure the radiator, engine end hoses, and check for leais, [NOTICE | Excessive pressure can damage the cooling system components. Do not exceed 137 kPa (7.4 kgifem, 20 psi Repair or replace components if the system will not hold epecified pressure for at least 6 seconds. COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the ‘ccumultion of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified in the maintenance schedule. Mix only distilled, low mineral water anti-freeze. ththe RECOMMENDED ANTIFREEZE: Pro Honda Coolant or an equivalent high quality sthylene glyeel antifreeze containing corrosion protection inhibitors specifically recommended for ute in aluminum ons RECOMMENDED MIXTURE: 50-50% (Distilled water and antifreeze) REPLACEMENT/AIR BLEEDING Remove the radiator cap. or checking place the motor positen on fat, RADIATOR ‘ANTIFREEZE SOLUTION SD (ETHYLENE GLYCOL BASE LOW MINERAL SOLUTION) OR DISTILLED WATER RADIATOR CAP. 6-4Remove the lower cowl (page 2-4), Remove the drain bolt on the water pump cover and drain the system coolant. Reinstall the drain bolt with the now sesling washer. Tighten the water pump drain bolt to the specified torque. TORQUE: 12 Nem (1.2 kgm, 9 Ibft) Disconnect the siphon tube from the radiator. Drain the reserve tank coolant. Empty the coolant and rinse the inside of the reserve ‘tank with water, Reinstall the radiator siphon tube. Fill the system with the recommended coolant through the filler opening up to filler neck. Remove the radiator reserve tank cap and fill the reserve tank to the upper level line. Bleed air from the system as follows: 4. Shift the transmission into neutral. Start the engine and let it idle for 2 ~ 3 minutes. 2.Snep the throttle 3 - 4 times to bleed air from the sysiem. 2.Ston the engine and add coolant up to the proper level if necessary. Reinstall the radiator cap. 4. Check the level of coolant in the reserve tank and fil to the upper level if itis low. COOLING SYSTEM FILER NECK FILLER CAP,COOLING SYSTEM a — — ee SSS THERMOSTAT THERMOSTAT REMOVAL Open and suppor the front end of fuel tank (page 3-4). Drain the coolant (page 6-5) Remove the bolts and thermostat housing caver. Remove the O-ring from the thermostat housing THERMOSTAT HOUSING COVER Remove the thermostat from the housing. THERMOSTAT INSPECTION Wear insulated gloves and adequate eye protection. Keep flammable materials away trom the electic heating element, Visually inspect the thermostat for damage. Heat the water with an electric heating element to Do net let the operating temperature for § minutes. ‘thermosiator Suspend the thermostat in heated water to check iis thermometer operation, touch the pan, or you wil get @ falsevosing Reblace the thermostat if the valve stays open at Foom temperature, or if it responds at temperatures other than those specified. ‘THERMOSTAT BEGIN TO OPEN: 80 ~ 84°C (176 ~ 183 F) VALVE LIFT: 8 mm (0, ‘minimum at 95 °C (208 THERMOSTAT 6-6COOLING SYSTEM THERMOSTAT INSTALLATION "AIR BLEED HOLE Install the thermostat housing onto the cylinder heed. Install the new O.ring onto the thermostat housing THERMOSTAT HOUSING COVER (fP Install the thermostat housing cover onto the cylinder hhead and tighten the housing cover bolts. TORQUE: 12 Nem (1.2 kgfom, 9 Ibfft) Fill the coolant and bleed air from the system (page 6-5). THERMOSTAT HOUSING COVER. RADIATOR REMOVAL Open and support the front end of fuel tank (page 3-4 Drain the coolant ipage 6-5). Disconnect the lower radiator hose, [LOWER RADIATOR HOSECOOLING SYSTEM Disconnect the fan-motor 2P connector. Disconnect the upper radiator nose. Remove the radiator lower mounting belt/nut and washer. Remove the radiator upper mounting bolt. Slide the radiator to the right, then release the upper ‘arommat from the frame boss. Romove the radiator assembly. DISASSEMBLY HOOKS Remove the radiator grille, RADIATOR GRILLE Flemove the bolts anc side cover. Botts 6-8COOLING SYSTEM Romove the bolts and fan motor assembly. FAN MOTOR ASSEMBLY, Remove the nut and cooling fan. COOLING FAN NUT Remove the fan motor wire from the clamp. FAN MOTOR Remove the flange nuts and fen motor from the fan motor shroud. 6-9COOLING SYSTEM ASSEMBLY 3 Nem (0.27 kgfem, 2.0 lbftt COOLING FAN FAN MOTOR FAN MOTOR ‘SHROUD RADIATOR sive ¢over Nem (0.5 kgm, 3.6 IbEft) Install the fan motor onto the fan motor shroud and tighton the flange nuts to the specified toraue. FAN MOTOR TORQUE: 5 Nem (0.5 kgfem, 26 Ibfft) Install the fan motor wire to the clemp. Install the cooling fan onto the fan motor shaft by aligning the flat surfaces. 6-10COOLING SYSTEM Apply a locking agent tothe cooling fan nut threads. a “YY Install and tighten the nut tothe sperified torque. TORQUE: 3 N-m (0.27 kafem, 2.0 Ibf-t) COOLING FAN Install the cooling fan motor assembly onto aN GOR ASSES the radiator. Install and tighten the bolts. Install the side cover and tighten the bolts. BDSCOvET {e cwvetu'nor Install the hook at the raaistor grille to the radiator ODS RADIATOR GRILLE 6-11COOLING SYSTEM INSTALLATION Install the radiator assembly, aligning its grommet with the frame boss. Install the washer and upper mounting bolt, then tighten the bolt. Install the radiator lower mounting bolnut, tighten the nut securely, Connect the upper radiator hese and tighten nose band screw securely. Connect the lower radiator hose and tighten hose band screw securely, Connect the fan motor 2P connector. Fillthe system with recommended coolant (nage 6-5) WATER PUMP MECHANICAL SEAL INSPECTION Inspect the inspection hole for signs of coolant leakage. If there is leakage, the mechanical seal is defective. Roplace the weter pump as an as 6-12COOLING SYSTEM REMOVAL Drain the coolant (page 6-4) Disconnect the lower radiator hose and bypass hose from the water pump cover. Remove the bolts and water pump cover. Remove the O-ring from the water pump body. Disconnect the water pump-to-water joint hose and ll cooler water hose from the water pump body. Remove the water pump body from the crankcase. 6-13COOLING SYSTEM INSTALLATION WATER PUMP BODY 12 Nem (1.2 kgm, 9 IDE) Apply engine oil toa new O-ring and install it onto the stepped portion of the water pump. Inetall tho water pump into the crankcase while aligning the water pump shaft groove with the oil pump. sshaft end by turning the water pump impeller, ware PUMP WATER HOSE Install a new O-ring into the graove in the water pump body. Connect the water hose. 6-14COOLING SYSTEM Connect the water pump-to-water joint hose Install the water pump cover, two SH bolts and two flange bolts. Tighten the flange bolts to the specified torque. BOLTS. TORQUE: 12 Nem (1.2 kgfor, 9 bff) Tighton the two SH bolts. Connect the lower radiator hose and bypass hose, then tighten the clamp screws. Fill the system with recommended coolant (page 6-5) Install the lower cowl (page 2-5). RADIATOR RESERVE TANK REMOVAL Remove the rear shock absorber (page 14-10) Disconnect the siphon tube end drain coolant from the reserve tank. Remove the radiator reserve tank Drain the coolant, INSTALLATION Installation isin the reverse order of removal. Install the flange collar and washer as shown. Install the rear shock absorber (page 14-13), 6-15ENGINE REMOVAL/INSTALLATION 7-07. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION TA ENGINE INSTALLATION 16 DRIVE SPROCKET REMOVAL 13 DRIVE SPROCKET INSTALLATION — 7-8 ENGINE REMOVAL 14 SERVICE INFORMATION GENERAL + Ahoist or equivalent is required to support the motorcycle when removing and installing the engine. + Atloor Jack or other adjustable support is required to support and maneuver the engine. + Do not use the oil filter as a jacking point. = + The following components require engine removal for service. = Crankcase, transmission (Section 11) = Crankshatt piston/cylinder (Section 12) = Shift fork, shift drum (Section 12) + When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified ‘sequence. if you mistake the tighten torque or sequence, loosen all mounting fasteners, then tighten them again to the spec- Ified torque in the correct sequence. 7-1ENGINE REMOVAL/INSTALLATION SERVICE DATA Tm SPECIFICATIONS Engine dry weight _ 68 kg (149 Ibs) Engine ol capacity After disassembly ‘4 ter 46 US at 3:9 Imp a Coolant capacity Radiator and engine 3.2 liter (838 US at 2.82 Imp at) TORQUE VALUES Front engine henger botts/nuts 50 Nem (6:1 kgf, 37 Ib Fear upper engine hanger botunut 50 Nem 6.1 kgm, 37 len) Rear lower engine hanger botinut 80 Nem (6:1 kgf, 37 lbh Drive sprocket special bolt 54 Nem (65 kgm, #0 Ib Gearshift nkage bolt 20 Nem (2.0 kgm, 14 A) 7-2ENGINE REMOVAL/INSTALLATION DRIVE SPROCKET REMOVAL Loosen the drive chain |page 3-18). Remove the drive sprocket cover bolts and sprocket cover, ‘SPROCKET COVER Hemove tne diive chain guide plate. 9 DRIVE THAN GUIDE PUATE aia K Remove the drive sprocket, washer and the drive AVEC A) washer ‘wngam psot sprocket with the drive chain from the countershaftENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Pippen water HOSE Drain tho engine oil {page 3-11). Drain the coolant (page 6-4) Remove the following: ~ clutch cable (page 9-3) ~ air cleaner housing (page 6-53) = rediator (page 67) — exhaust pipe/mufflor (page 2-8) ~ starter motor terminal nut (page 1-4) Disconnect the upper water hose. Disconnect the PAIR air supply hoses from the reed valve covers, Disconnect the ignition plug caps. Disconnect the crankcase breather tube. "AR SUPPLY HOSES: Disconnect the following: ~ crank pulse generator 2P connector ~ regulatorirectfier 3P/4P connector ~ speed sensor 3P connector ~ oll pressure/neutral switch 2P connector ~ side stand switch 2P connector ECT sensor 3P connector CONNECTORS ee ae : 2P CONNECTOR — cam pulse generator 2P connectorENGINE REMOVAL/INSTALLATION Remove the gearshift arm pinch bolt, then remove the gearshift arm frorn the goarchift epinclo. ‘Support the engine using a jack or other adjustable ‘Support to ease engine hanger bolts removal. EOLTSINUTS/COLLARS. aoe Note: Do not support the engine at the oil iter. Remove the bolts and water by-pass cover. Romove the right side of the front engine hanger bolt, nut and distance collar. Remove the left side of the front engine hanger bott, rut and distance collar. Remove the rear upper and lower engine hanger bolts /nute, Remove the engine. Note the direction and position of the hanger bolts, ruts and distance collars. 7-5ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION + The jack height must be continually adjusted to relieve strass from the mounting fasteners. + Route the wire and cables properly (page 1-23). NoTE: Be sure to tighten all engine mounting fasteners to the specified torque. Carefully install the engine into the frame. Loosely install the reer upper end rear lower engine hanger bolts/nuts. Loosely install the right and left side of the front engine hanger bolt, nut and distance collar Tighten all the engine hanger bolts to the specified torque, ‘TORQUE: Ri/L. front engine hanger bolts/nuts: 50 Nem (5.1 kglem, 37 Ibfeft) Rear lower engine hanger bolts/nuts: 50 Nem (6.1 kgiem, 97 Ibift) Rear upper engine hanger bolts/nuts: 50 Nem (8.1 kgiem, 97 Ibift) Tighten the right side of the front engine hanger bolt to the specified torque. 7-6 3) ‘ REAR LOWER ENGINE HANGER BOLTINUT REAR LOWER ENGINE HANGER BOLTINUT FRONT ENGINE HANGER BOLT/NUT.ENGINE REMOVAL/INSTALLATION Install the new O-ring to the water by-bass cover. Install the water by-pass cover to the cylinder and tighten the cover bolts securely. linkage to the spindle by aligning the slit of the shift pedal and the punch mark of the spindle. Tighten the bolt to the specified torque. TORQUE: 20 Nem (2.0 kgform, 14 bff) Install the following: wire band cam pulse ganeretor 2P connectorIE REMOVAL/INSTALLATION DRIVE SPROCKET INSTALLATION crank pulse generator 2P connector ~ regulator/redtfior 3P/4P connector = speed sensor 3P connactor ~ cil pressure/nutral switch 2P connector ~ side stand switch 2P connector Install the ignition coil caps. Connect the PAIR air supply hoses to the reed valve covers. Pour recommended engine oil up to the proper level (page 3-12), Fill the cooling system with recommended coolant ‘and bleed the air (page 6-4). Install the drive chain on to the sprocket, Install the drive sprocket to the counter shaft with the punch mark facing out end align the teeth of the drive sprocket and counter shaft. Install the the washer and tighten the special bolt to the specitied torque. ‘TORQUE: 54 Nem (5.5 kgfem, 40 loft) 7-8ENGINE REMOVAL/INSTALLATION Install the drive chain guide plate. p oFIVE TRAIN Guibe RTE NS Install the drive sprocket cover and tighten the cover SUIDEBLATE bolts securely. iCYLINDER HEAD/vaLves 10 Nem (1.0 kgfem, 7 bt) 12.Nem (1.2 kgfom, 9 Ibe) 20 Nem (2.0 kof, 48. Nem (4.9 kgfom, 14 Ibi) %e / 35 lb) 8-08. CYLINDER HEAD/VALVES SERVICE INFORMATION a1 VALVE GUIDE REPLACEMENT TROUBLESHOOTING a3 VALVE SEAT INSPECTION/ REFACING CYLINDER COMPRESSION TEST a4 CYLINDER HEAD COVER REMOVAL 8-4 SYUNDERHEAD ASSEMBLY CYLINDER HEAD COVER ‘CYLINDER HEAD INSTALLATION DISASSEMBLY /ASSEMBLY 85 CAMSHAFT INSTALLATION CAMSHAFT REMOVAL 86 ‘CYLINDER HEAD COVER: CYLINDER HEAD REMOVAL 8-11 INSTALLATION CYLINDER HEAD DISASSEMBLY —--12,-«S— CAM CHAIN TENSIONER LIFTER CYLINDER HEAD INSPECTION 8.13 8-16 87 8-20 8-21 8-23 8-28 8-29 SERVICE INFORMATION GENERAL This section covers service of the cylinder head, valves and camshatt The camshaft services can be done with the engine installed in the frame. The cylinder head service requires engine When disassembling, mark and store the disassembled parts to ensure that they ere reinstelled in their original locations. Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. Camshait lubricating oil is fed through cil passages in the cylinder head. Clean the oll passages before assembling the cylinder head. Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. 8-1CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm in) = crmommo aenciam ‘ylinder compression - 1,275 kPa (13.0 kgf/cm’, 185 psi) — | 950 nin rpm) Valve cearence IN| 0.16 = 003 (€.006= 0.001) __— EX 0.25 = 003 (0.010 = 0.001) = Camshaft Camlobe height LIN 36.040 - 36.280 (1.419 - 1.428) 36.01(1.42) [Ex 95.000 - 36.040 (1400-1410), 35.77 (441) iano - . = [00s 6.002 Oil earance 0.020 - 0.062 (0.006 ~ 0.0026), Valve titer | Valve lifter 0.0. 25.978 ~ 25.993 (10228 - 1.0233) _ Valve liter bore 1D. _ 26,010 ~ 26,026 (10240 - 10246) 26.04 (1.026) Valve, ValvestenO.D. =| IN 4.475 ~ 4.490 (0.1762 -0.1758) 4,465 (0.1758) veins alte EX 4.465 — 4.480 (0.1758 - 0.1764) 4.455 (0.1754) Valve guide 1.0. INEX | 4.500-4.512(0.1772-0.1776) |: 840 (0.1787) ‘Stem-to-guide clearance IN| 0.010 ~ 0.037 (0.0004 - 0.0015) 0.075 (0.0020) | EX | 0.020 - 0.047 (0.0008 - 0.0019) 0.085 (0.0083) Valve guide projecion above | IN| 145-147 (057 -0.58) — Eyliner bead EX | 148-150 (0.58 0.59) Valve seat width INEX | 0.90 1.10 (0035 - 0.043) ) Valve soring free length IN| 409 (160) 40.08 (1.578) =X | 40.9 (1.61) | 40.08(1.578) | Cylinder heed warpage I = 0.10 0.000 TORQUE VALUES Cylinder head mounting boltiwashor Camehatt holder flange bolt Cylinder head cover belt Breather plate flange bolt PAIR reed valve cover SH bolt ‘Cam sprocket flange bolt ‘Cam chain lifer mounting socket bolt Cam chain tensioner pivot socket bolt Cylinder head stud bok: (exhaust pipe stud bolt) 48 Nem (4.9 kgfem, 36 Ibi) 12.Nem (12 kgm, 9 IDF) 30 Nem (10 kgm, 7 bf) 12 Nem (12 kgm, 9 Ibftt) 32 Nem (12 kgm, 9 Kote) 20 Nem (2.0 kgfem, 14 Ibift) 40 Nem (10 kgfem, 7 bf) 30 Nem (10 kam, 7 bf) See page 1-14 Apply molybdenum cisulfide cil tothe ‘threads and seating surface Apply oil tothe threads ‘Apply @ locking agent to the threads CT bolt rbot Apply @ locking agent to the threads Apoly @ locking agent to the threads 8-2CYLINDER HEAD/VALVES err TOOLS Compression gauge attachment O7RMJ-MY50100 Equivalent commercially available Valve spring compressor 0757-0010000 Velve spring compressor ettachment 07959-KM30101 ‘Teppet hole protector (07HMG-MR70002 Valve guide driver Valve guide reamer, 4.508 mm Valve seat cutters Seat cutter, 275 mm (45 IN/EX) (07742-0020000 O7HMH-MLO0101 ~ these re commercially aveilable (07780-0010200 Flat cutter, 27 mm (32° EX) (07780-0013300 Flat cutter, 30 mm (32" IN) 0780-0012200 Interior eutter, 24 mm (60° INEX) 07780-0010600 Cutter holder, 4.5 mm (0781-01060 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 stethoscope. + Ifthe performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky, check for a saized piston ring (Section 12) Compre + Valves: = Incorrect valve adjustment ~ Burned or bent valve ~ Incorrect valve ming ~ Broken valve spring = Uneven valve seating + Cylinder head: ='Leaking or damaged head gasket ~ Warped or cracked cylinder head + Worn cylinder, piston or piston rings (section 12) Compression too high, overheating or knocking + Exoaaslve earbon Bulld-up on piston erown-or on cembus tion chamber Excessive smoke + cylinder head: = Worn valve stem or valve guide = Damaged stem seal + Worn cylinder, piston or piston rings (section 12) Excessive noise * Cylinder head: incorrect vaive adjustment too low, hard starting or poor performance at low speed Sticking valve or broken valve epring Damaged or worn camshaft, = Loose or worn cam chain Worn or damaged cam chain Worn or camaged cam chain tensioner = Worn cam sprocket teeth + Worn cylinder, piston or piston rings (section 12) Rough idle + Low evlinder compression 8-3CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove all direct ignition coil/spark plug caps and spark plugs (page 36). ‘Open and support the frant end af fuel tank (page 3-4), Disconnect the fuel pumplreserve sensor 3 connestor Install compression gauge ino the sperk plug hole. TooL: Compression gauge attachment 07RMJ-MY50100 (Equivalent commercially avai able) Open the throttle al the way and crank the engine with the starter motor until the gauge reading stops fising Te avcidciecharg. The maximum reading ie ing te battery do seconds, starter mote "Compression pressure: ‘more than seven "4,275 kPa (13.0 kgflemt, 185 psi) at 350 min* (rpm) jally rosched within 4-7 Law compression can be caused by: = Blown cylinder head gasket = Improper valve adjusiment ~ Valve leakage = Worn piston ring or cylinder High compression can be caused by: ~ Carbon deposits in combustion chamber or on Piston he: CYLINDER HEAD COVER REMOVAL Remove the following: = Ignition coil (page 5-62) ~ Spark plug cap (page 3-8) Remove the crankcase breather tube. Disconnect the PAIR air suction tubss from the PAIR. reed valve covers, 8-4CYLINDER HEAD/VALVES Remove the cylinder head cover bolts and rubber- washers, BOLTSWASHERS CYLINDER HEAD COVER — Remove the cylinder head cover. evi VER Remove the cylinder head cover packing. Mo ee CYLINDER HEAD COVER DISASSEMBLY/ASSEMBLY Remove the bolts ana PAIR check valve cover. Check the PAIR check valve for wear or damage, replace if necessary. Installtion is in the reverse order of removal ‘TORQUE: 12 Nem (1.2 kafm, 8 Ibftt), PAIR CHECK VALVES,CYLINDER HEAD/VALVES Remove bolts end breather separate and gasket. Install the new gasket to the cover. Install the breather plate, ‘Apply the locking agent to the bolt threads and tight- ‘en itto the specified torque. TORQUE: 12 Nem (1.2 kgiem, 9 Ib) CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-4). ‘Avoid damaging the cam pulse generator while removing the camshafts. Remove the bolt and cam pulse generator from the cylinder head, Remove the timing hole cap and O-ring.Inisnot necessary to remove he cam sprociet from she camshatt except whan rplecng the camshat andor eam sprocket Be care nott0 op the cam sprocket bots into the Turn the erankshatt clockwise, align the "T” mark on the ignition pulse generator rotor with the index mark ‘on the right crankcase cover. Make sure the No.1 piston is at TDC (Top Dead Center) ‘on the compression stroke Remove the cam chain tensioner liter sealing bolt and sealing washer. ‘Turn the tensioner lifter shaft fully in (clockwise) and secure it using the following tool ‘This tool can easily be made from a thin (1 mrn thickness) pieve of steel 150m 4, 18mm 18mm 5 mm MATERIAL THICKNESS: 1.0 mm you plan to replace the camshaft and/or cam sprock- ‘et, loosen the cam sprocket bolts as follow: = Remove the cam sprockat bolts trom intake and ‘exhaust camshafts CYLINDER HEAD/VALVES STOPPER TOOL INDEX MARK SPALING WASHERCYLINDER HEAD/VALVES Susend the cam chain with apiece of wire to prevent the ehain from Faling i the crankcase, ~ Turn the crankshaft one full turn (360°), remove the other cam sprocket bolts from the camshafts. ~ Remove the belt. ~ Remove the bolts and cem pulse generator rotor Loosen and remove the camshaft holder bolts. then remove the cam sprocket, cam chain guide 8, camshaft heldar and eamshatt. LNOTICE | From outside to inside, loosen the bolts ina crisscross pattern in several steps or the camshaft holder might ly remove the dowel pins from the camshaft holder 8-8CYLINDER HEAD/VALVES Remove the valve lifters and shims, Be careful not to damage the valve lifter bore. ‘Shim may stick to the inside of the valve lifter. Do Not allow the shims to fall into the crankcase. + Mark all vaive lifters and shims to ensure correct reassembly in their original locations. + The vaive liter can be easily removed with @ valve lapping tool or magnet. + The shims can be easily removed with tweezers or a magnet. INSPECTION CAMSHAFT Check the cam and journal surfaces of the camshaft for scoring, scratches or evidence of insufficient lubrication, Check the oil holes in the camshat for clogging. ‘Support both ends of the camshaft with V-blocks and check the camshaft runout with a dial gauge. ‘SERVICE LIMIT; 0.05 mm (0.002 in) Using 2 micrometer, measure each cam lobe height. SERVICE LIMITS: IN: 36.01 mm (1.42 in) EX: 36.77 mm (1.41 in) CAMSHAFT HOLDER Inspect the bearing suriace of camshaft holder SHAE OL for scoring, scratches, or evidence of insufficient lubrication. Inspect the oil orifices of the holders for clogging.CYLINDER HEAD/VALVES Do not rotate the sing pastignuge CAM CHAIN GUIDE B Inspect the cam chain slipper surface of the cam chain guide for wear or damage. CAM CHAIN GUIDE B ‘CAMSHAFT OIL CLEARANCE SURSTIGRUGE Wipe any oil from the journels of the camshaft, eylinder head and camshaft holders. Ley a strip of plastigauge lengthwise on top of each camshaft journal, Install the camshaft holder onto the camshafts. Apply ongino oil to the threads and eeeting surfeces ofthe camshaft holder botts Install the twenty holder bolts with the eight sealing washers. ‘The camshaft holder have the number "1 thru. 207 Temporarily tighten the four bolts of the center area ‘gradually in the sequence 6 - § - 8-7 until the dowel pins on the camshaft holder inserts into the pin holes inthe eylinder head (the clearence between the hold erand head is 1-5 mm). Next. tighten all the holder bolts in the numerical order cast on the camshaft holder (1 thru. 20) in several steps, then tighten them to the epetifiod torque, TORQUE: 12 Nem (1.2 kgfm, 9 Ib-f) Remove the camshaft holders and measure the width of each plastigauge. ‘The widest thickness determines the oll clearance. ‘SERVICE LIMIT: 0.10 mm (0,008 in) When the service limits are exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft holders as @ Set if the clearance atill exceeds the service limit 8-10CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Drain the coolant (page 6-4 SOCKET BOLTS Romove the camshaft ipage 8-6) Remove the cylinder drain bolt and sealing washer Drain coolant from eylinder heed and eylinder block. Check that the sealing washer is in good condition, replace if necessary. Reinstall the sealing washer and drain bolt. Remove the socket bolts, sealing washers and cam chain tensioner liter and gasket. Remove the cep aut, sealing washer and com chain tensioner. WATER HOSE Disconnect the water hose. Remove the thermostat housing cover ard thermostat CAP NUT Loosen he 9mm Remove the ten 9 mm bolts\washers. Remove the two 6 mm flange balts.CYLINDER HEAD/VALVES. CYLINDER HEAD DISASSEMBLY Remove the cylinder head. DOWEL PINS: Remove the gesket and dowel pi Remove the right evankease cover and ignition pulee generator rotor (page 17-7) Remove the socket bolt, cam chain guide and cellar. Remove the cam chain and timing sprocket from the cranishar. Remove the spark plugs from the cylinder head, Install the tappet hele protector into the valve lifter bore, Tool: Tappet hele protector ‘o7Hmc-1in70002 [An equivalent tool can easily be made from a plastic 35 mm film container as shown. 25mm .D. (when compressed) 8-12CYLINDER HEAD/VALVES Remove the valve spring cotters using the special \VALVE SPRING COMPRESSOR . tools as shown. Toos: Valve spring compressor 07757-00100 Valve spring compressor attachment 07959-KM30101 NOTICE To prevent loss of tension, do not compress the valve springs more than necessary f0 remove the cotters. ‘ATTACHMENT 5g ‘Maal parts cur- Remove the following: irgdsassembly — Spring retainer vawe §& so they canbe — Valve spring placed back — Valve ‘other orignal — Store seal fecations: _ Valve spring seat VALVE SPRING. 76. ‘STEM SEAL a SPRING SEAT COTTER CYLINDER HEAD INSPECTION ‘COMBUSTION CHAMBER CYLINDER HEAD ‘Avid éamagna Remove carbon deposits from the combustion cham- tte gasiet ber, being careful not to damage the gasket surface. ‘surface. Cheek the spark plug hole and valve areas for cracks. Check the cylinder hesd for warpage with a straight ‘edge and feeler gauge. ‘SERVICE LIMIT: 110 mm (0.004 in)CYLINDER HEAD/VALVES. VALVE LIFTER BORE Inspect each valve liftor bore for eeratchos or abnormal wear. Measure each valve lifter bore ID. ‘SERVICE LIMIT: 26.04 mm (1.025 in} VALVE LIFTER Inspect each vaive lifter for scratches or abnormal ‘Measure each valve lifter 0.D. ‘SERVICE LIMIT: 25.97 mm (1.022 in} VALVE SPRING Measure the the vaive spring free length SERVICE LIMITS: 40.8 mm (1.578 in} Replace the springs if they are shorter than the service limi. CAM CHAIN TENSIONER/CAM CHAIN ‘CAN CHAIN TENSIONER GUIDE Inspect the cam chain tersioner and cam chain guide for excessive wear or damage, replace if necessary. cam dunn cuoe 8-14Feface the vave ‘s2at5 whenever the vale guides are veplaned (oage 8:17, VALVE/VALVE GUIDE Check that the valve moves smoothly in the quide. Inspect each valve for bending. burning or abnormal ‘stom wear. Check valve movement in the guide, measurs and record each valve stem 0.0. ‘SERVICE LIMITS: IN 4.405 mm (0.1758 in) EX: 4.485 mm (0.1754 in} Ream the guides to remove any carbon deposits before checking clearances. Insert the reamer from the combustion chamber sida Of the head and always rotate the reamer clockwise, Too: Valve guido reamer, 4.608 mm 07HMH-MLOO101 Measure and record each valve guide |.D. ‘SERVICE LIMIT: IN/EX: 4.540 mm (0.1787 in) Subtract each valve stem .D. from the correspond- ing guide |.D. to obtain the stem to-quide clearence. SERVICE LIMITS: IN: 0.075 mm (0.0030 in) EX: 0.085 mm (0.0033 in} If the stem-to-guide clearance is out of standard, determine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace any guides as nacessary and ream to fit If the stem-to-guide clearance is out of standard with the now guides, roplace the valvee and guid. CYLINDER HEAD/VALVES VALE GUIDE REAMER 8-15CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer see- tion of a refrigerator for about an hour, Heat the cylinder head to 100 ~ 150°C (212 - 3007) with s hot plate or oven, Do not use a torch to heat the cylinder head: it may cause warping. ‘Support the cylindr head and diive out the valve guides from the combustion chamber side of the cylinder head, Too: Valve guide driver o7HMO-MLO0101 Drive in tre guide :o the specified depth from the top. of the cylinder head. TOOL: Valve guide driver 07743-00200 SPECIFIED DEPTH: IN: 145 - 14.7 mm (0.57 - 0.58 in) EX: 14.8 — 15.0 mm (0.59 - 0.59 in) Use cutting olan Let the cylinder head cool to room temperature. the reamer ring this oceraton. Rear the new valve quide after installation. Insert the reamer from the combustion chamber Side of the head and always rotate the reamer clockwise, Too! val ‘Quide roamer, 4.508 mm O7HMH-MLO0101 Cleen the cylinder head thoroughly to remove any metal particles. Reface the valve seat (see following steps). 8-16CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING Ie valves cannot beground. ta vane face s ‘burned or bady wera or #1 oo tacts the seat uneveniy,repiaae the vahe. Clean the intoke and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the vaive seats. Tap the valves and seats using a rubber hose or other hané-lapping tool. Romove the valve and inspect the valve seat face, Inspect the vaive seat face for: + Uneven seat width: = Replace the valve and reface the valve seat. + Damaged face: = Replace the velve and reface the valve seat. + Contact area (too high or too low) = Reface the valve seat. “The valve seat contact should be within the specified ‘width and even all around the circumference. STANDARD: 0.90 - 1.10 mm (0.035 ~ 0.043 in) SERVICE LIMIT: 1.5 mm (0.06 in) If the seat width is not within specification, reface the valve seat (page 6-18). de JL DAMAGED FACE UNEVEN SEAT WioTH Too Low TOO HIGH a 7 SEAT WIDTH 8-17CYLINDER HEAD/VALVES VALVE SEAT REFACING Valve seat cutters/grinders or equivalent valve seat refacing equipment are recommended to correct & worn valve seats, \ Follow the refac- If the contact area is too high on the valve, the seat [conTAGTTO0 HIGH ing manufactur must be lowered using a 32° flat cutter. oe: ersopersig ifthe contact area is too (ow on the valve, the seat Se yen Inaction mugt be raid using 860" inttr cater > > = CONTACT T00 Low ou sear = \ wioTH oe > Use a 45-degree cutter to remove any roughness or irregularities from the seat. ROUGHNESS TOOLS: Sest cutter, 27.5 mm (45 IN/EX) (07780-0010200 Cutter holder, 4.6 mm (07781-0010600 or ‘equivalent commercially available Use a 32-degree cutter to remove the top 1/4 of the ing valve seat material. Too! OLo SEAT WIDTH Flat cutter, 27 mm (32° EX) _07780-0013300 Flat cutter, 30 mm (32° IN) _07780-0012200 Cutter holder, 4.5 mm 0781-0010600 or equivalent commercially available 8-18Use 2 60-degree cutter to remove the bottom 1/4 of the old eet. Toois: Interior cutter, 24 mm. (60" IN/EX) ‘o7780-0010600 Cutter holder, 4.5 mm (07781-0010600 or equivalent commer- ally available Using 2 45' soat cutter, cut the seat to tho proper width. Make sure that all pitting and irregulerities ‘are removed. Refinish if necessary. After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure. NOTICE Excessive lapping pressure may deform or damage the seat + Change the angle of lapping tool frequently to pro vent uneven seat weer. + Donotallow lapping compound to enter the guides. After lapping, wash all r eylinder hoad and valve. idual compound off the CYLINDER HEAD/VALVES OLD SEAT WIOTH 1.9 mm (0.04 in) ‘ HAND-LAPPING TOOL. 8-19CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY INTAKE VALVE SPRING VALVE UFTER = . BD srensea EX comers oom RETAINER ‘SPRING =| —F VALVE eas a EXHAUST VALVE Sle “7 ‘STEM SEAL INTAKE VALVE Blow through all oil passages in the cylinder head with compressed air. Install the tappet hole protector into the valve lifter bore. TooL: Tappet hole protector o74MG-Min70002 Grease the Install the valve spring seats. ai ALVES cottes to ees Install the new stem seals. q ) Bee iye insaloion Lubricate the valve stems with molybdenum ution, the valve into the valve guide while turning it slowly to avoid damage to the stem seal SPRING SEAT COTTER 8-20CYLINDER HEAD/VALVES ‘Sugar the cyl» install the valve spring with the tightly wound coils, ey head sbore facing the combustion chamber. the work Dench suace toprevent passe vale amage Install the valve spring retainer. iSIVE SERS COO RESSOR, Install the valve cotters using the special tool as showin, NoTE: To prevent lose of tension, do not comprose the valve spring more than necessary. TooLs: Valve spring compressor 07757-00100 Valve spring compressor attachment 07958-KM30101 ‘Tap the valve sterrs gently with two plastic hammers: as shown to seat the cotters firmly Se BANE Inetell and tighten the epark plugs. TORQUE: 12 Nem (1.2 kgfem, 9 Ibe) CYLINDER HEAD INSTALLATION Install the timing sprocket by aligning the wide teeth between the crankshaft and sprocket. Install the cam chain.CYLINDER HEAD/VALVES Install the cam chain guide and bolywasher. Install the washer, cam chain tensioner end socket bolt. Tighten the cam chain guide bolt tothe specified torque. ‘TORQUE: Cam chain guide bolt: 12 Nem (1.2 kgiem, 9 Ibfft) Install the ignition pulse generator rotor and right ‘crankcase cover (page 17-1). Install the dowel pins and new cylinder head gasket as shown, Ingeall the eylinder head onto the eylinder block. Apply molybdenum disulfide oil zolution to the threads and seating surface of the § mm bolts/wash- 's and install them. Install the two 6 mm flange bolts. Tighten the ¢ mm bolts in @ crisscross pattern in 2-3 steps to the spectfied toraue. TORQUE: 48 Nem (4.9 kafem, 36 Ibftt) 8-22CYLINDER HEAD/VALVES Tighten the 6 mm flange bolts. Install the cam chain tensioner onto the cylinder head. cap NUT WATER HOSE Tighten the nut to the specified torque. TORQUE: 10 Nem (1.0 kafom, 7 Ibfft) Connect the water hose. Remove the following: = Thermostat housing |page 6-7) — Cemshaft (eee below! CAMSHAFT INSTALLATION Install the new gasket and cam chain tensioner onto the cylinder. sockeT B0LTs Install the new sealing washers and tighten the sock- ct bolts to the sperified torque. TORQUE: 10 Nem (1.0 kafem, 7 Ibf-ft) Inetall the camshaft (see below), Insta tho chine Apply molybdenum oil solution to the outer surface of andvalve lifters in the each valve lifter. their original loo ‘ens. Install the shims and valve lifters into the valve lifter bores.CYLINDER HEAD/VALVES. If the cam sprockets are removed, install the cam ‘sprockets onto the camshafts. Instal the cam NO.1 CYLINDER CAM LOBES pulse generetor + Install the intake cam sprocket with the timing mark ‘rotor withthe (IN) facing outward and the No.1 cem labes facing ‘No.1 camshaft up and out ae shown, ites "200 YO install the exhaust cam sprocket with the timing Hae ees Seun mark (EX) facing outward and the No.1 cam lobes ‘eatown — f8cing up and out as shown. EXHAUST CAM SPROCKET. INTAKE CAM SPROCKET . Clean and apply a locking agent to the cam sprocket bolt threads, Install the cam sprocket bolts, CE Clean and apply a locking agent to thecam cam pulse generator rotor throade. Install the cam pulse generator rotor and mounting ey ERNLIL bolts. BoLTs Turn the oranishatt clockwiao and align the 7" mar y CHAK ‘on the ignition pulse generator rotor with the index Pas mark on the right crankcase cover 8-24CYLINDER HEAD/VALVES Be sure the dowel pins inthe ‘amshalt hotter ‘ign progeny with ‘he hos inthe vines hese Apply molybdenum oll solution to the camshaft jour nals of the cylinder head and camshat holder. stall the cam chain over the cam sprockets and then install the intake and exhaust camshatts. + Install each camshaft to the correct locations with the identification marks. “IN*: Intake camshaft “EX*: Exhaust camshaft ‘+ Make sure that the timing marks on the cam sprock- ‘ts are facing outward and flush with the cylinder head upper surface as shown. Apply molybdenum oil solution to the camshaft holder as shown. Install the camshat holder onto the camshafts. Apply engine oil to the threads and seating surfaces ‘of the cameheft holder bolte. Install the cam shaft holder 8 and holder bolt (color: silver) trom the front side of the eam sprockets. Install the twenty bolts to the cam shaft holder. Finger tighten tne bolts. The camshaft holder has the number “1 through 20, cast into it, Gradually tightan the 43, #5, #8, and 47 bolts (in thet order) 1/4 to 1/2 turn at a time to draw the holder down evenly until the cleerance between the cylinder hhead and the holder is 2 - 3 mm all the way around. If the holder tilts toward the #1 cylinder during this process, readjust bolts #6, #5, #8, and #7 as necessary to keep the holder level When the holder is perallel with the cylinder head, resume tightening the bolts in the sequence specified above.CYLINDER HEAD/VALVES 8-26 (Once the clearance is within 2 - 3 mm, begin tightening all the bolts in numerical order (#1, #2, #3...#20) ‘Vé tun at a time until the holder is fully seated against the cylinder head. TORQUE: 12 Nem (1.2 kgm, 9 bff) Install the cam chain guide B, and tighten the bolts. Incase the cam sprockets were removed, tighten the. ‘cam sprocket boite to the specified torque. = Aut SPaocker SOLTS 7 ric inkt TORQUE: 20 Nem (2.0 kgfm, 14 Ibft) ‘Turn the crankshaft clockwise one full wen (360°) and tighten the other cam sprocket bolts. In case the cam pulse generator rotor bolts were removed, tighten the rotor bolts to the specified torque TORQUE: 12 Nem (1.2 kgfim, 9 bt)CYLINDER HEAD/VALVES Remove the stopper tool from the eam chain ‘STOPPER TOOL Install a new sealing washer and tighten the sealing bolt. Recheck the valve timing. Apply oilto the new O-ring, and instal it onto the cam pulse generator. Install the cam pulse generator into the cylinder heed, CAM PULSE: GENERATOR BOLTS Install and tighten the mounting bolt securely.CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION Apply sealant to the cylinder head semi-circular eut- outs as shown. Install the cylinder head packing into the groove of the cylinder head cover. Install the cylinder heed cover onto the oylinder heat Install the washers with thelr "UP" mark facing up. Install and tighten the cylinder head cover special bolts to the specified torque. TORQUE: 10 Nem (1.0 kgfem, 7 ibfft) CYLINDER HEAD COVER ns 8-28CYLINDER HEAD/VALVES Connect the sir supply hoses to the PAIR reed valve tall the following: ignition coil (#2-#3Mpage 17-7) park plug cap (page 3-7) CAM CHAIN TENSIONER LIFTER REMOVAL Remove the cam chain tensioner sealing bolt and ‘sealing washer. Turn the tensioner shaft fully in (clockwise) and ‘s0cur9 it using tho stepper tool to provent damaging the cam chain. See page 8-7 for details of the tool note ne instala- Remove the bolts and cam chain tensioner lifter. ‘ton diectio of Remove the gasket. ine gaster VA 49 sour SEALING WASHER ‘STOPPER TOOL SOCKET BOLTSCYLINDER HEAD/VALVES. 8-30 INSTALLATION Install the new gasket onto the cam chain tensioner lifter. Install the cam chain tensioner lifter into the cylinder head. Install and tighten the mounting bolts securely. Remove the stopper tool. Install a new sealing washer ard tighten the sealing bolt securely. Install the removed parts in the reverse order of removal, SOCKET BOLTSMEMO9. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 91 CLUTCH 4 TROUBLESHOOTING 9-2 GEARSHIFT LINKAGE 912 RIGHT CRANKCASE COVER SHIFT FORK/SHIFT DRUM 9-13 Fewover $3 RIGHT CRANKCASE COVER LIFTER LEVER 9-4 INSTALLATION 9-14 SERVICE INFORMATION GENERAL + This section covers service of the clutch, gearshift linkage, shift drum and shift forks. All service can be done with the engine installed in the frame. + Transmission oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motoreysle creeps with clutch disengaged, inspect the transmission oll lavel hefore servicing the clutch system, SPECIFICATIONS Unit: mm (in) mew STANDARD SERVICE LIMIT EE Clute lever tree play [10-20 (s— 1876) huten Soring free length | 48.8 (192) wsceh Disc thickness | 2.92~ 3.08 (0.118 - 0.121) 26 (0.10) L Plate werpage — 030 (0.012) Clutch outer guide 1D, 24.994 ~ 25,004 (09840 0.8644) 25.01 0.985) an. 34975 ~34.991 (13770-13776) 3497 (137) — 24.96 (0.983) TORQUE VALUES Cutch center losk nut 128 Nem (13:1 kgm, 96 Ib) Apply ol to the threads Stake the nut Cutch spring bolywasher 12 Nem (12 kgfrm, 9 Inf) Gil pump driven sprockst bolt 15Nem (U5 kgm, Tot) Apply a locking agent to the threads Shift crum center sosket bolt 23Nem (23 kgm, 17 Ibfst) Apply a locking agent to the threads Shit crum stopoer arm pivot bolt 12 Nem (12 kgfm, 9 bt) Gearshift spindle return spring pin 22 Nem (2.2 kgfem, 16 lof) TOOLS Qutch center holder 07724-0050002 Equivalent commercially available Diver 07749-0010000 ‘tachment 32 X 38mm 07746-c010100 ‘tachment, 37 X 40mm 07746-0010200 Plot, 17 mm 07746-0040400 Pilot, 35 mm (07746-0040800CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch lever too hard to pull in + Damaged clutch liftar mechanism + Faulty clutch liter bearing + Cluteh lifter piece installed improperly (Clutch slips when accelerating + Worn clutch dise + Weakclutch springs + Transmission oll mixed with molybdenum or graphite additive Clutch will not disengage or motoreycle creeps with dutch disengaged + Clutch plate warped + Loose clutch lock nut * Gil level too high + Improper cil viscosity + Damaged clutch lifter mechanism + Clutch liter piece installed improperly Hard to shit + Improper clutch operation + Improper oil viscosity + Bent shift fork + Bent shift fork shaft + Bent fork daw + Damaged shift drum cam groove + Loose stopper plato bolt + Damaged stopper plate and pin + Damaged gearshift spindle ‘Transmission jumps out of gear + Worn shift drum stopper arm + Weak or broken shift arm return spring + Loose stopper plate bolt + Bent shift fork shaft Damaged shift crum cam groove Damaged or bent shift forks ‘Worn gear engagement dogs or slots Gearshift pedal will not return + Weak or broken gearshift spindle return spring + Bent gearshift spindleRIGHT CRANKCASE COVER REMOVAL { cuurci caste (CABLE BRACKET The litter arm spinde is ‘ergaged withthe ‘itch iter piece inside the ront wwankcase cover. CLUTCH/GEARSHIFT LINKAGE Drain the engine cil (pege 315). Remove the bolts and clutch cable guide, then disconnect the clutch cable end from the clutch litter lever. Remove the right crankcase cover SH bolts and clutch cable guide. Remove the right crankcase cover while turning the clutch liter arm counterclockwise to disengage the lifter arm spindle from the lifter piece. Remove the two dowel pins and gasket. Cleen the right crenkease cover mating surfaces. | DOWEL PINS 9-3CLUTCH 9-4 CLUTCH/GEARSHIFT LINKAGE CLUTCH LIFTER LEVER Remove the clutch lifter lever, return spring and wash- ‘er trom the right crankcase cover. ‘Check the lifter lever spindle for wear or damage. ‘Check the return spring for fatigue or damage. RETURW SPRING Check the lifter lever cil goal and noadle bearinge for wear or damage. Insiall the clutch lifter lever with the washer end spring in the reverse order of removal. REMOVAL Romove the right oranicase cover (page 9-2). Romove the clutch spring bolts, springs end. pressure plate. Rehovot cu theres ton beirut. fl Remove the ‘allowing: = Cluteh discs ~ Clutch plates ~ Spring seat = dadder spring JUDDER SPRING CLUTCH PLATEUnstake the clutch center lock nut. Hold the clutch center with the clutch center holder, then remove the lock nut. TOOL: Clutch center hol 07724-0050002 (Equivalent commer- ly available) Discard the lock nut. Remove the lock washer, thrust washer and clutch center. Remove the washer CLUTCH/GEARSHIFT LINKAGECLUTCH/GEARSHIFT LINKAGE Bo caret not bend the grnton use gererater rotor tangs Fepece the eutch spring Align the gear teeth of the scissors gears (primary rive gear and sub-gear) by inserting a screwdriver into the gear hole indicated by the punch mark on the sub-gear through the hole in the crankcase, and remove the clutch outer. Remove the clutch outer guide. CLUTCH OUTER Remove the oil pump driven sprocket bolt/washer. Femove the oil pump drive/driven sprocket and drive chain as an assembly, INSPECTION Clutch lifter bearing ‘Turn the inner race of the lifter be finger. The bearing should turn smoothly and quietly. ‘Also check that the outer race of the bearing fits tight= ly in the pressure plate Replace the bearing If the inner race does not turn smoothly, quietly, orif the outer race fits loosely inthe pressure plate. ing with your Drive the bearing out of the pressure plate. Drive a new bearing into the pressure plate with its mark side facing out. Toots: Driver 07743-0010000 Attachment, 2X 35mm 07746-01010 Pilot, 17 mm (07746-0040400 Clutch spring Measure the clutch spring free length SERVICE LIMIT: 47.5 mm (1.87 in} pagers ateRepisce the toh asc anc pltes asa set Repace tre oleh esos ard Dites 2s a Set CLUTCH/GEARSHIFT LINKAGE Clutch center Check the grooves of the clutch center for damage or wear caused by the clutch plates. Ropiace if necoseery. CLUTCH CENTER ‘Clutch titer piece Check the clutch lifter piece for damage or LIFTER PIECE abnormal wear. Clutch dise Replace the clutch discs if they show signs of scoring or discoloration. CLUTCH Disc Measure the disc thickness of each disc. SERVICE LIMIT: 2.6 mm (0.10 in} Clutch plate Check each disc plate for warpage on a surface plate CLUTCH PLATE using a feeler gauge. ‘SERVICE LIMIT: 0.30 mm (0.012 in)CLUTCH/GEARSHIFT LINKAGE Clutch outer/clutch outer gui ‘Check he slots of the clutch outer for damage or wear ‘caused by the clutch discs. place if necessary. CLUTCH OUTER Measure the 0.9. and I,D. of the clutch outer guide. ‘SERVICE LIMITS: ©.D: 34.97 mm (1377 in} LD: 25.01 mm (0985 in) | 10 the mainshaft 0.0. at the clutch outer guide sliding surface. ‘SERVICE LIMIT: 24.98 mm (0.983 in) CLUTCH OUTER NEEDLE BEARING REPLACEMENT Press the needle bezring out of the clutch outer using the special tools. RIVER Toots: PILOT/BEARING Drive (0749-0010000 a Attachment, 37X 40mm —_07746-0010200 Pilot, 35 mm. (0746-0040000 ATIACHMENT/PILOT 9-8CLUTCH/GEARSHIFT LINKAGE Press a new needle bearing into the clutch outer so [paiyen ‘that the casing of the needle bearing is below 0.60.6 mm (0.016 - 0.023 in} from the oil pump drive sprock et side of the clutch outer surface as shown. Toots: Driver (07749-00100 Attachment, 37% 40mm _07746-0010200, Pilot, 35 mm 07746-0040800 0.4- 0.6 mm (0.016 - 0.023 in} ATTACHMENT/PILOT INSTALLATION LS... OUTER GUDE ‘SPROCKET WASHER x CLUTCH DISCS. 15 Nem (1.5 kgfem, 11 Ib) Lock NUT ] 128 Nery 18.1 kot, CLUTCH Disc (GREEN) ——> Og Bene YS) supber serine uFTER PIECE (049 UFTER BEARING “7” LIFTER PLATE SPRING —12Nem (1.3 kgf, 9 Ibe) instal Install the clutch outer guide, oll pump drive/eriven pump driven’ sprocket and drive chain as an assembly. sorockat with its “OUT” matk fac:CLUTCH/GEARSHIFT LINKAGE Be cares net to bend te ignition pulse ponortor rotor fangs. ‘Apply @ locking agent to the threads of the oil pump driven sprocket bolt. Tighten the driven sprocket bolt to the specified torque. BOLT WASHER TORQUE: 15 Nem (1.5 kgfem, 11 Ibfft) ‘Align the primary drive gear and sub-gear teeth with Install the clutch outer. Be sure the clutch outer sits securely onto the pos tioning tabs of the oil pump drive sprocket. Rotate the ‘oil pump drive chain while installing the clutch outer t0 properly seat it. Make sure that the primary driven gear of the clutch ‘outer is flush with the primary drive sub-gear. Release the cam chain tensianer (page @-23). Install the washer onto the clutch outer, Install the clutch center. Inetell the thrust washer. Install the lock washer with ts “OUTSIDE” mark fecing out. S occas TEMS ASIC 9-10CLUTCH/GEARSHIFT LINKAGE Install the new lock nut. Hold the clutch center with the clutch center holder, then tighten the lock nut to the specified torque. Toot: Clutch center holder ‘TORQUE: 128 Nem (13.1 kgm, 95 Ib) Be careful no: 10 Stake lock nut into the mainshaft groove with a amage the mai punch. shaft treads Apply engine oil and install the spring seet and See judeer spring. JUDDER Coat the elutch dices and plates with clean engine cil Stack the clutch discs end plates eltemetely.CLUTCH/GEARSHIFT LINKAGE. GEARSHIFT LINKAGE 9-12 Install the outer clutch disc colored “Green” in the shallow siot on the clutch outer. Sa Install the clutch liter piece. Install the pressure plate. Install the clutch springs and spring bolts. Tighten the bolts in a crisscross patter in 2-3steps, then tighten the bolts to the specified torque. TORQUE: 12 Nem (1.2 kgfom, 9 tbr) Install the right crankcase cover (page 9-14), GEARSHIFT LINKAGE REMOVAL Remove the following: ~ Right crankcase cover (page 9-3) = Clutch assembly (page 9-4) Romove the bolt and gearshift pedal link. Pull the gearshift spindle assembly and thrust washer ut of the crankcase, GEARSHIFT SPINDLECLUTCH/GEARSHIFT LINKAGE Remove the following: rE URTSeENG] ~ Stopper arm socket bolt cen cg = Stopper arm ~ = Return spring = Washer = Dowel pins ~ Socket holt = Gearshift cam IGEARSHIFT CAM. GEARSHIFT LINKAGE INSPECTION Check the gearshift spindle for wear, damage fr bending. Check the return spring for fatigue or damage. GEARSHIFT SPINOLE RETURN SPRING SHIFT FORK/SHIFT DRUM ‘ion the dows! REMOVAL pin onthe si the wae groove ‘cn the gearshift 279 Remove the shift drum bearing set plate bolywasher ‘Separate the crankcase halves (page 11-3) Remove the shift fork shaft and ehift forks.CLUTCH/GEARSHIFT LINKAGE Remove the shift drum ‘SHIFT DRUM/SHIFT FORK INSPECTION Check the shift ork guide pin for abnormal wear ordamage Measure the shit fork LD. ‘SERVICE LIMIT 12.03 mm (0.474 in) Measure the shit fork law thickness 4 SERVICE LMT: 5.9 mm (0.23 in) ' Measute the shit fork shat 0.0. f ™, Turn the outer race of the shift drum bearing with ms your Finger The bearing should turn smoothly and freely without excessive play. I necessary replace the bearing. 4 ‘SERVICE LIMIT: 11.95 mm (0.470 in} Inspect the shift drum quide grooves for abnormal ‘wear or damage, 9-14CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the shift drum Into the lower crankcase. ‘The shift forks have location marks: “RT for right *L" for left “C* for center IDENTIFICATION MARKS: Install the shift forks into the shift drum guide groove with the identification merks facing toward the right side of the engine and insert the fork shaft. (GEARSHIFT LINKAGE INSTALLATION Install the following: = Washer = Return spring = Stopper arm = Socket bolt ‘Tighten the stopper arm socket bolt to the specified torque. ‘TORQUE: 12 Nem (1.2 kafem, 9 Ibftt) # UL GearsHieT CAM -15,CLUTCH/GEARSHIFT LINKAGE Install the dowel pin onto the shift drum. Install the gearshift cam while holding the stopper ‘arm using 2 screwdriver as shown. Apply a locking agent to the gearshift cam socket bolt threads Install and tighten the socket bolt to the ‘specified torque. TORQUE: 23 Nem (2.3 kgfom, 17 IbEtt) Install the thrust washer and gearshift spindle assembly into the crankcase while aligning the spring ends ‘with the crankcase stopper pin, Install the thrust washer and gearshift spindle assan- bly into the crarkcase while aligning the spring ends with the crankcase stopper pin, Install the gearshift pedal link aligning its slit with the punch markon the gearshift spindle, Install and tighten the pinch bolt to the specified torque TORQUE: 20 Nem (2.0 kgm, 16 Ibttt) Install the clutch assembly (page #2). RIGHT CRANKCASE COVER INSTALLATION Apply @ sealant to the mating surfaces of the crankcase as shown, 9-16CLUTCH/GEARSHIFT LINKAGE Install the two dowel pins. SET Install the right crankcase cover while turning the lifter arm clockwise to engage the liter erm groove with the lifter piece flange. ‘Set the clutch cable guide onto the right crankcase cover. Connect the alutoh cable end to the clutch lifter lover. Install and tighton the right crankcase cover SH bolts heveuen cLucH caste / ABLE BRACKET Pour the recommended engine oll (page 3-14), Install the removed parts in tne reverse order of removal 9-17ALTERNATOR/STARTER CLUTCH 103 Nem [10.5 kgfom, 76 Ibftt) 10-010. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION 101 FLYWHEEL REMOVAL 103 ‘TROUBLESHOOTING 101 STARTER CLUTCH. 105, ALTERNATOR COVER REMOVAL 10.2 FLYWHEEL INSTALLATION 107 STATOR 102 ALTERNATOR COVER INSTALLATION 10-8 SERVICE INFORMATION GENERAL ‘srecmrIcATIONS atm Ge [ Se riven or bone 00. Soest 20364-20080) ce 5 TORQUE VALUES: 12 tem 12 kote 9 Pye ier arr soon Eau conmarty ite ‘TROUBLESHOOTING 10-1ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL 3P CONNECTOR Remove the left side cover (page 2-2). Disconnect the alternator $P connector, The aerator Remove the alternator cover SH bolts and cover (st 1s alternator cover. rogrescty axrgered © IP The engine oil will run out when the alternator cover true! beat is amoved. Sets closn oil pan under the engi end (eee add the recemmended oi tothe specified level afr Remove the gasket and dowel pin. STATOR REMOVAL Remove the alternator wire grommet from the alternator cover. Remove the socket bolt and stator wire clamp. Remove the socket bolts and stator. STATOR sockeT Bolts = SSS 10-2ALTERNATOR/STARTER CLUTCH INSTALLATION STATOR 12. Nem (1.2 kgfem, 9 Ibtft) ALTERNATOR COVER Install the stator into the alternator cover. GROMMET WIRE CLAMP Apply sealant to the wire grommet, then install the ‘wire grommet into the alternator groove securely. Install and tighten the stator mounting socket bolts to the specified torque. ‘SOCKET BOLTS TORQUE: 12 Nem (1.2 kgfem, 9 Ibfft) Install the wire clamp and tighten the boltto the spec ified toraue. TORQUE: 10 Nem (1.0 kgf-m, 7 tof-tt) STATOR FLYWHEEL REMOVAL Remove the alternator cover (page 10-2). Remove the starter reduction gear shaft and reduction gear. 10-3ALTERNATOR/STARTER CLUTCH Hold the flywheel using the flywheel holder, then remove the flywheel bolt. Toot: Flywheel holder (0725-0040000 (Equivalent commercially available) Remove the washer. Remove the flywheel using the epecial tool Toot: Rotor puller (07733-0020001 or (07983-3950000 Remove the woodruff key. Check the starter reduction gear and shatt for wear or SEDUCTION GEAT REDUCTION GEAR SHAFTALTERNATOR/STARTER CLUTCH STARTER CLUTCH INSPECTION Check the operation of the one-way clutch by turning the driven gear. You should be able to turn the driven gear counter- = clockwise smoothly, but the gear should not turn clockwiee. DISASSEMBLY Remove the starter driven gear by turning it counterclockwise, "4 Hold the flywheel with @ flywheel holder, and remove the starter clutch mounting torx bolts. ‘TORX BOLTS TOOL: Flywheel holder 07725-0040000 (Equivalent commercially available) Remove the starter one-way clutch assembly. A FLYWHEELHOLDER_ Check the starter driven gear for abnormal wear or damage. Meesure the starter driven gear boss 0.0. ‘SERVICE LIMIT: 51.684 mm (2.0348 in} Check the one-way clutch for wear or damage and ‘ONE-WAY CLUTCH 6ALTERNATOR/STARTER CLUTCH ASSEMBLY DRIVEN GEAR FLYWHEEL ‘CLUTCH OUTER 7B seradciutcr 16 Nem (1.8 kam, 12 Ib) A aaa asec ac spy rag . sprae cluTCH CLUTCH OUTER Install the starter one-way clutch assembly onto the STANTER CLUTCH ASSEMBLY ‘lywheel FLYWHEEL 10-6ALTERNATOR/STARTER CLUTCH yg Torx pours Apply @ locking agent to the starter clutch outer ‘mounting bolt threads. Hold the flywheel with 2 flywheel holder, and tighten the starter clutch mounting tore bolts Too: Flywheel holder 07725-0040000 (Equivalent commer ‘ally available in US.A) TORQUE: 16 Nem (1.6 kgfem, 12 Ibfft) FLYWHEEL HOLDER Install the starter driven gear into the one-way clutch while turning it counterclockwise. Recheck the one-way clutch operation. You should be able to turn the criven geer counter clockwise smoothly, but the gear should not turn clockwise. FLYWHEEL INSTALLATION Clean any oil from the crankshaft taper. Install the woodruff key on the crankshaft. Instell the flywheel aligning the key way in the fly ‘wheel with the woodruff key on the crankshaft. Apply surface. Install the washer and flywheel bolt. to the flywheel bolt threads and seating FurwueetALTERNATOR/STARTER CLUTCH Hold the flywheel using the flywheel holder, then tighten the bott to the specified torque. TooL: Flywheel holder (0725-0040000 (Equivalent commer- ally availabein USA) TORQUE: 103 Nem (10.5 legen, 76 lof) Apply molybdenum eil solution to the starter reduc tion gear sha. Apply oll to the starter reduction gear. Install the starter idle gear and shaft onto the crankcase. ALTERNATOR COVER INSTALLATION Apply sealant to the mating surface of the crankcase ‘as shown, Install the dowel pin and new gasket, 10-8ALTERNATOR/STARTER CLUTCH 1 altornator Install the altemator cover. Install and tighten the b: te : Connect the alternator 3P (Natural) connector. 3P CONNECTOR Install the left side cover (page 2-2) 10-9CRANKCASE/PISTON/CYLINDER 34 thm 8.5 afm, 28 Ib) 25 Nem (2.5 kefem, 18 lb) 11-011. CRANKCASE/PISTON/CYLINDER SERVICE INFORMATION m4 PISTON/CONNECTING ROD 11-4 TROUBLESHOOTING 12 CRANKSHAFT "7 CRANKCASE SEPARATION 13 CRANKCASE COMBINATION 1-12 SERVICE INFORMATION GENERAL This section covers crankcase separation for service of the crankshaft and piston, ‘The following garts must be removed before separating the crankcase, = Alternatorfflywheel (Section 10) ~ Clutch/gearshiftlirkage (Section 9) ~ Gylinder head (Section 8) = Engine (Section 6) = Oil pump (Section 4) Mark and store the disassembled parts to ensure that they are installed in their original locations. Mark and store the bearing inserts to ensure that the parts are instalied in the correct locations during reassembly. Ifthe inserts are improperly installed, they will block the oil hole, causing insufficient lubrication and eventual engine seizure. ‘The connecting rod bearing inserts are select fit and are identified by color codes. Select replacement bearings from the code tables. After installing new bearings, recheck them with a plastigauge to verify clearance. Apply molybdenum, Cisulfide oi to the crank pin during assembly. SPECIFICATIONS 1 Unit: rm tin) TEM STANDARD SERVICE MIT linger 63 7206 outers — 00 0 Taper = 0.100.008) | <7 — 2.08 0.002) Feton. piston | Piston mark arecion "IN" nar acing toward the intake side = fogs Piston OD. 71.965 709065 2.7939 -27947) [7080 2781) I 18 mm (08 n) fom botiom of ski 11002 17008 0.6664 0.6686) [aos era) ~~ F998 17000 0.6690-0.6893) | *16.88(0.650) 0.002 - 0.015 6) 001 Piston ringtoving | Top 0090 - 0.086 (00012 0.0026) 308 (0008) | groove clearance ‘Second 0.016 ~ 0.045 (0.0006 - 0.0018) 0.07 (0,003) Piston ring end gep | Top 028 -0.38 0.011 - 0915) 05 (0.02) Second | 040-055 0.015 - 0022) 0.7 (0.03) Oil (side rail) | 02-07 (0.01 ~0.03) 0.9 (0.04) ____| 0.16 ~ 0.060 (0.0008 - 0.0020) a Connecting rod small end LD. ‘T1016 ~ 17034 (0.6699 ~ 0.6706) 1704 (0.671) Connecting rod-to-piston pin clearance (0.016 - 0.041 (0.0006 - 0.0016) Crankpin oll clearance (0.930 ~ 0.082 (0.0012 0 | 2.06 (0.002) 11-1

Honda Cb900 F Hornet 02-03 Service Manual Eng by Mosue

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