XR 250 L 01

00-2
CONTENTS
E
N
G
I
N
E

A
N
D

D
R
I
V
E

T
R
A
I
N
C
H
A
S
S
I
S
1
GENERAL INFORMATION
2
MAINTENANCE
3
LUBRICATION
4
CYLINDER]PISTON
8
CLUTCH]GEARSHIFT LINKAGE
9
FUEL SYSTEM
ENGINE REMOVAL]INSTALLATION
6
CYLINDER HEAD]VALVES
7
5
11
12
10
LIGHTS]METERS]SWITCHES
16
WIRING DIAGRAMS
17
BRAKE SYSTEM
IGNITION SYSTEM
14
STARTING SYSTEM
15
13
TROUBLESHOOTING
18
19
E
L
E
C
T
R
I
C
A
L
FRAME]BODY PANELS]EXHAUST
SYSTEM
FRONT WHEEL]SUSPENSION]
STEERING
SuppIement: XR BAJA (T)
SuppIement: XR250]XR BAJA (V)
20
21
INTRODUCTION
This service manuaI describes the inspection, adjust-
ment, and service procedures for the main XR250 and
XR BAJA components.
AII procedures for the XR250 (V) and XR250 BAJA (T) (V)
that deviate from those for the XR250 (S) and XR BAJA
(S) are coIIectiveIy depicted in Sections 20 and 21.
Procedures for the XR250]XR250 III (Y) that deviate from
those for XR250]XR250 III (V) of the previous modeI year
are coIIectiveIy presented. However, deviations that do
not affect the actuaI workings - such as aIterations to
appearance - are not incIuded.
Section 1 describes service vaIues and information ap-
pIicabIe to aII procedures in this manuaI.
Section 2 coIIectiveIy depicts the removaI]instaIIation
of body paneIs that are frequentIy removed and rein-
staIIed during maintenance and service procedures.
Section 3 describes inspection and service methods and
procedures required to maintain vehicIe safety and the
function of each component.
Sections 4 and thereafter describe service procedures
for engine, frame and eIectricaI components.
This manuaI incorporates numerous iIIustrations, pho-
tographs, and symboIs to faciIitate understanding of
the information presented. Refer to the foIIowing page
for the basics on how to use this manuaI.
Honda Motor Co., Ltd.
Service PubIication Office
PIease note that the information and specifications
provided in this service manuaI are subject to
change without prior notification.
This service manuaI is intended for use by those
with a basic knowIedge and skiIIs regarding Honda
motorcycIes. Servicing by those without the requi-
site skiIIs and knowIedge is not recommended due
to the significant risk of faiIure despite ones best
efforts to foIIow the procedures described in this
manuaI.
CRANKSHAFT]TRANSMISSION
REAR WHEEL]SUSPENSION
CHARGING SYSTEM]ALTERNATOR
SuppIement: XR250]XR BAJA (Y)
22
SuppIement: XR250]XR BAJA (3)
23
00-3
(page 3-1)
Shows an appIicabIe reference page.
Refer to page 3-1 in this exampIe.
AppIy a Iocking agent. Use a middIe
strength Iocking agent unIess otherwise
specified.
Use optionaI tooI. For the tooI number,
refer to the parts Iists since optionaI
tooIs are grouped as motorcycIe parts.
Use siIicon grease.
ExampIe: SiIicon Grease G-40M manu-
factured by Shin-Etsu ChemicaI, Japan.
Use speciaI tooI.
Use moIybdenum disuIfide paste
(containing more than 40% moIybde-
num disuIfide, NLGI#2 or equivaIent).
ExampIe: MoIykote
G-n Paste manu-

factured by Dow Corning U.S.A.
Honda MoIy 60 (U.S.A. onIy)
RocoI ASP manufactured by RocoI
Limited, U.K.
RocoI Paste manufactured by Sumico
Lubricant, Japan
Use recommended cushion oiI.
Use moIybdenum disuIfide grease
(containing more than 3% moIybdenum
disuIfide, NLGI#2 or equivaIent).
ExampIe: MuIti-purpose M2 manufac-
tured Mitsubishi OiI Japan
MoIykote
BR-2 pIus manufactured by

Dow Corning, U.S.A.
Use brake fIuid, DOT 4. Use the
recommended brake fIuid, unIess
otherwise specified.
Use muIti-purpose grease (Lithium
based muIti-purpose grease NLGI#2 or
equivaIent).
RepIace the part(s) with new one(s)
before assembIy.
Use moIybdenum oiI soIution (mixture
of the engine oiI and moIybdenum
grease in a ratio of 1:1).
AppIy seaIant.
Use recommended engine oiI, unIess
otherwise specified.
Indicates heIpfuI information.
Information given under this symboI
incIudes tips and hints appIicabIe to
servicing and handIing.
NOTE
CAUTION
Description SymboI Description
SymboIs
The foIIowing symboIs are used throughout this manuaI in order to bring users attention to important information.
SymboI
Description SymboI Description
The foIIowing symboIs indicate oiI, grease, repIacement parts, and speciaI tooIs required for a specific task.
SymboI
Any speciaI grease not Iisted above is specified with its appIicabIe product name without using any of the symboIs above.
1-1
1
1. GENERAL INFORMATION
MODEL IDENTIFICATION
MODEL IDENTIFICATION 1-1
SPECIFICATIONS (XR250) 1-2
SPECIFICATIONS (XR BAJA) 1-4
SERVICE DATA 1-6
TOROUE VALUES 1-14
SPECIAL TOOLS 1-16
LUBRICATION AND SEAL POINTS 1-18
CABLE AND HARNESS ROUTING 1-19
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER COLOR LABEL
When ordering a painted component, use the modeI name
and coIor code specified in this IabeI.
1-2
GENERAL INFORMATION
SPECIFICATIONS (XR250)
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
VehicIe weight Front axIe
Rear axIe
TotaI
Seating capacity
TotaI vehicIe weight (VehicIe weight and
average 2 persons weight) Front axIe
Rear axIe
TotaI
Tire size Front tire
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda MD30
2,140 mm
820 mm
1,205 mm
1,405 mm
MD17E
0.249 Iitter
GasoIine
60 kg
68 kg
128 kg
2 persons
90 kg
148 kg
238 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
280 mm
14.5 m (50 km]h)
2.1 m
Engine Starting method
Engine type
CyIinder arrangement
Combustion chamber type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Intake vaIve opens at 1 mm Iift
Intake vaIve cIoses at 1 mm Iift
Exhaust vaIve opens at 1 mm Iift
Exhaust vaIve cIoses at 1 mm Iift
VaIve cIearance Intake
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
SingIe cyIinder, transverseIy positioned
HemisphericaI combustion chamber
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Forced pressure Iubrication
Trochoid
FuII fIow oiI fiItration using a wire mesh strainer and a
paper fiIter
1.7 Iitter
Air cooIed
FUEL SYSTEM Air fiItration
FueI tank capacity TotaI VoIume
Carburetor ModeI
Venturi diameter
Paper fiIter
9.7 Iitter
VE88A
32 mm
1-3
GENERAL INFORMATION
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
CDI (Capacitive Discharge Ignition)
8 BTDC]1,300 rpm
CR8 EH-9 (NGK) or U24FER9 (NIPPON DENSO)
0.8 0.9 mm
DRIVE TRAIN CIutch system
CIutch operating
system
Primary reduction Type
Ratio
Transmission Type
Gearshift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
FinaI reduction Type
Ratio
Wet muIti-pIate coiI spring
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
Left gearshift pedaI
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.000 (13]39)
WHEELS Caster
TraiI
Tire pressure Front
Rear
25 25
92 mm
1.50 kg]cm
2
1.50 kg]cm
2
STEERING Steering angIe Left
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
HydrauIic disk brake
SHOCK
ABSORBER
Suspension type Front
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Engine seriaI number
Semi-doubIe cradIe
MD30 1000001 ~
MD17E 1700001 ~
1-4
GENERAL INFORMATION
SPECIFICATIONS (XR BAJA)
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda MD30
2,140 mm
820 mm
1,225 mm
1,405mm
MD17E
0.249 Iitter
GasoIine
62 kg
68 kg
130 kg
2 persons
92 kg
148 kg
240 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
280 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
9.7 Iitter
VE88A
32 mm
1-5
GENERAL INFORMATION
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
CDI
8 BTDC]1,300 rpm
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Shift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
Wet muIti-pIate
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
Left shift pedaI
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.000 (13]39)
WHEELS Caster
TraiI
Tire pressure Front
Rear
25 25
92 mm
1.50 kg]cm
2
1.50 kg]cm
2
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1000001 ~
MD17E 1700001 ~
1-6
GENERAL INFORMATION
at draining
at disassembIy
at oiI fiIter change
ITEM STANDARD SERVICE LIMIT
Engine oiI capacity 1.3 Iitter
1.7 Iitter
1.4 Iitter
Honda UItra U Engine OiI for 4-
Stroke MotorcycIe(SAE10W-30)
API Service CIassification SE or SG
grade engine oiI
0.15
0.15 0.22
0.02 0.09
Recommended engine oiI
(Choose an appropri ate viscosity most suitabIe to the
outside temperature)
Tip cIearance
Body cIearance
Side cIearance
OiI pump rotor
0.20
0.25
0.12
LUBRICATION SYSTEM
SERVICE DATA
Unit: mm
Type
Setting mark
Venturi diameter
PiIot screw opening
FIoat IeveI
IdIe speed
Main jet
SIow jet
ITEM SPECIFICATIONS SERVICE LIMIT
Carburetor VE 88A
VE 88A A
30.1 mm or equivaIent
2 1]8 turns out
18.5 mm
1,300 100 rpm
#138
#45
2 6 mm
Unit: mm
FUEL SYSTEM
ThrottIe grip free pIay
1-7
GENERAL INFORMATION
Warpage
VaIve seat width
Cam Iobe height
Runout
VaIve stem O.D.
VaIve guide I.D.
Stem-to-guide cIearance
VaIve seat width
Free Iength
Rocker arm I.D.
Sub-rocker arm I.D.
Rocker arm shaft O.D.
Sub-rocker arm shaft O.D.
Rocker arm-to-shaft cIearance
Sub-rocker arm-to-shaft cIearance
ITEM
Unit: mm
STANDARD SERVICE LIMIT
CyIinder compression 6.8 kgf]cm
2
400 rpm
0.10 0.02 mm
0.12 0.02 mm
1.1 1.2
30.672 30.872
30.719 30.919
4.975 4.990
4.955 4.970
5.000 5.012
5.000 5.012
0.010 0.037
0.030 0.057
1.1 1.2
1.1 1.2
43.44
44.03
11.500 11.518
7.000 7.015
7.000 7.015
11.466 11.484
6.972 6.987
6.972 6.987
0.016 0.052
0.013 0.043
VaIve spring
0.10
2.0
30.583
30.629
0.04
4.96
4.94
5.03
5.03
0.06
0.09
2.0
2.0
42.51
42.83
11.53
7.05
7.05
11.41
6.92
6.92
0.10
0.10
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
Inner
Outer
IN
EX
IN
EX
VaIve cIearance (on a coId engine)
CyIinder head
Camshaft
VaIve and
vaIve guide
Rocker arm
Sub-rocker
arm
1-8
GENERAL INFORMATION
ITEM
Unit: mm
ITEM
Unit: mm
STANDARD
CIutch
Mainshaft O.D. at cIutch outer guide
CIutch Lever free pIay
CIutch Spring free Iength
CIutch Disc thickness
CIutch outer I.D.
CIutch Outer guide
CIutch PIate warpage
10 20
37.2
2.92 3.08
25.000 25.021
24.959 24.980
19.990 20.010
19.959 19.980
CyIinder
Piston, piston
pin and
piston ring
73.00 73.01
IN mark facing to the intake side

18.5 mm from the skirt bottom
72.950 72.970
17.002 17.008
0.03 0.06
16.994 17.000
0.002 0.014
0.016 0.040
0.15 0.30
0.30 0.45
0.20 0.70
0.015 0.05
0.015 0.05
mark facing up
mark facing up
17.016 17.034 Connecting rod smaII end I.D.
73.11
0.05
0.05
0.10
72.87
17.05
0.1
16.97
0.05
0.09
0.30
0.45
0.86
0.12
0.12
17.06
CYLINDER]PISTON
I.D.
Taper
Out of round
Warpage
Piston mark direction
Piston O.D. measuring position
Piston O.D.
Piston pin hoIe I.D.
Piston-to-cyIinder cIearance
Piston pin O.D.
Piston-to-piston pin cIearance
Piston pin-to-connecting rod smaII end
cIearance
Piston ring end gap
Piston ring-to-ring
groove cIearance
Piston ring mark
SERVICE LIMIT
33.5
2.7
25.04
24.12
20.03
0.3
19.91
Top
Second
OiI (side raiI)
Top
Second
Top
Second
O.D.
I.D.
1-9
GENERAL INFORMATION
ITEM
Unit: mm
Crankshaft
Transmission
0.050 0.065
0 0.008
20.000 20.021
23.000 23.021
23.000 23.021
25.020 25.041
25.000 25.021
22.000 22.021
18.000 18.018
22.000 22.021
22.959 22.980
24.979 25.000
24.959 24.980
22.959 22.980
19.959 19.980
17.966 17.984
21.959 21.980
21.959 21.980
0.02 0.062
0.02 0.062
0.020 0.062
0.020 0.062
0.02 0.062
0.02 0.062
0.016 0.052
0.02 0.062
13.000 13.021
12.966 12.984
4.930 5.000
4.900 5.000
19.959 19.980
0.80
0.05
0.05
20.08
23.07
23.07
25.09
25.07
22.07
18.08
22.1
22.90
24.9
24.90
22.92
19.91
17.91
21.91
21.91
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
13.05
12.91
4.50
4.50
19.90
CRANKCASE]CRANKSHAFT]TRANSMISSION
Connecting
rod big end
Runout
Gear I.D.
Bushing I.D.
Bushing O.D.
M5
M6
C1
C2
C3
C4
C1
C2
C1
C2
C3
M6
side cIearance
radiaI cIearance
Mainshaft O.D. (M6)
Countershaft
O.D.
Gear-to-shaft
cIearance
Gear-to-
bushing
cIearance
Bush-to-shaft
cIearance
C1
C2
C4
M6
C4
M6
C1
C2
C3
C1
C2
Shift fork I.D.
Shift fork shaft O.D.
Operation area thickness
Shift drum O.D. at right crankcase
bearing portion
R., Center.
L.
1-10
GENERAL INFORMATION
ITEM
Unit: mm
Front wheeI
2.0
2.0
1.50 kg]cm
2
1.50 kg]cm
2
1.50 kg]cm
2
72.9
363.1
477 cc
90
Honda UItra Cushion oiI #5
0.1 0.2 kg-m

0.2
3.0
72.2
359.5
0.2
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
Remaining tread depth
FRONT WHEEL]SUSPENSION]STEERING
One
passenger
Two
passengers
Street
Highway
Street
Fork Spring free
Iength
OiI capacity
OiI IeveI
OiI type
Tube runout
A
B
Force Required for steering
ITEM
Unit: mm
Rear wheeI
2.0
2.0
1.50 kg]cm
2
1.50 kg]cm
2
1.50 kg]cm
2
30 40
520MOZ9]102LE
520VC5]102LE
181 7.5 kg when compressed to 10 mm

Tighten the adjuster to the maximum
strength position first, and then
Ioosen it back untiI 9 12 cIicks are
heard where the punch mark meets
the matching notch.
the matching notch.
0.2
3.0
10
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
One
passenger
Two
passengers
Street
Highway
Street
Drive chain Chain sIack
RepIacement
chain]Iink
Drive chain sIider thickness
Rear damper compression pressure
RK
DID
Rear
Rear compression adjuster instaIIation
position
Rear rebound adjuster instaIIation
position
1-11
GENERAL INFORMATION
Brake fIuid
Front brake Iever free pIay
Rear brake pedaI free pIay
Brake pad wear
Brake disc runout
Brake disc thickness
Mater cyIinder I.D.
Master piston O.D.
CaIiper cyIinder I.D.
CaIiper piston O.D.
DOT 4
10 20
10 20
3.5
4.5
12.700 12.743
14.000 14.043
12.657 12.684
13.957 13.984
27.000 27.050
27.000 27.050
26.935 26.968
26.935 26.968
FR
RR
FR
RR
FR
RR
FR
RR
FR
RR
To the service
Iimit groove
0.15
3.0
4.0
12.76
14.06
12.64
13.95
27.10
27.10
26.89
26.89
Unit: mm
BRAKE SYSTEM
ITEM STANDARD
AIternator
ReguIator]rectifier
Battery
TripIe phase AC
0.204 kW]5,000 rpm
0.1 1.0
SCR Shorter]tripIe phase fuII-wave rectification
14.0 14.8 V
12 V 4 Ah
0.5 A]5 10 h
5.0 A]0.5 h
2.0 mA maximum
12.8 V minimum
12.3 V maximum
Type
Output
Charging coiI resistance at
20 C
Type
VoItage range
Capacity
Charging current
Leakage current
BATTERY]CHARGING SYSTEM
Standard
Fast
VoItage at
20 C
FuII charging
Lack of charging
1-12
GENERAL INFORMATION
PuIse generator
ITEM SPECIFICATIONS
Ignition type
Spark pIug
CDI
Standard
OptionaI for Iow speed driving
OptionaI for high speed driving
IGNITION SYSTEM
NGK
CR8 EH-9
CR7 EH-9
CR9 EH-9
NIPPON DENSO
U24FER9
U22FER9
U27FER9
Spark pIug gap
Ignition timing
0.8 0.9 mm
8 BTDC]1,300 rpm
1,900 200 rpm
4,300 rpm
MP13
0.1 0.3
7.2 11.0 k
3.5 4.7 k
100 V minimum
460 580
0.7 V minimum
F mark
Engine rpm to start spark advance
Engine rpm to terminate spark
advance
Type Ignition coiI
Resistance
at 20 C
Primary coiI
Secondary coiI with
a pIug cap
Secondary coiI
without a pIug cap
Peak voItage
Resistance at 20 C
Peak voItage
ITEM STANDARD
Starter motor brush Iength 12.5 13.0
STARTER]STARTER CLUTCH
Unit: mm
SERVICE LIMIT
8.5
ITEM SPECIFICATIONS
Fuse
Light]buIb
20 A
5 A x 2, 15 A x 3
XR BAJA: 12 V 35]36.5 W XR250: 12 V 35]36.5 W
12 V 5]21 W
12 V 5 W
12 V 15 W
12 V 15 W
12 V 2 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
Primary
Secondary
HeadIight (high]Iow beams)
TaiI]brake Iights
License Iight
Front turn signaI Iight buIbs
Rear turn signaI Iight buIbs
Instrument iIIumination Iamp
Turn signaI indicator buIb
NeutraI indicator
Side stand indicator
High beam indicator buIb
LIGHTS]INSTRUMENTS]SWITCH
1-13
GENERAL INFORMATION
TOROUE VALUES
STANDARD TIGHTENING TOROUE
FASTENERS TYPE
5 mm hex boIt and nut
TIGHTENING TOROUE
(kgm)
TIGHTENING TOROUE
(kgm)
0.5
1.0
2.2
3.5
5.5
5 mm screw
6 mm screw and SH boIt
6 mm fIange boIt and nut
FASTENERS TYPE
0.4
0.9
1.2
2.7
4.0
Torque specifications Iisted beIow are for important fasteners. Others shouId be tightened to standard torque vaIues Iisted
above.
NOTES: 1. AppIy a Iocking agent to the threads.
2. Left hand screws.
3. CauIk the boIt head.
4. AppIy oiI to the threads and seating surface.
5. AppIy cIean engi ne oiI to the O-ring.
6. AppIy grease to the threads and seating surface.
7. U-nut.
8. ALOC boIt (RepIace with a new one when removed).
9. CastIe nut
10. RepIace with a new one when removed.
ITEM REMARKS
TIGHTENING TOROUE
(kgm)
THREAD DIA.
(mm)
OTY
Maintenance:
Crankcase oiI drain boIt
VaIve hoIe cap
Timing hoIe cap
Crankshaft hoIe cap
Lubrication System:
OiI pass pipe joint boIt (7 mm)
(8 mm)
OiI fiIter cover boIt
CyIinder Head]VaIves:
Spark pIug
CyIinder head cover boIt (6 mm)
(8 mm)
CyIinder head boIt (6 mm SH)
(10 mm)
Cam sprocket boIt
Rocker arm shaft
Sub-rocker arm shaft
VaIve adjusting]Iocking nut (IN)
(EX)
Cam chain tensioner set pIate boIt
CyIinder]Piston:
CyIinder boIt
CIutch]Gearshift Linkage:
Right crankcase cover boIt
CIutch center Iock nut
Shift drum stopper arm boIt
Shift return spring stopper boIt
Primary drive gear Iock nut
Gearshift pedaI boIt
1
4
1
1
2
1
2
1
13
1
2
4
2
2
4
2
2
2
4
11
1
1
1
1
1
Note 6
Note 6
Note 4
Note 1
Note 1
Note 1
Note 4
Note 3, 4
Note 1
Note 4
2.5
1.5
1.0
0.8
1.2
1.2
1.2
1.2
1.2
2.4
1.0
4.0
2.0
2.8
2.3
2.4
2.6
1.0
4.0
1.2
11.0
1.2
2.4
9.0
1.2
12
36
14
30
7
8
6
10
6
8
6
10
7
14
12
7
8
6
10
6
16
6
10
18
6
ENGINE
1-14
GENERAL INFORMATION
ITEM REMARKS
TIGHTENING TOROUE
(kgm)
THREAD DIA.
(mm)
OTY
Crankcase]Crankshaft]Transmission:
Crankcase boIt
Bearing set pIate boIt
AIternator:
Left crankcase cover boIt
Stator boIt
FIywheeI boIt
One-way cIutch outer boIt
PuIse generator socket boIt
CIamp socket boIt
Others:
Drive sprocket boIt
NeutraI switch
NeutraI switch nut
11
1
8
3
1
6
2
1
2
1
1
Note 1
Note 1
Note 4
Note 1
Note 1
Note 1
1.2
1.2
1.2
1.0
10.5
1.6
0.5
0.5
1.0
1.2
0.15
6
6
6
6
12
6
5
5
6
10
4
ENGINE (continued)
ITEM REMARKS
TIGHTENING TOROUE
(kgm)
THREAD DIA.
(mm)
OTY
Frame Body PaneIs]Exhaust System:
Sub-frame upper boIt
Sub-frame Iower side boIt
Exhaust pipe joint boIt
Exhaust pipe protector boIt
MuffIer band tightening boIt
MuffIer mounting boIt (Front)
(Rear)
Maintenance:
Down tube oiI drain boIt
Lubrication system:
OiI pipe boIt (12 mm)
OiI strainer nut
FueI system:
FueI strainer cup
FueI cock Iock nut
Engine mount:
Engine hanger nut
Engine hanger pIate nut
Front WheeI]Suspension]Steering:
Steering stem nut
Steering top thread
Spoke nippIe
Front brake disc boIt
Front axIe
Front axIe hoIder nut
Fork cIamp boIt (upper)
(Iower)
Fork center boIt
Fork boIt
1
2
4
2
2
1
1
1
1
1
1
1
4
6
1
1
31
4
1
4
4
4
2
2
Note 8
Note 7
Note 1
3.3
4.3
1.0
1.3
2.0
3.3
3.3
4.0
3.8
5.5
2.7
2.7
6.5
2.7
10.0
0.45
0.25 0.5
2.0
7.5
1.2
3.2
2.7
5.5
3.0
8
8
6
6
8
8
8
10
12
27
18
18
10
8
24
26
BC3.2
6
12
6
8
8
19
36
FRAME
1-15
GENERAL INFORMATION
ITEM REMARKS
TIGHTENING TOROUE
(kgm)
THREAD DIA.
(mm)
OTY
Rear WheeI]Suspension:
Driven sprocket nut
Rear brake disc pIate boIt
Rear axIe nut
Rear cushion boIt (upper)
(Lower)
Connecting rod nut (on the cushion arm)
(on the frame)
Cushion arm nut (on the swingarm)
Swingarm pivot nut
Chain cover boIt
Brake System:
Brake hose boIt
Brake hose guide screw
Reservoir cover screw
Front master cyIinder hoIder boIt
Front brake Iight switch screw
Front brake Iever pivot boIt
nut
Rear master cyIinder hoIder boIt
Push rod Iock nut
Front caIiper bracket boIt
Front caIiper pad pin
Front caIiper pad pin pIug
Front caIiper bIeeder vaIve
Front caIiper pin boIt A
Front caIiper pin boIt B
Rear caIiper pad pin
Rear caIiper pad pin pIug
Rear caIiper bIeeder vaIve
Rear caIiper pin boIt
Rear caIiper bracket pin boIt
Others:
Right step boIt
Side stand pivot boIt
nut
HandIe Iock screw
HeadIight guard nut
Speed sensor nut
6
4
1
1
1
1
1
1
1
2
4
2
2
2
1
1
1
2
1
2
1
2
1
1
1
1
1
1
1
1
2
1
1
2
2
1
Note 7
Note 8
Note 7
Note 7
Note 6, 7
Note 7
Note 7
Note 7
Note 1
Note 1
Note 1
Note 1
Note 1
Note 1
Note 7
3.3
4.3
9.5
4.5
4.5
5.0
4.5
7.0
9.0
1.2
3.5
0.43
0.2
1.4
0.12
0.6
0.6
1.4
1.8
3.0
1.8
0.25
0.6
2.3
1.3
1.0
0.25
0.6
2.8
1.2
4.3
1.0
4.0
2.3
0.5
1.2
8
8
16
10
10
10
10
12
14
6
10
5
4
6
4
6
6
6
8
8
10
10
8
8
8
10
10
8
12
8
10
10
10
8
6
18
FRAME (continued)
1-16
GENERAL INFORMATION
SPECIAL TOOLS
NewIy designed tooI
DESCRIPTION
Maintenance:
Compression gauge attachment
Wrench B
NippIe wrench
Drive chain cauIking tooI
Link pIate hoIder
FueI system:
FIoat IeveI gauge
PiIot screw wrench
CyIinder head]vaIve:
VaIve spring compressor
VaIve guide driver
VaIve guide reamer (5.010 mm)
Cutter hoIder, 5 mm
VaIve seat cutter
Seat cutter, 45 , 33 mm
Seat cutter, 45 , 27.5 mm
FIat cutter, 32 , 30 mm
Interior cutter, 60 , 30 mm
CIutch center hoIder
Gear hoIder
Bearing remover, 15 mm
Remover shaft, 15 mm
Remover head, 15 mm
SIiding weight
Shaft compressor
Remover head, 13 mm
SIiding weight
Crank case assembIy tooI
CoIIar
Shaft
Adaptor
UniversaI bearing puII er
Driver handIe A
Outer driver, 32 x 35 mm
PiIot, 15 mm
PiIot, 20 mm
PiIot, 17 mm
PiIot, 22 mm
PiIot, 28 mm
TOOL NUMBER
07RMJ-MY50100
07708-0030400
07701-0020300
07HMH-MR10103
07HMH-MR10130
07401-0010000
07908-4730001
07757-0010000
07942-MA60000
07984-MA60001
07781-0010400
07780-0010800
07780-0010200
07780-0012200
07780-0012000
07780-0014000
07923-KE10000
07724-0010100
07936-KC10000
07936-KC10100
07936-KC10200
07741-0010201
07936-1660120
07LMC-KZ10100
07741-0010201
07965-VM00000
07965-VM00100
07965-VM00200
07965-VM00300
07631-0010000
07749-0010000
07746-0010100
07746-0040300
07746-0010200
07746-0010300
07746-0040500
07746-0010300
07746-0040400
07746-0010400
07746-0041000
07746-0010600
07746-0041100
CyIinder compression pressure mea-
surement
VaIve cIearance adjustment
Spoke tightening
Drive chain repIacement
Carburetor fueI IeveI adjustment
Carburetor adjustment
VaIve removaI and instaIIation
VaIve guide removaI and instaIIation
VaIve guide cIeani ng and finishing
VaIve seat modification
InIet
Exhaust
InIet
Exhaust
InIet]Exhaust
CIutch disassembIy and assembIy
Primary drive gear removaI and instaIIa-
tion
Left mainshaft bearing removaI
BaIancer shaft bearing removaI
Right crankshaft removaI and instaIIa-
tion
Crankshaft bearing removaI
Bearing instaIIation
Left mainshaft bearing instaIIation
BaIancer shaft bearing instaIIation
Right mainshaft bearing instaIIation
Right countershaft bearing instaIIa-
tion
Left countershaft bearing instaIIation
Crankshaft bearing instaIIation
APPLICABLE PROCEDURE
1-17
GENERAL INFORMATION
DESCRIPTION
Steering stem socket
Steering stem driver
OiI seaI remover
Fork damper hoIder
Fork seaI driver
Fork seaI driver attachment
Bearing remover shaft
Bearing remover head, 15 mm
Driver handIe A
PiIot, 15 mm
NeedIe bearing remover
Bush driver pin
SphericaI bearing driver
Retainer wrench B
Retainer wrench body
Driver handIe A
PiIot, 17 mm
PiIot, 17 mm
PiIot, 17 mm
Brake System:
Snap ring pIiers
Charging system]AIternator:
FIywheeI hoIder
FIywheeI puIIer
TOOL NUMBER
07916-KA50100
07946-4300101
07948-4630100
07PMB-KZ40101
07947-KA50100
07947-KF00100
07746-0050100
07746-0050400
07749-0010000
07746-0010100
07746-0040300
07746-0010300
07931-MA70000
07946-KA50000
07GMD-KT80100
07HMF-KS60100
07710-0010200
07710-0010401
07746-0050100
07746-0050500
07749-0010000
07746-0010700
07746-0040400
07746-0010200
07746-0040400
07746-0010300
07746-0040400
07914-3230001
07725-0040000
07733-0020001
Steering top thread removaI and
instaIIation
Steering stem Iower bearing instaIIation
Bearing race removaI
Fork socket boIt removaI and instaIIation
Fork oiI seaI instaIIation
Front wheeI bearing removaI
Front wheeI bearing instaIIation
Bearing Iace instaIIation
Swingarm pivot (outer) bearing removaI
Swingarm pivot (inner) bearing removaI
and instaIIation
Swingarm pivot (outer) bearing instaIIa-
tion
Cushion arm needIe bearing removaI
and instaIIation
Cushion connecting rod needIe bearing
removaI
Cushion arm sphericaI bearing removaI
and instaIIation
Rear cushion sphericaI bearing removaI
and instaIIation
Bearing retainer removaI and
instaIIation
Rear wheeI bearing removaI
Cushion connecting rod needIe
bearing instaIIation
Right rear wheeI bearing instaIIation
Left rear wheeI bearing instaIIation
Snap ring removaI and instaIIation
FIywheeI removaI and instaIIation
1-18
GENERAL INFORMATION
LUBRICATION AND SEAL POINTS
LOCATION MATERIAL NOTE
CyIinder inner surface
Piston outer surface
Piston pin hoIe inner waII
Piston ring surface
Cam chain surface
Rocker arm shaft (rocker arm sIiding surface)
Sub-rocker arm shaft (sub rocker arm sIiding surface)
CIutch disc Iining
CIutch arm pivot
Shift fork shaft outer surface
VaIve adjust screw thread
Each transmission gear
FIywheeI boIt thread and seating surface
CyIinder head boIt (10 mm) thread and seating surface
CyIinder boIt (10 mm) thread and seating surface
CIutch center Iock nut thread and seating surface
Primary drive gear Iock nut thread and seating surface
Each bearings
Each O-rings
Each oiI seaI Iips
Each oiI seaI surface
Piston pin outer surface
Connecting rod smaII end
Camshaft Iobe
Camshaft center journaI
Rocker arm sIiding surface
Sub-rocker arm adjusting screw contact area
VaIve sIiding surface
CIutch outer guide outer surface
Outer surface of each transmission gear
M3]4, C5, and C6 gearshift fork groove
CIutch Iifter arm pivot
Each oiI seaI Iips
Rocker arm shaft threads
Sub-rocker arm shaft threads
Bearing set pIate boIt threads
Cam sprocket boIt threads
Shift drum stopper arm boIt threads
Stator boIt threads
One-way cIutch outer boIt threads
PuIse generator cIamp socket boIt threads
Honda UItra U Engine OiI
for 4-Stroke MotorcycIe
(SAE10W-30)
API Service CIassification
SE, SF or SG grade
engine oiI
Use moIybdenum oiI
soIution (mixture of the
engine oiI and moIybde-
num grease in a ratio of
1:1).
MuIti-purpose grease
Three Bond #13238 or
#2415
Coating width:
3 mm at the middIe
of boIt thread
Coating width:
6.5 1 mm from tip
Coating width:
5 1 mm from tip
Coating width:
6.5 1 mm from tip
ENGINE
ThrottIe grip inner surface
ThrottIe cabIe guide groove
CIutch Iever pivot
Side stand pivot
HandIe grip rubber inner surface
CEMEDINE #540 or Honda
Bond A
FRAME
2-1
2. FRAME]BODY PANELS]EXHAUST SYSTEM
SERVICE INFORMATION
This section covers removaI and instaIIation of the frame body paneIs and exhaust system.
Route aII tubes and cabIes correctIy as iIIustrated in CABLE AND HARNESS ROUTING in Section 1 (page 1-19).
RepIace aII gaskets when removing the muffIer component.
When instaIIing the muffIer, IooseIy instaII aII boIts and nuts first, then tighten aII joint nuts, before finaIIy tightening aII
mounting boIts.
Inspect the instaIIed muffIer to ensure it has no Ieaks.
TOROUE VALUES
Exhaust pipe joint nut 1.0 kgm
Exhaust pipe protector mounting boIt 1.3 kgm
MuffIer cIamp boIt 2.0 kgm
MuffIer mounting boIt (front) 3.3 kgm
(rear) 3.3 kgm
TROUBLESHOOTING
Excessive exhaust noise
Broken exhaust system
Exhaust gas Ieak
Poor performance
Deformed exhaust system
Exhaust gas Ieak
CIogged muffIer
SERVICE INFORMATION 2-1
TROUBLESHOOTING 2-1
FRONT FENDER 2-2
SIDE COVER]SEAT 2-2 2
REAR FENDER 2-3
UNDER GUARD 2-7
EXHAUST PIPE]MUFFLER 2-7
2-2
FRAME]BODY PANELS]EXHAUST SYSTEM
FRONT FENDER
REMOVAL
Remove the boIts, washers and coIIars.
Remove the front fender.
INSTALLATION
InstaIIation is in the reverse order of removaI.
SIDE COVER]SEAT
REMOVAL
Remove the boIt and socket boIts.
Remove the side cover.
Remove the seat.
INSTALLATION
InstaII the seat.
NOTE:
At instaIIation, aIign the front hook of the seat with the fueI
tank boss and both side hooks with the frame hooks.
AIign the side cover boss with the grooves on the rear fender
when instaIIing the side cover.
InstaII and secureIy tighten the boIts and socket boIts.
FRONT FENDER
BOLTS]WASHERS]COLLARS
BOLTS
SIDE COVER
SOCKET BOLTS
AIign
SEAT
AIign
SIDE COVER
AIign
2-3
REAR FENDER
REMOVAL
REAR FENDER A
Remove the seat and side covers (page 2-2).
Disconnect the taiIIight]brake Iight 3P (BIack) coupIer.
Using the main switch key, remove the taiI bag cabIe.
Remove the taiI bag strap.
UnIoad the in-vehicIe tooI set from the bag.
Remove the taiI bag socket boIts, coIIars and bottom pIate.
Remove the taiI bag.
Remove the boIts.
3P (BLACK) COUPLER
TAIL BAG SOCKET BOLTS]COLLARS
BOTTOM PLATE STRAP
BOLT
BOLTS
2-4
Remove the rear fender A.
REAR FENDER B
Disconnect the right and Ieft turn signaI connector and the
Iicense Iight 2P (Red) coupIer.
Remove the wire harness from the cIamps of rear fender B.
Remove the rear fender nuts, coIIars and boIts.
Remove the rear fender B and the rear turn signaI units.
REAR FENDER A
CLAMPS
CONNECTOR]COUPLER
NUT]COLLAR]BOLT REAR FENDER B
REAR TURN SIGNAL UNI T
2-5
INSTALLATION
REAR FENDER B
InstaII the rear fender B and the rear turn signaI units.
InstaII and tighten the boIts, coIIars, and rear fender nuts.
NOTE:
When instaIIing the rear turn signaI units, aIign the Iug of the
rear turn signaI unit stay with the stopper of the rear fender
as shown in the iIIustration.
AIign
TAIL BAG
REAR FENDER A
REAR FENDER B
REAR TURN SIGNAL UNITS
BOLT]COLLAR]NUT REAR FENDER B
2-6
Connect the right and Ieft turn signaI connector and the Ii-
cense Iight 2P (Red) coupIer.
NOTE:
Route wires of the right and Ieft turn signaI connector and the
Iicense Iight 2P (Red) coupIer correctIy as iIIustrated in CABLE
AND HARNESS ROUTING i n Section 1 (page 1-19).
REAR FENDER A
InstaII the rear fender A.
NOTE:
Route wires of the taiIIight]brake Iight correctIy as iIIustrated
in CABLE AND HARNESS ROUTING in Section 1 (page 1-19).
InstaII and tighten the boIts.
CLAMPS
CONNECTOR]COUPLER
REAR FENDER A
BOLTS
BOLT
2-7
InstaII the foIIowing components.
Bottom pIate
CoIIars
TaiI bag socket boIts
PIace the in-vehicIe tooI set inside the taiI bag and tie it with
the taiI bag strap.
InstaII the taiI bag cabIe and Iock it using the main switch key.
Connect the taiIIight]brake Iight 3P (BIack) coupIer.
InstaII the seat and the side covers (page 2-2).
UNDER GUARD
RemovaI
Remove the boIts and under guard.
InstaIIation
EXHAUST PIPE]MUFFLER
REMOVAL
Remove the right side cover (page 2-2).
Loosen the muffIer cIamp boIt.
TAIL BAG
COLLARS]SOCKET BOLTS
3P (BLACK) COUPLER
BOTTOM PLATE STRAP
BOLTS
UNDER GUARD
MUFFLER CLAMP BOLT
2-8
Remove the exhaust pipe joint nuts and exhaust pipe.
Remove the muffIer mounting boIts and muffIer.
JOINT NUTS
EXHAUST PIPE
MUFFLER
BOLTS
MUFFLER
InstaIIation
EXHAUST PIPE
GASKET
GASKET
3.3 kgm
3.3 kgm
2.0 kgm
1.3 kgm
1.0 kgm
2-9
Torque VaIues:
Exhaust pipe joint nut: 1.0 kgm
MuffIer cIamp boIt: 2.0 kgm
MuffIer mounting boIt (front): 3.3 kgm
(rear): 3.3 kgm
NOTE:
AIways repIace the gaskets with new ones.
InstaII the exhaust pipe joint with the mark facing up.
LooseIy instaII aII boIts and nuts. AIways tighten the joint
nuts first, then tighten the mounting boIts.
MOUNTING BOLTS MUFFLER CLAMP BOLTS
JOINT NUTS
EXHAUST PIPE JOINT
MARK
3-1
3. MAINTENANCE
MAINTENANCE SCHEDULE 3-2
FUEL TUBE 3-9
FUEL COCK 3-9
THROTTLE OPERATION 3-9
CHOKE OPERATION 3-10
AIR CLEANER 3-10
SPARK PLUG 3-11
VALVE CLEARANCE 3-11
ENGINE OIL 3-13
ENGINE OIL FILTER 3-15
IDLE SPEED ADJUSTMENT 3-15
CYLINDER COMPRESSION 3-16
3
DRIVE CHAIN 3-17
DRIVE CHAIN SLIDER 3-20
BRAKE FLUID 3-20
BRAKE PAD WEAR 3-21
BRAKE SYSTEM 3-21
BRAKE LIGHT SWITCH 3-21
HEADLIGHT BEAM ADJUSTMENT 3-22
CLUTCH 3-22
SIDE STAND 3-23
SUSPENSION 3-23
WHEEL 3-24
STEERING HEAD BEARING 3-25
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
NOTE:
1. Inspections shown in the Before starting coIumn incIude inspections required for high speed driving.
2. Inspections marked by are those required by the Road Traffic Law in Japan whiIe inspections marked are those
recommended by Honda.
3. Items marked X in the Remarks coIumn do not appIy to the motorcycIes in this service manuaI.
4. Descriptions with in the Remarks coIumn are the repIacement intervaIs of components criticaI for motorcycIe
safety.
These intervaIs are determined based on average driving conditions. Those who drive their motorcycIes in extreme
conditions need to repIace these components more frequentIy.
5. Highway driving in the Specification coIumn means driving at 80 km]h or faster.
ITEM
MAINTENANCE INTERVAL
REMARKS
B
e
f
o
r
e

s
t
a
r
t
i
n
g
A
f
t
e
r

f
i
r
s
t

o
n
e
m
o
n
t
h

o
r

1
0
0
0
k
m

o
f

d
r
i
v
i
n
g
E
v
e
r
y

6
m
o
n
t
h
s
E
v
e
r
y

1
2
m
o
n
t
h
s
PersonaI use
B
r
a
k
e

s
y
s
t
e
m
H
o
s
e RepIacement of brake hoses
RepIacement of rubber components used
in the master cyIinder, the wheeI cyIinder
cup, the dust seaI and the disk caIiper
Wear of the brake pad
RepIacement of brake fIuid
RepIacement of the air cIeaner eIement
Change engine oiI
RepIacement of the fueI hose
Every 4 years
Every 2 years
Refer to page 3-3
Every 1 year
Every 20,000 km
After first one month or 1,000 km of
driving and every 6,000 km thereafter
Every 4 year
M
a
s
t
e
r

c
y
I
i
n
d
e
r
,
w
h
e
e
I

c
y
I
i
n
d
e
r
,
a
n
d

d
i
s
k

c
a
I
i
p
e
r
B
r
a
k
e
p
a
d
O
i
I

a
n
d
g
r
e
a
s
e
E
n
g
i
n
e
E
n
g
i
n
e
L
u
b
r
i
c
a
t
i
o
n
s
y
s
t
e
m
F
u
e
I
s
y
s
t
e
m
3-3
MAINTENANCE
ITEM REMARKS
S
t
e
e
r
i
n
g

s
y
s
t
e
m
H
a
n
d
I
e
b
a
r
Free pIay, Iooseness, or
rattIe
Smoothness of steering
operation
Front wheeI turning
angIe
Damage
InstaIIation condition of
the fork spindIe
Looseness or rattIe of
the fork spindIe bearing
Free pIay and cIearance
between the pedaI and
the fIoor pIate
PedaI TraveI and braking
effort
Braking effort
Iooseness, rattIe or
damage
Leakage, damage, and
InstaIIation condition
Brake fIuid IeveI
Performance, wear, and
damage
CIearance between the
brake drum and the
brake Iining
Wear of the brake shoe
surface and the brake
Iining
Wear and damage of the
brake drum
B
e
f
o
r
e

s
t
a
r
t
i
n
g
A
f
t
e
r

f
i
r
s
t

o
n
e
m
o
n
t
h

o
r

1
0
0
0
k
m

o
f

d
r
i
v
i
n
g
E
v
e
r
y

6
m
o
n
t
h
s
E
v
e
r
y

1
2
m
o
n
t
h
s
PersonaI use
SPECIFICATION
F
r
o
n
t
w
h
e
e
I
F
r
o
n
t

f
o
r
k
Inspect the area
around the steering
stem
Inspect the area
around the steering
stem
B
r
a
k
e

s
y
s
t
e
m
B
r
a
k
e

p
e
d
a
I
Free pIay Brake pedaI : 10 20 mm
Brake Iever : 10 20 mm
at the Iever end
R
o
d
a
n
d
c
a
b
I
e
H
o
s
e
a
n
d
p
i
p
e
R
e
s
e
r
v
o
i
r
t
a
n
k
Brake fIuid IeveI
Front wheeI: must be above the
Iower Iimit
Rear wheeI: must be between the
upper and Iower Iimits
M
a
s
t
e
r

c
y
I
i
n
d
e
r
,
w
h
e
e
I

c
y
I
i
n
d
e
r
,
a
n
d

d
i
s
k

c
a
I
i
p
e
r
B
r
a
k
e

d
r
u
m

a
n
d
b
r
a
k
e

s
h
o
e
X
X
X
X
3-4
MAINTENANCE
ITEM REMARKS
B
r
a
k
e

s
y
s
t
e
m
B
r
a
k
e

d
i
s
k

a
n
d

p
a
d
CIearance between the
brake disk and the brake
pad
Wear of the brake pad
Wear and damage of the
brake pad
Tire pressure
Crack and damage of the
tires
Tire tread depth and
excessive wear
Foreign objects stuck in
the tire tread, such bits
of metaI or graveI
Looseness of wheeI nuts
and boIts
Damage of the rim, the
side Iink and the wheeI
disk
the front wheeI bearing
B
e
f
o
r
e

s
t
a
r
t
i
n
g
A
f
t
e
r

f
i
r
s
t

o
n
e
m
o
n
t
h

o
r

1
0
0
0
k
m

o
f

d
r
i
v
i
n
g
E
v
e
r
y

6
m
o
n
t
h
s
E
v
e
r
y

1
2
m
o
n
t
h
s
PersonaI use
SPECIFICATION
A wear indicator is
equipped
NormaI thickness Front : 3.5 mm
Rear : 4.5 mm
Service Iimit Front : 3.0 mm
Rear : 4.0 mm
W
h
e
e
I
s

a
n
d

t
i
r
e
s
W
h
e
e
I
s

a
n
d

t
i
r
e
s
(Unit: kg]cm
2
)
One
passenger
Two
Passengers
Street
Highway
Street
Front Rear
Tire size
1.50
1.50
1.50
3.00-
21 51P
1.50
1.50
1.50
4.60-
18 63P
Remaining tread
Front : more than 0.8 mm
Rear : more than 0.8 mm
Tightening torque for the front axIe
hoIder: 1.0 1.4 kg-m
Tightening torque for the front axIe
nuts: 7.0 8.0 kg-m
Tightening torque for the rear axIe
nuts: 8.0 11.0 kg-m
WheeI rim runout at the rim end:
Front IateraI runout: 2.0 mm maxi-
mum
verticaI runout: 2.0 mm maximum
Rear IateraI runout: 2.0 mm maxi-
mum
verticaI runout: 2.0 mm maximum
Inspect the area
around the axIe nut
and the axIe hoIder
3-5
MAINTENANCE
ITEM REMARKS
W
h
e
e
I
s
a
n
d

t
i
r
e
s
W
h
e
e
I
s
the rear wheeI bearing
Damage
the connections and
damage of the suspen-
sion arms
Leakage and damage
instaIIation points
Free pIay of the cIutch
Iever
Appropriate cIutch
operation
Leakage and fIuid IeveI
the transmission
mechanism
the connections
the spIine
the universaI joints
Looseness of the chain
InstaIIation condition
and wear of the
sprockets
B
e
f
o
r
e

s
t
a
r
t
i
n
g
A
f
t
e
r

f
i
r
s
t

o
n
e
m
o
n
t
h

o
r

1
0
0
0
k
m

o
f

d
r
i
v
i
n
g
E
v
e
r
y

6
m
o
n
t
h
s
E
v
e
r
y

1
2
m
o
n
t
h
s
PersonaI use
SPECIFICATION
Inspect the area
around the cushion
spring
X
X
X
D
r
i
v
e

t
r
a
i
n
S
h
o
c
k

a
b
s
o
r
b
i
n
g

s
y
s
t
e
m
C
h
a
s
s
i
s
s
p
r
i
n
g
s
S
u
s
p
e
n
-
s
i
o
n

a
r
m
s
S
h
o
c
k
a
b
s
o
r
b
e
r
s
C
I
u
t
c
h
Free pIay of the cIutch Iever:
10 20 mm at the Iever end
Transmission fIuid IeveI must be
between the upper and Iower Iimits
marked on the dip stick
Maximum sIack in the chain is 30
40 mm when the side stand is used
and measured at the center of the
front and rear sprockets.
T
r
a
n
s
m
i
s
s
i
o
n
P
r
o
p
e
I
I
e
r

s
h
a
f
t
a
n
d

d
r
i
v
e

s
h
a
f
t
C
h
a
i
n

a
n
d
s
p
r
o
c
k
e
t
s
3-6
MAINTENANCE
ITEM REMARKS
E
I
e
c
t
r
i
c
a
I

s
y
s
t
e
m
I
g
n
i
t
i
o
n

s
y
s
t
e
m
Condition of the spark
pIug
Ignition timing
Condition of the timing
cam
Function of the spark
advancing (and retard-
ing) device
Battery fIuid IeveI
Specific gravity of the
batterys eIectroIyte
Connection of the
battery terminaIs
the eIectricaI connec-
tions
Smoothness of starting
and noise
Low speed operation
and acceIeration
Condition of exhaust gas
Condition of the air
cIeaner eIement
B
e
f
o
r
e

s
t
a
r
t
i
n
g
A
f
t
e
r

f
i
r
s
t

o
n
e
m
o
n
t
h

o
r

1
0
0
0
k
m

o
f

d
r
i
v
i
n
g
E
v
e
r
y

6
m
o
n
t
h
s
E
v
e
r
y

1
2
m
o
n
t
h
s
PersonaI use
SPECIFICATION
Spark pIug gap: 0.8 0.9 mm
CaIibration-free
system. No inspec-
tion required.
No-contact system.
No inspection
required.
EIectronic spark
advancing system.
No inspection
required.
A fuIIy encIosed
maintenance-free
battery. No inspec-
tion required.
A fuIIy encIosed
maintenance-free
battery. No inspec-
tion required.
A viscous air cIeaner.
No inspection
required.
B
a
t
t
e
r
y
E
I
e
c
t
r
i
c
a
I
w
i
r
i
n
g
E
n
g
i
n
e
E
n
g
i
n
e
Engine idIe speed: 1,300 100 rpm
3-7
MAINTENANCE
ITEM REMARKS
E
n
g
i
n
e
E
n
g
i
n
e
VaIve cIearance
Engine oiI IeveI and
contamination
Engine oiI Ieakage
Engine oiI IeveI
CIogging of the oiI
cIeaner
FueI Ieak
Condition of the
carburetor Iinkage
Condition of the throttIe
vaIve and the choke
vaIve
CIogging of the fueI fiIter
FueI IeveI
CooIant IeveI
CooIant Ieaks
Function of the radiator
cap
Operation
IIIuminating condition,
dirt, and damage
Operation
B
e
f
o
r
e

s
t
a
r
t
i
n
g
A
f
t
e
r

f
i
r
s
t

o
n
e
m
o
n
t
h

o
r

1
0
0
0
k
m

o
f

d
r
i
v
i
n
g
E
v
e
r
y

6
m
o
n
t
h
s
E
v
e
r
y

1
2
m
o
n
t
h
s
PersonaI use
SPECIFICATION
VaIve cIearance when coId
Intake : 0.08 0.12 mm
Exhaust: 0.10 0.14 mm
Engine oiI IeveI must be between the
upper and Iower Iimits marked on the
dip stick
L
u
b
r
i
c
a
t
i
o
n

s
y
s
t
e
m
A cartridge type
cIeaner. No inspec-
tion required.
X
X
X
F
u
e
I

s
y
s
t
e
m
C
o
o
I
i
n
g
s
y
s
t
e
m
L
i
g
h
t
s

a
n
d
t
u
r
n

s
i
g
n
a
I
s
H
o
r
n

a
n
d
I
o
c
k
3-8
MAINTENANCE
ITEM REMARKS
Appropriate rear view
imaging
Dirt and damage
Operation
Looseness and damage
of instaIIation points
Function of the muffIer
Check if the same
probIem exists
Lubrication and greasing
on the chassis compo-
nents
B
e
f
o
r
e

s
t
a
r
t
i
n
g
A
f
t
e
r

f
i
r
s
t

o
n
e
m
o
n
t
h

o
r

1
0
0
0
k
m

o
f

d
r
i
v
i
n
g
E
v
e
r
y

6
m
o
n
t
h
s
E
v
e
r
y

1
2
m
o
n
t
h
s
PersonaI use
SPECIFICATION
Rear view mirrors
onIy
R
e
a
r

v
i
e
w

m
i
r
r
o
r
s
a
n
d

r
e
f
I
e
c
t
i
n
g
m
i
r
r
o
r
s
R
e
f
I
e
c
t
o
r
s
,

a
n
d

v
e
h
i
c
I
e
r
e
g
i
s
t
r
a
t
i
o
n

n
u
m
b
e
r
p
I
a
t
e

o
r

v
e
h
i
c
I
e

I
D
n
u
m
b
e
r

p
I
a
t
e
I
n
s
t
r
u
m
e
n
t
s
E
x
h
a
u
s
t

p
i
p
e

a
n
d
m
u
f
f
I
e
r
V
e
h
i
c
I
e

f
r
a
m
e

a
n
d
v
e
h
i
c
I
e

b
o
d
y
P
r
o
b
I
e
m

o
b
s
e
r
v
e
d
o
n

t
h
e

p
r
e
v
i
o
u
s

d
a
y
O
t
h
e
r
s
3-9
MAINTENANCE
FUEL TUBE
Check the fueI tube for damage or Ieakage. RepIace the tube
if any defect is observed.
FUEL TUBE
O-RING FUEL COCK
FUEL COCK
Turn the fueI cock OFF.
Remove the strainer cup.
CIean the strainer cup using cIeaning soIvent.
InstaII a new O-Iing on the strainer cup. Tighten the strainer
cup to the specified torque.
TOROUE: 2.7 kgm
After reinstaIIing the strainer cup, turn the fueI cock ON and
ensure no Ieak is observed.
THROTTLE OPERATION
Make sure that the appropriate free pIay is maintained at the
throttIe grip fIange.
FREE PLAY: 2 6 mm
Ensure that no deterioration, damage, or kinking is observed
in the throttIe cabIes. Check that the throttIe grip operates
smoothIy at aII steering angIes.
STRAINER CUP
FUEL TUBE
FUEL COCK
FREE PLAY
3-10
MAINTENANCE
Minor adjustments are made with the adjuster on the throttIe
hoIder.
Adjust the free pIay by Ioosening the Iock nut and turning the
adjuster.
Major adjustments are made with the adjuster on the carbu-
retor.
Adjust the free pIay by Ioosening the Iock nut on the puII side
of the throttIe cabIes and turning the adjuster.
RepIace the throttIe cabIes if the specified free pIay or smooth
operation cannot be obtained by the adjustments described
above.
CHOKE OPERATION
Check that the choke knob operates smoothIy.
AIR CLEANER
Remove the studs and open the air cIeaner case cover.
ADJUSTER LOCK NUT
LOCK NUT ADJUSTER
CHOKE KNOB
STUDS
COVER
3-11
MAINTENANCE
Remove the air cIeaner eIement hoIder.
Remove and repIace the air cIeaner eIement.
Air cIeaner change intervaI: Every 20,000 km
NOTE:
This air cIeaner eIement is a viscous air cIeaner in which
fiIter paper is saturated with oiI, and cannot be cIeaned.
Those who drive their motorcycIes in extreme conditions
need to repIace it more frequentIy.
SPARK PLUG
Disconnect the spark pIug cap.
Remove the spark pIug and inspect the spark pIug for any
damage, dirt, or deposit.
If any dirt or deposit is observed, cIean the spark pIug using a
spark pIug cIeaner or wire brush.
Recommended spark pIugs:
NGK: CR8 EH-9 (Standard)
CR7 EH-9 (OptionaI for Iow speed driving)
CR9 EH-9 (OptionaI for high speed driving)
NIPPON DENSO: U24FER9 (Standard)
U22FER9 (OptionaI for Iow speed driving)
U27FER9 (OptionaI for high speed driving)
Adjust the spark pIug gap.
SPARK PLUG GAP: 0.8 0.9 mm
InstaII and tighten the spark pIug to the specified torque.
TOROUE: 1.2 kgm
VALVE CLEARANCE
INSPECTION
NOTE:
Inspect and adjust vaIve cIearance whiIe the engine is coId
(35 C or beIow).
Remove the crankshaft hoIe cap and the timing hoIe cap.
ELEMENT HOLDER
ELEMENT
Check gap, dirt and deposit
Check crack
Check washer damage
TIMING HOLE CAP
CRANKSHAFT HOLE CAP
3-12
MAINTENANCE
Rotate the crankshaft countercIockwise to aIign the T mark
on the fIywheeI with the index notch on the Ieft crankcase
cover. Make sure the piston is at the top dead center.
NOTE:
Make sure to rotate the crankshaft countercIockwise since the
decompressor cam is instaIIed on the camshaft. When the
crankshaft is rotated cIockwise, the decompressor cam pre-
vents the vaIve from obtaining the correct cIearance.
Remove the vaIve hoIe caps.
Insert a thickness gauge between the adjuster screw and the
sub-rocker arm and measure the vaIve cIearance.
VALVE CLEARANCE:
IN : 0.10 0.02 mm
EX : 0.12 0.02 mm
ADJUSTMENT
Adjust by Ioosening the vaIve adjuster Iock nut and turning
the adjuster screw.
Wrench B 07708-0030400
HoId the adjuster screw and tighten the Iock nut.
TOROUE:
IN : 2.4 kgm
EX : 2.6 kgm
Inspect the vaIve cIearance again after tightening the Iock nut.
INDEX NOTCH
T MARK
VALVE HOLE CAPS
THICKNESS GAUGE
WRENCH B
3-13
MAINTENANCE
AppIy engine oiI to a new O-ring for the vaIve hoIe cap and
instaII the ring on the cap.
InstaII the vaIve hoIe cap and tighten to the specified torque.
TOROUE: 1.5 kgm
AppIy engine oiI to a new O-ring for the crankshaft hoIe cap
and instaII it on the cap.
AppIy grease to the threads and seating surface.
InstaII the crankshaft hoIe cap and tighten to the specified
torque.
TOROUE: 0.8 kgm
AppIy engine oiI to a new O-ring for the timing hoIe cap and
instaII it on the cap.
AppIy grease to the threads and seating surface.
InstaII the timing hoIe cap and tighten to the specified torque.
TOROUE: 1.0 kgm
ENGINE OIL
INSPECTION
Support the motorcycIe in an upright position at IeveI ground.
Remove the oiI fiIIer cap]dipstick.
Check the oiI IeveI with the oiI fiIIer cap]dipstick by inserting it
into the oiI fiIIer opening without screwing the cap in.
If the oiI IeveI cannot be detected by the dipstick, check the oiI
IeveI with the crankcase oiI check boIt (page 3-14).
If engine oiI is on the dipstick, proceed to the foIIowing in-
spection.
Start the engine and Iet it idIe for 5 minutes to warm up.
Stop the engine and check the oiI IeveI immediateIy.
If the oiI IeveI is beIow the LOWER mark on the dipstick, fiII
to the UPPER mark with the recommended engine oiI.
Change the engine oiI if contaminated excessiveIy.
O-RING
VALVE HOLE CAP
O-RINGS
CRANKSHAFT HOLE CAP
TIMING HOLE
CAP
OIL FILLER CAP]DIPSTICK
OIL FILLER OPENING
UPPER MARK
LOWER MARK
3-14
MAINTENANCE
CHECKING OIL LEVEL IN ENGINE
Remove the crankcase oiI check boIt and the seaIing washer.
If engine oiI fIows out through the crankcase oiI check boIt
hoIe, start the engine and check the engine oiI IeveI (page 3-
13).
If no oiI fIows out through the hoIe, fiII with the recommended
engine oiI to the UPPER mark and recheck the oiI IeveI (page
3-13).
OIL CHANGE
Warm up and stop the engine.
Remove the down tube oiI drain boIt and seaIing washer to
drain the engine oiI.
NOTE:
When draining the oiI (on frame side), avoid spiIIing oiI on
the front tire.
Remove the crankcase oiI drain boIt and seaIing washer to
drain the engine oiI.
Check the seaIing washers for damage. RepIace with a new
one if damaged.
InstaII the down tube oiI drain boIt]seaIing washer and crank-
case oiI drain boIt]seaIing washer. Tighten to the specified
torque.
TOROUE:
Crankcase oiI drain boIt : 2.5 kgm
Down tube oiI drain boIt : 4.0 kgm
Remove and cIean the oiI strainer nut before adding oiI (page
4-2).
SEALING WASHER
CHECK BOLT
OIL FILLER CAP]DIPSTICK
DRAIN BOLT]SEALING WASHER
DRAIN BOLT]SEALING WASHER
3-15
MAINTENANCE
FiII with the recommended engine oiI through the oiI fiIIer
opening.
RECOMMENDED ENGINE OIL:
Honda UItra U Engine OiI for 4-Stroke MotorcycIe
(SAE10W-30), or
API Service CIassification SF or SG grade engine oiI
OIL CAPACITY: 1.3 Iitter (at oiI change)
1.4 Iitter (at oiI fiIter change)
Start the engine and check that there are no oiI Ieaks from
any engine component.
Stop the engine and check the oiI IeveI.
TEMPERATURE and OIL VISCOSITIES
ENGINE OIL FILTER
Remove the oiI fiIter cover boIts.
Remove the oiI fiIter cover, oiI fiIter, spring and O-ring.
Remove the O-ring from the oiI fiIter cover.
AppIy engine oiI to a new O-ring and instaII it to the oiI fiIter
cover.
InstaII the spring, a new oiI fiIter, and the oiI fiIter cover.
Tighten the oiI fiIter cover boIt.
TOROUE: 1.2 kgm
NOTE:
PIace the oiI fiIter with its rubber seaI facing toward the oiI
fiIter cover.
FiII with the engine oiI.
Start the engine and check that oiI IeveI is sufficient with no
oiI Ieaks.
IDLE SPEED ADJUSTMENT
NOTE:
Warm up the engine before proceeding to idIe speed ad-
justment.
Adjust the piIot screw before proceeding to idIe speed ad-
justment when the carburetor is overhauIed.
Warm up the engine and shift the transmission into neutraI.
TEMPERATURE
BOLTS
FILTER COVER
SPRING OIL FILTER
RUBBER SEAL
O-RING
3-16
MAINTENANCE
Turn the throttIe stop screw to obtain the specified idIe speed.
IDLE SPEED: 1,300 100 rpm
THROTTLE STOP SCREW
CYLINDER COMPRESSION
Remove the spark pIug.
Connect the compression gauge to the cyIinder head.
Compression gauge attachment 07RMJMY50100
FuIIy open the throttIe vaIve.
Turn on the starter motor to see the cyIinder compression.
NOTE:
Inspect the cyIinder compression whiIe the engine is coId.
Attach the compression gauge attachment and compres-
sion gauge secureI y to prevent any compression Ieakage.
Do not continuousIy run the starter motor for more than 7
seconds to Iimit the battery discharge.
CYLINDER COMPRESSION: 6.8 kg]cm
2
at 400 rpm
If compression is Iow, check the foIIowing:
Compression Ieakage from any of the vaIves
Improper vaIve cIearance adjustment
Poor cyIinder gasket performance
Worn piston ring
Worn cyIinder or piston
If compression is high, check carbon deposits on the piston
head or the cyIinder head.
COMPRESSION GAUGE ATTACHMENT
3-17
MAINTENANCE
AXLE NUT
DRIVE CHAIN
CHAIN SLACK INSPECTION
Use the side stand to hoId the motorcycIe.
Measure the sIack in the Iower drive chain run midway be-
tween the sprockets.
CHAIN SLACK: 30 40 mm
CHAIN SLACK ADJUSTMENT
NOTE:
Drive chain adjustment must be conducted whiIe raising the
rear wheeI off the ground by Iifting the engine.
Loosen the rear axIe nut and turn the Ieft and right adjuster
pIates to adjust the sIack.
NOTE:
Be sure the same adjuster pIate index marks aIign with the
stopper pins on both sides.
RepIace the drive chain if the red marking on the adjuster
pIates reaches the stopper pin.
Tighten the rear axIe nut to the specified torque.
TOROUE: 9.5 kgm
DRIVE CHAIN CLEANING]LUBRICATION
CIean the drive chain with detergent and dry the chain com-
pIeteIy. AppIy SAE #80#90 gear oiI to the drive chain and
wipe off any excess oiI.
NOTE:
Because this drive chain contains O-rings, avoid the cIeaning
and Iubricating methods described beIow. FaiIure to note this
precaution may resuIt in deterioration of O-rings contained
within the chain, Ieakage of the appIied grease, and a shorter
chain Iife.
Use of a steam cIeaner or high pressure washer
Use of a spray can type chain cIeaner containing soIvent
or appIying gasoIine to the chain
ADJUSTER PLATE
ADJUSTER PLATE
RED MARKING
DETERGENT
WASH
DRY
LUBRICATE
GEAR OIL
(SAE #80 OR #90)
3-18
MAINTENANCE
CHAIN REPLACEMENT
CAUTION:
Loosen the drive chain.

AssembIe the speciaI tooI.
Drive chain cauIking tooI 07HMH-MR10103
Link pIate hoIder 07HMH-MR10130
CAUTION:
Attach the drive chain cauIking tooI to the drive chain and
sever the chain by removing the cauIked master Iink joint pin.
Drive chain cauIking tooI 07HMH-MR10103
Remove excess Iinks using the drive chain cauIking tooI to
create a drive chain with the specified number of Iinks.
NOTE:
IncIude the master Iink as a Iink when counting the number of
Iinks.
REPLACEMENT CHAIN: RK: 520MOZ9]102LE
DID: 520VC5]102LE
LINK PLATE HOLDER
DRIVE CHAIN CAULKING TOOL
MASTER LINK
DRIVE CHAIN
CAULKING TOOL
ONE LINK
MASTER LINK
102 LINKS
3-19
MAINTENANCE
InstaII the repIacement drive chain composed of the speci-
fied number of Iinks.
InstaII O-rings with each joint pin of a new master Iink. Insert
the master Iink from the inner side (the side proximaI to the
motorcycIe body) of the drive chain into the Iink hoIes.
InstaII O-rings and Iink pIate with the inserted master Iink.
Check the protruding Iength of the master Iink joint pin (see
iIIustration).
PROTRUDING PIN LENGTH: RK: 1.2 1.4 mm
DID: 1.15 1.55 mm
CAUTION:
CauIk each of the joint pins of the master Iink with the drive
chain cauIking tooI.
Measure the size of cauIked pins with a sIide caIiper.
CAULKED PIN SIZE: RK: 5.5 5.8 mm
DID: 5.4 5.6 mm
CAUTION:
Check that none of the cauIked pins have any cracks.
If any of the cauIked pins has a crack, repIace the master Iink,
the Iink pIate and the O-rings with new repIacement parts and
cauIk them accordingIy.
CAUTION:
O-RINGS
LINK PLATE
MASTER LINK
MASTER LINK
SLIDE CALIPER
CRACKS
3-20
MAINTENANCE
SPROCKET INSPECTION
Check the teeth of the drive and driven sprockets for wear
and damage. RepIace both sprockets if necessary.
NOTE:
When repIacement is required, both drive and driven sprock-
ets must be repIaced.
BRAKE FLUID
Check that the brake fIuid reservoir IeveIs for the front and
rear brakes are above the LOWER LEVEL .
NOTE:
Check the brake fIuid IeveIs with the reservoirs heId horizon-
taI.
DRIVE CHAIN SLIDER
Check the drive chain sIider for wear and damage. RepIace
the sIider if necessary.
NOTE:
If the drive chain contacts the swingarm due to a defective
drive chain sIider, both the drive chain and swingarm may be
damaged or worn. RepIace the defective drive chain sIider as
soon as possibIe.
GOOD REOUIRES REPLACEMENT
CHAIN SLIDER
<FRONT> LOWER LEVEL
<REAR>
LOWER LEVEL
3-21
MAINTENANCE
BRAKE PAD WEAR
VisuaIIy inspect the brake pads for wear.
RepIace the pair of pads if either pad is worn out to its service
Iimit.
NOTE:
When repIacement is required, both pads in a pair must be
repIaced.
BRAKE SYSTEM
Inspect the components of the brake hydrauIic system for
Ieaks. RepIace any defective component.
BRAKE PEDAL HEIGHT
Inspect the brake pedaI height.
Adjust the brake pedaI by Ioosening the Iock nut and turning
the push rod.
BRAKE PEDAL HEIGHT: 20 mm
NOTE:
After adjusting the brake pedaI height, check that the brake
Iight operates properIy. Adjust the brake Iight if necessary.
BRAKE LIGHT SWITCH
NOTE:
Brake Iight adjustment must be carried out after adjusting the
brake pedaI height.
Adjust the brake Iight switch so that the brake Iight comes on
as soon as the brake is appIied.
HoId the switch body and turn the brake Iight adjuster to ad-
just the switch actuating point.
After adjustment, check if the switch actuating point is cor-
rectIy set by stepping on the brake pedaI.
NOTE:
The front brake Iight switch has no adjustment mechanism.
<FRONT>
WEAR INDICATOR
<REAR>
WEAR INDICATOR
LOCK NUT
PUSH ROD
ADJUSTER
SWITCH
3-22
MAINTENANCE
HEADLIGHT BEAM ADJUSTMENT
XR250:
Use the headIight adjuster screw to adjust the headIight beam.
CLUTCH
Check the cIutch Iever free pIay at the Iever end.
FREE PLAY: 10 20 mm
XR BAJA:
Loosen the verticaI adjuster boIt to adjust the verticaI beam.
SecureIy tighten the verticaI adjuster boIt after adjustment.
Loosen the horizontaI adjuster boIt to adjust the horizontaI
beam.
SecureIy tighten the horizontaI adjuster boIt after adjustment.
ADJUSTER SCREW
VERTICAL ADJUSTER BOLT
HORIZONTAL ADJUSTER BOLT
VERTICAL ADJUSTER BOLT
HORIZONTAL ADJUSTER BOLT
3-23
MAINTENANCE
For major adjustment, Ioosen the Iock nut Iocated proximaI
to the cIutch arm and turn the adjuster nut.
SUSPENSION
AppIy the front brake and compress the front forks severaI
times to check the action of the front forks.
Check the front forks for any oiI Ieaks, damage, or Iooseness.
For minor adjustment, open the cIutch Iever cover, Ioosen the
Iock nut and turn the adjuster.
SIDE STAND
Raise the rear wheeI off the ground by Iifting the engine.
Check whether a 2.0 3.0 kg Ioad appIied to the end of the
side stand makes the side stand smoothIy retract into its
stowed position.
If not, appIy grease to the side stand pivot and repeat the
inspection procedure above.
If the side stand retracts too easiIy at a Iower Ioad, check if
the side stand return spring has sagged.
LOCK NUT
ADJUSTER NUT
LOCK NUT
ADJUSTER
SIDE STAND
3-24
MAINTENANCE
Bounce the rear of the motorcycIe severaI times to check the
action of the rear cushion.
Check the rear cushion for any oiI Ieaks, damage, or Ioose-
ness.
SPOKE INSPECTION
Check the spokes for distortion and Iooseness.
Tighten the spoke nippIes if any Iooseness is detected.
NippIe wrench 07701 0020300
TOROUE: 0.25 0.5 kgm
Raise the rear wheeI off the ground by Iifting the engine.
Move the swingarm sideways to check if the swingarm pivot
bearings are worn.
If any wear is detected, check and repIace the bearings if nec-
essary (page 12-6).
WHEEL
TIRE PRESSURE
Check the tire pressure.
NOTE:
Check the tire pressure whiIe the tires are coId.
Tire Pressure (Unit: kg]cm
2
)
One passenger
Two Passengers
Front
1.50
1.50
1.50
3.0021 51P
Rear
1.50
1.50
1.50
4.6018 63P
Street
Highway
Street
Tire size
3-25
MAINTENANCE
TIRE AND RIM DAMAGE
Check the tires for cut and wear.
Check the wheeI bearings for Iooseness. RepIace the bear-
ings with new ones if necessary.
Check the front and rear wheeI rims for corrosion and the
wheeI for sIack (pages 11-9, 12-4).
STEERING HEAD BEARING
Raise the front wheeI off the ground by Iifting the engine.
Move the front fork in aII directions and ensure that the front
fork moves smoothIy with no sIack during verticaI or horizon-
taI movements.
If any verticaI sIack is detected, check the steering head bear-
ing. RepIace the bearings if any defect is observed (page 11-
28).
Ensure that the wires and cabIes do not interfere with the
movement of the front fork.
4-1
4. LUBRICATION
SERVICE INFORMATION
Maintenance work covered in this section can be conducted without dismounting the engine.
Once any of the oiI pump components reach their service Iimit, the entire oiI pump assembIy must be repIaced.
Prevent contamination of the engine by any foreign objects during oiI pump removaI and instaIIation.
Do not bend the oiI pipe.
After instaIIing the oiI pump, ensure no Ieak is observed.
TROUBLESHOOTING 4-1
OIL STRAINER SCREEN CLEANING 4-2
4
OIL STRAINER NUT CLEANING 4-2
OIL PUMP 4-3
OIL PASS PIPE 4-8
OIL PIPES 4-9
at draining
at disassembIy
1.7 Iitter
1.4 Iitter
Stroke MotorcycIe (SAE10W-30)
API Service CIassification SF or SG
grade engine oiI
0.15
0.15 0.22
0.02 - 0.09
Tip cIearance
Body cIearance
Side cIearance
OiI pump rotor
0.20
0.25
0.12
Torque VaIues
OiI pass pipe joint boIt (7 mm) 1.2 kgm
(8 mm) 1.2 kgm
OiI fiIter cover boIt 1.2 kgm
OiI pipe boIt (12mm) 3.8 kgm
OiI strainer nut 5.5 kgm
TROUBLESHOOTING
Engine oiI IeveI too Iow
NormaI oiI consumption
OiI Ieaks
Worn or improperIy instaIIed piston rings
Worn vaIve guides or seaIs
Worn cyIinder
Engine oiI contamination
OiI and]or fiIter not changed often enough
Worn piston rings
SPECIFICATIONS
4-2
LUBRICATION
OIL STRAINER SCREEN CLEANING
Drain the engine oiI (page 3-14).
Remove the right crankcase cover (page 9-3).
Remove the boIt and the stopper pIate.
Remove the oiI strainer screen and cIean it.
InstaII the oiI strainer screen.
InstaII the right crankcase cover (see page 9-14).
NOTE:
Be carefuI not to Iet the O-ring faII when instaIIing the right
crankcase cover.
OIL STRAINER NUT CLEANING
NOTE:
AIways cIean the strainer nut before adding engine oiI
Remove the inIet oiI pipe (page 4-9).
Remove the oiI strainer nut and cIean it.
Check the O-ring for degradation and damage. RepIace the
ring if degraded or damaged.
InstaII the oiI strainer nut and tighten it to the specified torque.
TOROUE: 5.5 kgm
InstaII the inIet oiI pipe (page 4-11).
BOLT
STOPPER PLATE
STRAINER SCREEN
INLET OIL PIPE
STRAINER NUT
STRAINER NUT
O-RING
4-3
LUBRICATION
OIL PUMP
REMOVAL
Remove the O-ring.
Remove the oiI pump driven gear.
Remove the cIutch (page 9-5).
Remove the oiI pump boIts.
Remove the stopper pIate and the oiI pump.
Remove the gasket and doweI pins.
DISASSEMBLY
Remove the boIts.
DRIVEN GEAR
O-RING
BOLT
STOPPER PLATE
OIL PUMP
GASKET
DOWEL PINS
BOLTS
4-4
LUBRICATION
Remove the foIIowing:
Pump cover B
Drive pin
Spacer
Outer rotor B
Inner rotor B
Pump cover A
Outer rotor A
Inner rotor A
Drive pin
DoweI pins
Pump shaft
Cotter pin
CoIIar
Spring
OiI check vaIve
Pump body
INSPECTION
NOTE:
Measure in severaI pIaces and use the Iargest reading.
If any of the measured vaIues have reached the specified ser-
vice Iimit, repIace the oiI pump as an assembIy.
BODY CLEARANCE
InstaII the inner rotor A and outer rotor A into the pump cover A.
InstaII the pump shaft correctIy.
Measure the body cIearance by inserting a thickness gauge
between the pump cover A and outer rotor A.
SERVICE LIMIT: RepIace if the cIearance is 0.25 mm or
greater
SPACER COVER B
DRIVE PIN
INNER ROTOR B OUTER ROTOR B
COVER A INNER ROTOR A PUMP SHAFT
OUTER ROTOR A
DRIVE PIN DOWEL PIN
COTTER PIN COLLAR]SPRING]
CHECK VALVE
PUMP BODY
4-5
LUBRICATION
InstaII the inner rotor B and outer rotor B into pump cover B.
Measure the body cIearance by inserting a thickness gauge
between the pump cover B and outer rotor B.
greater
TIP CLEARANCE
InstaII the inner rotor A and outer rotor A into pump cover A.
Measure the tip cIearance by inserting a thickness gauge be-
tween the inner rotor A and outer rotor A.
greater
Measure the tip cIearance by inserting a thickness gauge be-
tween the inner rotor B and outer rotor B.
greater
SIDE CLEARANCE
InstaII the inner rotor A and outer rotor A into pump cover A.
PIace a straight edge ruIer on the components assembIed
above and measure the side cIearance by inserting a thick-
ness gauge between the straight edge ruIer and the inner ro-
tor A, outer rotor A, and pump cover A.
greater
4-6
LUBRICATION
PIace a straight edge ruIer on the components assembIed
above and measure the side cIearance by inserting a thick-
ness gauge between the straight edge ruIer and the inner ro-
tor B, outer rotor B, and pump cover B.
greater
ASSEMBLY
InstaII the foIIowing to the pump body.
OiI check vaIve
Spring
CoIIar
New cotter pin
PUMP COVER B
OUTER ROTOR B
PUMP BODY
DOWEL PIN
PUMP SHAFT
OUTER ROTOR A
INNER ROTOR B
SPACER
DRIVE PINS
INNER ROTOR A
PUMP COVER A
COTTER PIN SPRING]COLLAR]
CHECK VALVE
4-7
LUBRICATION
InstaII the foIIowing:
Pump shaft
NOTE:
InstaII the pump shaft with the cutout side toward the pump
cover A.
DoweI pins
Drive pin
Inner rotor A
Outer rotor A
Pump cover A
Inner rotor B
Outer rotor B
Spacer
Drive pin
Pump cover B
SecureIy tighten the boIts.
INSTALLATION
InstaII the gasket and doweI pins.
COVER A INNER ROTOR A PUMP SHAFT
OUTER ROTOR A DRIVE PIN
DOWEL PIN
SPACER OUTER ROTOR B COVER B
DRIVE PIN INNER ROTOR B
BOLTS
GASKET
DOWEL PIN
4-8
LUBRICATION
InstaII the stopper pIate and oiI pump.
InstaII and secureIy tighten the oiI pump boIts.
InstaII the cIutch (page 9-11).
AppIy engine oiI to a new O-ring and instaII it.
InstaII the oiI pump driven gear.
NOTE:
AIign the cutout of the oiI pump driven gear shaft hoIe with
the cutout of the pump shaft.
InstaII the right crankcase cover (9-14).
NOTE:
Be carefuI not to Iet the O-ring off when instaIIing the right
crankcase cover.
OIL PASS PIPE
REMOVAL
Remove the exhaust pipe (page 2-7).
Remove the starter motor (page 16-7).
Remove the oiI pass pipe joint boIts and seaIing washers.
Remove the oiI pass pipe.
NOTE:
Be carefuI not to bend the oiI pass pipe.
INSPECTION
Check the oiI pass pipe and pipe boIts for damage or bend
and repIace if necessary.
If cIogged, cIean with cIeaning soIvent.
NOTE:
Never use any highIy fIammabIe cIeaning agent such as gaso-
Iine or Iow fIash point soIvents for cIeaning the oiI pass pipe.
BOLTS
STOPPER PLATE OIL PUMP
ALIGN
DRIVEN GEAR O-RING
BOLTS]SEALING WASHERS
OIL PASS PIPE
4-9
LUBRICATION
INSTALLATION
InstaII the oiI pass pipe.
InstaII new seaIing washers and the oiI pass pipe joint boIIs.
Tighten the boIts to the specified torque.
TOROUE: (7 mm) 1.2 kgm
(8 mm) 1.2 kgm
InstaII the starter motor (page 16-13).
InstaII the exhaust pipe (page 2-8).
OIL PIPES
REMOVAL
OutIet pipe
Remove the oiI outIet pipe boIts and the oiI outIet pipe.
NOTE:
Be carefuIIy not to bend the oiI outIet pipe.
Remove the doweI pins and the O-rings.
InIet pipe
Remove the under guard (page 2-7).
Remove the oiI inIet pipe boIt.
BOLTS] SEALING WASHERS
OIL PASS PIPE
BOLTS
OIL PIPE
O-RING
DOWEL PINS
BOLTS
4-10
LUBRICATION
Remove the oiI inIet pipe boIt (12 mm) and seaIing washers.
Remove the oiI inIet pipe.
NOTE:
Be carefuI not to bend the oiI inIet pipe.
Remove the doweI pin and O-ring.
INSPECTION
Check the oiI pipe for damage or bends and repIace if neces-
sary.
If cIogged, cIean with cIeaning soIvent.
NOTE:
Never use any highIy fIammabIe cIeaning agent such as gaso-
Iine or Iow fIash point soIvents for cIeaning the oiI pipe.
INSTALLATION
OutIet pipe
InstaII the doweI pins and new O-rings.
OIL PIPE SEALING WASHERS
BOLT
O-RING
DOWEL PIN
O-RINGS
DOWEL PINS
4-11
LUBRICATION
InstaII the oiI outIet pipe and oiI pipe boIts.
SecureIy tighten the boIts.
NOTE:
Be carefuI not to bend the oiI outIet pipe.
InIet pipe
InstaII the doweI pin and a new O-ring.
InstaII the oiI inIet pipe.
InstaII new seaIing washers and tighten the oiI pipe boIts (12
mm) to the specified torque.
TOROUE: 3.8 kgm
NOTE:
Be carefuI not to bend the oiI pipe.
SecureIy tighten the oiI pipe boIt.
InstaII the under guard (page 2-7).
BOLTS
OIL PIPES
O-RING
DOWEL PIN
SEALING WASHERS
BOLT
BOLT
5-1
5. FUEL SYSTEM
SERVICE INFORMATION
CAUTION:
Maintenance work covered in this section can be conducted without dismounting the engine.
After any procedures that require turning the fueI cock OFF, turn the fueI cock back ON and ensure that no Ieak is
observed.
Do not forcibIy bend or twist the cabIes. Deformed or damaged cabIes may cause maIfunctions.
Note the Iocations of the O-rings when disassembIing the fueI system. RepIace them with new ones when reassembIing
the system.
Before disassembIing the carburetor, Ioosen the drain screw on the fIoat chamber to drain gasoIine from the carburetor
into a gasoIine container.
After removing the carburetor, wrap the intake port of the engine with a shop toweI or a piece of tape to prevent any
foreign materiaI from entering the engine.
SPECIFICATIONS
TROUBLESHOOTING 5-2
CRANKCASE BREATHER 5-3
CARBURETOR 5-4
5
PILOT SCREW ADJUSTMENT 5-18
AIR CLEANER CASE 5-19
FUEL TANK 5-22
Unit: mm
Torque VaIues
FueI strainer cup 2.7 kgm
FueI cock Iock nut 2.7 kgm
Sub-frame upper boIt 3.3 kgm
Sub-frame Iower side boIt 4.3 kgm
Type
Setting mark
Venturi diameter
PiIot screw opening
FIoat IeveI
IdIe speed
Main jet
SIow jet
Carburetor VE 88A
VE 88A A
2 1]8 turns out
18.5 mm
1,300 100 rpm
#138
#45
2 6 mm

5-2
FUEL SYSTEM
SpeciaI TooI
FIoat IeveI gauge 07401 001000
PiIot screw wrench 07908 4720201
TROUBLESHOOTING
Engine does not start
The fueI cock is turned OFF
No fueI in the fueI tank
No fueI getting to the carburetor
CIogged fueI strainer
CIogged fueI tube
FauIty fIoat vaIve
FauIty fIoat IeveI
Poor airfIow through the fueI tank cap vent
Engine fIooded with fueI
CIogged air cIeaner
Carburetor overfIow
FauIty air suppIy through the air intake Iine
Deteriorated fueI
CIogged sIow jet Iine
Improper choke use
No spark generated by the spark pIug (refer to IGNI-
TION SYSTEM)
ExcessiveIy Iean air-fueI mixture
CIogged fueI jets
FauIty fIoat vaIve
FIoat IeveI too Iow
CIogged fueI system
CIogged carburetor air vent tube
ExcessiveIy rich air-fueI mixture
Choke vaIve stuck open
FauIty fIoat vaIve
FIoat IeveI too high
CIogged air cIeaner
Carburetor overfIow
The engine bareIy starts, staIIs or idIes roughIy
Poor vaIve cIearance adjustment
CIogged fueI suppIy Iine
The cyIinder head cover boIt (8 mm) is excessiveIy
tight
Ignition maIfunction
ExcessiveIy rich or Iean air-fueI mixture
Deteriorated fueI
Incorrect idIing speed adjustment
Poor piIot screw adjustment
CIogged sIow jet Iine
FauIty fIoat IeveI
Afterburning when engi ne brake is appIied
ExcessiveIy Iean air-fueI mixture in the sIow jet Iine
FauIty air intake through the air cut-off vaIve tube
Misfiring during acceIeration or backfire
FauIty ignition system
Poor performance and poor fueI economy
CIogged air cIeaner
FauIty ignition system
5-3
FUEL SYSTEM
CRANKCASE BREATHER
INSPECTION
Check that the tubes are secureIy connected.
Confirm that the tubes are not damaged, crushed, or cracked.
Determine that the crankcase breather tube is correctIy in-
staIIed.
REMOVAL AND INSTALLATION
REMOVAL
Disconnect the breather chamber air cIeaner case tube.
Disconnect the engine breather tube.
Undo the boIt and remove the engine breather chamber]
breather chamber drain tubes.
INSTALLATION
NOTE:
CorrectIy route the tubes as shown beIow.
BREATHER CHAMBER AIR CLEANER CASE TUBE
ENGINE BREATHER CHAMBER ENGINE BREATHER TUBE
BREATHER CHAMBER DRAIN TUBE
BREATHER CHAMBER AIR CLEANER
CASE TUBE
ENGINE BREATHER TUBE
ENGINE BREATHER CHAMBER
BREATHER CHAMBER DRAIN TUBE
5-4
FUEL SYSTEM
CARBURETOR
REMOVAL
Remove the fueI tank (page 5-22).
Remove the foIIowing components:
Nut
Carburetor sub-air cIeaner tube
Carburetor sub-air cIeaner case
ThrottIe sensor 3P (NATURAL) coupIer
Connecting tube band screw
Loosen the Iock nuts and disconnect the throttIe cabIes from
the throttIe drum.
FUEL TANK
NUT
SUB-AIR CLEANER CASE
TUBE
3P (NATURAL) COUPLER
SCREW
LOCK NUTS
THROTTLE CABLES
5-5
FUEL SYSTEM
Remove the throttIe stop screw from the hoIder.
Undo the boIt and remove the throttIe stop screw hoIder.
Remove the engine breather chamber (page 5-3).
Screw
ThrottIe sensor
ThrottIe sensor joint
Loosen the insuIator band screw.
Undo the insuIator boIt and remove the insuIator.
Remove the insuIator O-ring.
Remove the carburetor assembIy.
HOLDER CHAMBER
THROTTLE STOP SCREW
SENSOR
SCREW JOINT
INSULATOR
BOLT
CARBURETOR ASSEMBLY
5-6
FUEL SYSTEM
CARBURETOR SUB-AIR CLEANER ELEMENT
CLEANING
Remove the carburetor sub-air cIeaner case cover.
Remove the eIement, cIean it with water and dry it compIeteIy.
NOTE:
Do not appIy oiI to the carburetor sub-air cIeaner eIement.
AIways cIean the carburetor sub-air cIeaner eIement when
cIeaning the air cIeaner eIement.
InstaII the eIement.
InstaII the carburetor sub-air cIeaner case cover.
DISASSEMBLY
FueI tube
Carburetor overfIow tube
Air cut-off vaIve tube
Spring
Vacuum piston]diaphragm
COVER
Screws
Tube cIamp
Vacuum chamber
ELEMENT
AIR CUT-OFF VALVE TUBE FUEL TUBE
CARBURETOR OVERFLOW TUBE
TUBE CLAMP VACUUM CHAMBER
SCREWS
SPRING
PISTON]DIAPHRAGM
5-7
FUEL SYSTEM
Remove the jet needIe hoIder by turning countercIockwise.
Remove the spring and jet needIe.
Screw
Tube joint
Tube joint hoIder
O-ring
Choke Iever pivot screw]washer
Choke Iever
Dust cover
Choke vaIve nut
JET NEEDLE SPRING
HOLDER
SCREW TUBE JOINT O-RING
HOLDER
SCREW]WASHER
LEVER
DUST COVER
NUT
5-8
FUEL SYSTEM
Spring
Choke vaIve
Screws
Air cut-off vaIve cover
Spring
Air cut-off vaIve]diaphragm
Screws
FIoat chamber
SPRING
CHOKE VALVE
SCREWS
COVER
SPRING
AIR CUT-OFF VALVE]DIAPHRAGM
SCREW
FLOAT CHAMBER
5-9
FUEL SYSTEM
O-ring
BaffIe pIate
FIoat pin
FIoat
FIoat vaIve
Main jet
NeedIe jet hoIder]needIe jet
SIow jet
PiIot screw]spring]washer]O-ring
NOTE:
Count and record the number of turns required before the
piIot screw IightIy contacts the seat.
O-RING
BAFFLE PLATE
FLOAT FLOAT VALVE
FLOAT PIN
PILOT SCREW]SPRING]WASHER]O-RING
SLOW JET
MAIN JET
NEEDLE JET HOLDER]NEEDLE JET
5-10
FUEL SYSTEM
CARBURETOR PASSAGE CLEANING
Using compressed air, bIow and cIean the carburetor air and
fueI passages.
CAUTION:
INSPECTION
CHOKE VALVE
Check the needIe of the choke vaIve for damage and distor-
tion, and repIace if necessary.
Check the spring for damage and sagging, and repIace if nec-
essary.
PILOT SCREW
Check the needIe of the piIot screw for damage and distor-
tion, and repIace if necessary.
Check the spring for damage and sagging, and repIace if nec-
essary.
Check the O-ring for degradation and damage, and repIace if
necessary.
FLOAT VALVE, VALVE SEAT
Check the fIoat for damage and repIace if necessary.
Check the fIoat vaIve and the vaIve seat for cuts, cIogging,
and damage. CIean or repIace them if necessary.
Check the mating surfaces of the vaIve and the vaIve seat for
wear and repIace if necessary.
SPRING
CHOKE VALVE
O-RING SPRING
WASHER PILOT SCREW
FLOAT VALVE
VALVE SEAT
5-11
FUEL SYSTEM
InstaII the foIIowing components:
Main jet
NeedIe jet hoIder]needIe jet
SIow jet
PiIot screw]spring]washer]O-ring
NOTE:
Tighten the piIot screw untiI it IightIy contacts the seat and
then Ioosen it back the number of turns you have recorded
when removing the screw during the carburetor disassem-
bIy.
CHOKE VALVE
ASSEMBLY
AIR CUT-OFF VALVE
SPRING
VACUUM CHAMBER
SPRING
INSULATOR
AIR CUT-OFF
VALVE COVER
SPRING
CHOKE VALVE LEVER
THROTTLE SENSOR
TUBE JOINT
PILOT SCREW]
SPRING]WASHER]
O-RING
O-RING
NEEDLE JET
NEEDLE JET HOLDER
FLOAT VALVE
FLOAT PIN
FLOAT
MAIN JET
BAFFLE PLATE
FLOAT CHAMBER
JET NEEDLE
HOLDER
SPRING
JET NEEDLE
VACUUM PISTON]
DIAPHRAGM
SLOW JET PILOT SCREW]SPRING]WASHER]
O-RING
NEEDLE JET
MAIN JET
NEEDLE JET HOLDER
PILOT SCREW]SPRING]WASHER]O-RING
SLOW JET
MAIN JET
NEEDLE JET]NEEDLE JET HOLDER
5-12
FUEL SYSTEM
FIoat pin
FIoat
FIoat vaIve
BaffIe pIate
FLOAT LEVEL INSPECTION
Measure the fIoat IeveI with the fIoat vaIve just touching the
fIoat Iip.
FLOAT LEVEL: 18.5 mm
FLOAT LEVEL GAUGE 07401 0010000
NOTE:
Set the fIoat IeveI gauge so that it is perpendicuIar to the fIoat
chamber mounting surface and in Iine with the main jet.
If the fIoat IeveI exceeds the specification, check the fIoat vaIve
and the vaIve seat and repIace them if necessary.
New O-ring
FIoat chamber
NOTE:
PIace the fIoat chamber so that its doweI pin faces toward the
piIot screw.
FLOAT
FLOAT VALVE
FLOAT PIN
BAFFLE PLATE
FLOAT LEVEL GAUGE
O-RING
FLOAT CHAMBER
5-13
FUEL SYSTEM
Screws
Air cut-off vaIve]diaphragm
NOTE:
AIign the center Iug of the air cut-off vaIve with the hoIe on
the carburetor body.
Spring
Air cut-off vaIve cover
Screws
SCREW
SPRING
AIR CUT-OFF VALVE]DIAPHRAGM
ALIGN
COVER
SCREWS
5-14
FUEL SYSTEM
Choke vaIve
Spring
Choke vaIve nut
Dust cover
Choke Iever
NOTE:
AIign the hoIe of the choke Iever with the choke vaIve and
instaII the choke Iever into the Iever sIot.
Choke Iever pivot screw]washer
SPRING
CHOKE VALVE
DUST COVER
NUT
ALIGN LEVER
SCREW]WASHER
5-15
FUEL SYSTEM
New O-ring
Tube joint hoIder
Tube joint
NOTE:
SecureIy instaII the tube joint hoIder into the tube joint sIot.
Screw
NOTE:
Before tightening the screw, make sure that the end sIot of
the tube joint hoIder is aIigned with the Iug of the carburetor
body.
InstaII the jet needIe and spring.
InstaII and rotate the jet needIe hoIder cIockwise untiI it Iocks.
Vacuum piston]diaphragm
Spring
NOTE:
SecureIy instaII the Iip of the diaphragm into the sIot of the
carburetor body.
O-RING TUBE JOINT
HOLDER
SCREW
ALIGN
JET NEEDLE SPRING
HOLDER
SPRING
ALIGN VACUUM PISTON]DIAPHRAGM
5-16
FUEL SYSTEM
Vacuum chamber
Tube cIamp
Screws
NOTE:
InstaII the vacuum chamber with its Iug facing the diaphragm
Iip.
FueI tube
Carburetor overfIow tube
Air cut-off vaIve tube
New insuIator O-ring
InsuIator
InsuIator boIt
Band screw
NOTE:
AIign the sIot of the insuIator with the Iug of the carburetor
when instaIIing the insuIator.
INSTALLATION
InstaII the carburetor assembIy to the connecting tube.
TUBE CLAMP VACUUM CHAMBER
SCREWS
AIR CUT-OFF VALVE TUBE
FUEL TUBE
CARBURETOR ASSEMBLY
INSULATOR
BOLT ALIGN
5-17
FUEL SYSTEM
InstaII the throttIe sensor joint to the throttIe vaIve shaft by
inserting the stem of the throttIe sensor joint into the sIot of
the throttIe vaIve shaft.
InstaII the throttIe sensor.
NOTE:
When instaIIing the throttIe sensor to the throttIe joint, aIign
the sIot of throttIe sensor with the Iug of throttIe joint.
When instaIIing the throttIe sensor to the carburetor body,
aIign the hoIe of throttIe sensor with the Iug of carburetor
body.
SecureIy tighten the screws.
Engine breather chamber (page 5-3)
ThrottIe stop screw hoIder
BoIt
ThrottIe stop screw
Connect the throttIe cabIes to the throttIe drum.
SecureIy tighten the Iock nut.
Connect the throttIe sensor 3P (NATURAL) coupIer.
NOTE:
Route the throttIe sensor wire correctIy as shown in CABLE
AND HARNESS ROUTING ( page 1-19).
SecureIy tighten the connecting tube band screw.
SENSOR
SCREWS
JOINT
HOLDER CHAMBER
THROTTLE STOP SCREW
BOLT
LOCK NUT THROTTLE CABLES
SCREW
5-18
FUEL SYSTEM
Carburetor sub-air cIeaner case
Carburetor sub-air cIeaner tube
Nut
NOTE:
Route the tubes correctIy as shown in CABLE AND HARNESS
ROUTING (page 1-19).
InstaII the fueI tank (page 5-22).
After instaIIing the fueI tank, turn the fueI cock ON and ensure
no Ieak is observed.
PILOT SCREW ADJUSTMENT
IDLING DROP METHOD:
NOTE:
The piIot screw is pre-set at the factory and adjustment is
not required unIess the piIot screw or the carburetor body
is repIaced. Just tighten the piIot screw untiI it IightIy con-
tacts the seat and then Ioosen it back the number of turns
you have recorded when removing the screw during the
carburetor disassembIy.
Secure the motorcycIe in an upright position at IeveI ground
whiIe working on the motorcycIe.
Warm up the engine before proceeding to piIot screw ad-
justment.
1. Connect a tachometer abIe to read 50 rpm or Iess in accor-
dance with the tachometer manufacturers instructions.
2. Tighten the piIot screw untiI it IightIy contacts the seat and
then back it out by the specified number of turns.
PILOT SCREW OPENING: 2 1]8 turns out
PiIot screw wrench 07908 4730001
NOTE:
Do not tighten excessiveIy. Tightening the piIot screw hard
against its seat wiII damage the seat.
NUT
SUB-AIR CLEANER CASE TUBE
FUEL COCK
PILOT SCREW WRENCH
5-19
FUEL SYSTEM
3. After warming up the engine, turn the throttIe stop screw
in or out to obtain the specified idIing speed.
4. Turn the carburetor piIot screw in or out about one haIf of
a turn to obtain the highest idIing speed.
5. Open and cIose the throttIe a coupIe of times and adjust
the idIing speed to the specified rpm.
6. SIowIy tighten the carburetor piIot screw to reduce the
idIing speed by 50 rpm beIow the specified rpm.
7. From the piIot screw setting obtained in Step 6 above, turn
the piIot screw out the number of turns for the specified
piIot screw opening.
PILOT SCREW OPENING AFTER IDLE SPEED REDUCTION:
3]4 of a turn out
8. Turn the throttIe stop screw to obtain the specified idIing
speed.
If the specified idIe speed can not be obtained, repeat the aII
adjustment steps from Step 1.
AIR CLEANER CASE
REMOVAL
Rear fender (page 2-3)
MuffIer (page 2-7)
Battery case (page 14-6)
ReguIator]rectifier (page 14-8)
AIternator 3P (BLACK) coupIer
CIamp
THROTTLE STOP SCREW
REGULATOR]RECTIFIER
3P BLACK COUPLER
CLAMP
5-20
FUEL SYSTEM
Remove the rear brake reservoir tank bracket boIt.
NOTE:
Be sure the brake reservoir tank is IeveI after removed in or-
der to prevent air from entering into the brake system.
Loosen the connecting tube band screw and remove the con-
necting tube from carburetor.
Remove the sub-frame Iower side and upper boIts.
Disconnect the breather chamber air cIeaner case tube.
Remove the air cIeaner housing and sub-frame assembIy.
DISASSEMBLY
Screw
Mud guard
BOLT
LOWER SIDE BOLT
UPPER BOLT
LOWER SIDE BOLT
TUBE
MUD GUARD SCREW
5-21
FUEL SYSTEM
Air cIeaner case boIt
Air cIeaner case
Resonator band screw
Resonator
ASSEMBLY
AssembIy is in the reverse order of disassembIy.
BOLT
AIR CLEANER CASE BOLT
RESONATOR SCREW
AIR CLEANER CASE
5-22
FUEL SYSTEM
INSTALLATION
TOROUE:
Sub-frame upper boIt: 3.3 kgm
Sub-frame Iower side boIt: 4.3 kgm
NOTE:
Route the wires and harnesses correctIy as shown in CABLE
AND HARNESS ROUTING ( page 1-19).
Make sure that the breather chamber air cIeaner case tube
is connected accordingIy.
FUEL TANK
REMOVAL
Disconnect the fueI tube.
Remove the seat (page 2-2).
Undo the fueI tank mounting boIt and remove the fueI tank.
DISASSEMBLY
Remove the fueI cock Iock nut.
UPPER BOLT
LOWER SIDE BOLT
FUEL TUBE
FUEL TANK
BOLT
LOCK NUT
5-23
FUEL SYSTEM
Remove the fueI strainer and O-ring.
CLEANING
CIean the fueI strainer with cIeaning soIvent.
ASSEMBLY
InstaII the fueI strainer with a new O-ring.
InstaII the fueI cock.
Tighten the fueI cock Iock nut to the specified torque.
TOROUE: 2.7 kgm
INSTALLATION
InstaII the fueI tank.
NOTE:
AIign the fueI tank hook with the rubber mount on the frame.
SecureIy tighten the fueI tank mounting boIt.
Connect the fueI tube.
InstaII the seat (page 2-2).
After instaIIing the fueI tank, turn the fueI cock ON and ensure
no Ieak is observed.
O-RING
STRAINER
LOCK NUT
FUEL TANK
BOLT
FUEL TUBE
6-1
6. ENGINE REMOVAL]INSTALLATION
SERVICE INFORMATION
During removaI and instaIIation, secureIy support the motorcycIe with a jack or box and carry out the work carefuIIy so
as not to damage the motorcycIe frame, engine, cabIes and harnesses.
During removaI and instaIIation, cover the frame with masking tape for protection.
The foIIowing shouId be inspected and]or adjusted after re-instaIIing the engine.
OiI pump (Section 4)
Carburetor (Section 5)
CyIinder head]vaIves (Section 7)
CyIinder]piston (Section 8)
CIutch]gearshift Iinkage (Section 9)
AIternator (Section 14)
The foIIowing components require engine removaI for service.
Crankshaft]baIancer (Section 10)
Transmission (Section 10)
Shift forks]shift drum]shift spindIe (Section 10)
The foIIowing shouId be inspected and]or adjusted after re-instaIIing the engine.
ThrottIe cabIe (page 3-9)
CIutch cabIe (page 3-22)
Drive chain (page 3-17)
Torque VaIues
Engine hanger nut 6.5 kgm
Engine hanger pIate nut 2.7 kgm
Swingarm pivot nut 9.0 kgm
Drive sprocket boIt 1.0 kgm
Gearshift pedaI boIt 1.2 kgm
Rear master cyIinder boIt 1.4 kgm AppIy Iocking agent to threads
OiI pipe boIt (12 mm) 3.8 kgm
DRIVE SPROCKET REMOVAL 6-2
ENGINE REMOVAL 6-3
6
ENGINE INSTALLATION 6-4
DRIVE SPROCKET INSTALLATION 6-5
6-2
DRIVE SPROCKET REMOVAL
Loosen the rear axIe nut and turn the Ieft and right adjuster
pIates to Ioosen the drive chain.
BoIt
Drive sprocket cover
Drive chain protector
Drive sprocket boIts
Fixing pIate
NOTE:
In order to remove the fixing pIate, remove the drive sprocket
boIt first, and then turn the fixing pIate to aIign the fixing pIate
teeth with the countershaft teeth.
REAR AXLE NUT
ADJUSTER PLATE
BOLTS
DRIVE SPROCKET COVER
CHAIN PROTECTOR
BOLTS
FIXING PLATE
6-3
Remove the drive sprocket.
ENGINE REMOVAL
Drive sprocket (page 6-2)
Carburetor (page 5-4)
Spark pIug cap (page 15-8)
Starter mortar cabIe (page 16-7)
Engine earth cabIe (page 16-7)
PuIse generator]neutraI switch 3P (NATURAL) coupIer
OiI pipe (page 4-9)
Rear master cyIinder protector pIate (page 13-24)
Brake pedaI return spring
Breather tube
Engine hanger boIt]nut
Engine hanger pIate boIts]nuts
Upper engine hanger pIates
DRIVE CHAIN
DRIVE SPROCKET
3P (BLACK) COUPLER
BREATHER TUBE HANGER PLATE BOLTS
HANGER BOLT HANGER PLATES
6-4
Engine hanger boIt]nut
Engine hanger boIt
Engine hanger pIate boIts
Front engine hanger pIates
ENGINE INSTALLATION
InstaII the engine.
InstaII the upper and front engine hangar pIates.
NOTE:
InstaII the upper engine hanger pIates with the marks facing
out.
Right: KCZ-R
Left: KCZ-L
Tighten the foIIowing boIts and nuts to the specified torque
TOROUE:
Engine hanger pIate nut: 2.7 kgm
Engine hanger nuts: 6.5 kgm
Swingarm pivot nut: 9.0 kgm
InstaII the breather tube.
Swingarm pivot nut]boIt
Engine assembIy
HANGER BOLT]NUT
HANGER PLATES
HANGER PLATE BOLTS]NUTS HANGER BOLT]NUT
PIVOT BOLT]NUT
HANGER BOLTS]NUTS
HANGER PLATE
BOLTS]NUTS
PIVOT BOLTS]NUTS
6-5
OiI pipe (page 4-10)
PuIse generator]neutraI switch 3P (NATURAL) coupIer
Engine earth cabIe (page 16-13)
Starter mortar cabIe (page 16-13)
Spark pIug cap (page 15-8)
Carburetor (page 5-16)
FiII with the engine oiI (page 3-14)
DRIVE SPROCKET INSTALLATION
InstaII the drive chain to the drive sprocket and instaII them to
the countershaft.
NOTE:
InstaII the drive sprocket with the OUT mark facing out.
Fixing pIate
NOTE:
In order to instaII the fixing pIate, aIign the fixing pIate teeth
with the countershaft teeth and then rotate the pIate untiI the
pIate hoIes Iine up with the drive sprocket boIt hoIes.
RETURN SPRING
PROTECTOR PLATE
3P (BLACK) COUPLER
OUT MARK DRIVE CHAIN
DRIVE SPROCKET
FIXING PLATE
6-6
Drive sprocket boIts
TOROUE: 1.0 kgm
Drive chain protector
Drive sprocket cover
BoIts
Adjust the drive chain after instaIIation (page3-17).
BOLTS
CHAIN PROTECTOR
BOLTS
DRIVE SPROCKET COVER
7-1
7. CYLINDER HEAD]VALVES
SERVICE INFORMATION
Maintenance work covered in this section can be conducted with the engine instaIIed in the frame.
AIways Ioosen the cam chain tensioner before camshaft removaI and instaIIation.
AppIy moIybdenum oiI soIution to the camshaft journaI and the cam sIipper surface as primary Iubrication before
assembIy.
Engine oiI to Iubricate the camshaft is suppIied via the oiI pass pipe. CIean the oiI pass pipe before assembIing the
cyIinder head.
Be carefuI not to bend the oiI pipe.
After disassembIing the parts, inspect and measure them, and then bIow them dry with compressed air.
Mark the originaI Iocation of each part in order to readiIy identify the Iocation when re-instaIIing it.
SPECIFICATIONS
TROUBLESHOOTING 7-3
CYLINDER HEAD COVER REMOVAL 7-4
CYLINDER HEAD COVER
DISASSEMBLY 7-5
CAMSHAFT REMOVAL 7-7
CYLINDER HEAD REMOVAL 7-9
CYLINDER HEAD DISASSEMBLY 7-10
VALVE GUIDE REPLACEMENT 7-12
7
VALVE SEAT INSPECTION AND
REFACING 7-13
CYLINDER HEAD ASSEMBLY 7-15
CYLINDER HEAD INSTALLATION 7-16
CAMSHAFT INSTALLATION 7-17
CYLINDER HEAD COVER ASSEMBLY 7-20
CYLINDER HEAD COVER
INSTALLATION 7-22
Warpage
VaIve seat width
Cam Iobe height
Runout
VaIve stem O.D.
VaIve guide I.D.
VaIve seat width
Free Iength
ITEM
Unit: mm
SPECIFICATIONS SERVICE LIMIT
CyIinder compression 6.8 kgf]cm
2
400 rpm
0.10 0.02 mm
0.12 0.02 mm
1.1 1.2
30.672 30.872
30.719 30.919
4.975 4.990
4.955 4.970
5.000 5.012
5.000 5.012
0.010 0.037
0.030 0.057
1.1 1.2
1.1 1.2
43.44
44.03
VaIve spring
0.10
2.0
30.583
30.629
0.04
4.96
4.94
5.03
5.03
0.06
0.09
2.0
2.0
42.51
42.83
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
INNER
OUTER
CyIinder head
Camshaft
VaIve and
vaIve guide
7-2
Rocker arm I.D.
Sub-rocker arm I.D.
ITEM
Unit: mm
SPECIFICATIONS SERVICE LIMIT
11.500 11.518
7.000 7.015
7.000 7.015
11.466 11.484
6.972 6.987
6.972 6.987
0.016 0.052
0.013 0.043
11.53
7.05
7.05
11.41
6.92
6.92
0.10
0.10
Rocker arm
Sub-rocker
arm
IN
EX
IN
EX
Torque VaIues
Spark pIug 1.2 kgm
CyIinder head cover boIt (6 mm) 1.2 kgm
(8 mm) 2.4 kgm
CyIinder head boIt (6 mm SH) 1.0 kgm
(10 mm) 4.0 kgm AppIy oiI to threads and mating surfaces
Cam sprocket boIt 2.0 kgm AppIy Iocking agent to threads
Rocker arm shaft 2.8 kgm AppIy Iocking agent to threads
Sub-rocker arm shaft 2.3 kgm AppIy Iocking agent to threads
VaIve adjuster Iock nut (IN) 2.4 kgm
(EX) 2.6 kgm
Cam chain tensioner set pIate boIt 1.0 kgm
OiI pass pipe joint boIt (7 mm) 1.2 kgm
(8 mm) 1.2 kgm
SpeciaI TooIs
VaIve spring compressor 07757-0010000
VaIve guide driver 07942-MA60000
VaIve guide reamer (5.010 mm) 07984-MA60001
Cutter hoIder, 5 mm 07781-0010400
VaIve seat cutter
Seat cutter, 45 , 33 mm 07780-0010800
Seat cutter, 45 , 27.5 mm 07780-0010200
FIat cutter, 32 , 30 mm 07780-0012200
FIat cutter, 32 , 25 mm 07780-0012000
Interior cutter, 60 , 30 mm 07780-0014000
7-3
TROUBLESHOOTING
Engine top-end probIems can usuaIIy be diagnosed by a compression test or by the noise coming from the top-end.
If hard to start and poor performance at Iow speed is observed, check for white smoke in the crankcase breather tube.
Such smoke is a sign of wear, breakage, or sticking of piston rings.
Poor idIing performance
Low compression
ExcessiveIy Iow compression
Incorrect vaIve cIearance adjustment
Seized or defective vaIves
Incorrect vaIve timing
Damaged vaIve spring
Poor vaIve seat seaIing
Leaking cyIinder head gasket
Warped or cracked cyIinder head
FaIse spark pIug instaIIation
ExcessiveIy high compression
Carbon deposits on the piston or in the combustion
chamber
White smoke from the muffIer
Worn vaIve guide or vaIve stem
Worn vaIve stem seaI
Noise
Incorrect vaIve cIearance adjustment
Seized vaIves or broken vaIve springs
Worn or damaged camshaft
Broken cyIinder or piston
7-4
CYLINDER HEAD COVER RE-
MOVAL
Remove the spark pIug cap.
Disconnect the breather tube.
Remove the upper engine hanger pIate (page 6-4).
NOTE:
The cyIinder head cover can be removed with the engine in-
staII in the frame.
Remove the crankshaft hoIe cap and the timing hoIe cap.
Rotate the crankshaft countercIockwise to aIign T mark on
the fIywheeI with the index notch on the Ieft crank case cover
(where the piston is at the top dead center).
Remove the cyIinder head cover boIts and remove the cyIin-
der head cover.
NOTE:
Loosen the boIts in a crisscross pattern in two or more steps
in ascending order.
Remove the gasket and the doweI pins.
HANGER PLATE
BREATHER TUBE
INDEX NOTCH TIMING HOLE CAP
CRANKSHAFT HOLE CAP T MARK
HEAD COVER
BOLTS
GASKET
DOWEL PINS
7-5
CYLINDER HEAD COVER DISAS-
SEMBLY
Remove the foIIowing component:
VaIve hoIe caps
Sub-rocker arm shafts
SeaIing washers
CAUTION:
Sub-rocker arm shafts
Wave washers
Rocker arm shafts
SeaIing washers
VALVE HOLE CAP
SUB-ROCKER ARM SHAFT
SEALING WASHERS
WAVE WASHERS
SUB-ROCKER ARM (EX)
SUB-ROCKER ARM (IN)
SEALING WASHERS
ROCKER ARM SHAFTS
WAVE WASHERS
7-6
Remove the rocker arms from the cyIinder head cover.
ROCKER ARM AND SUB-ROCKER ARM
INSPECTION
Inspect the rocker arms and sub-rocker arms for wear or dam-
age.
If any rocker arm sIipper surface is damaged or worn, aIso
inspect the cam surface of the camshaft (page 7-8).
Measure the I.D. of the foIIowing components.
SERVICE LIMIT:
Sub-rocker arm (IN]EX): 7.05 mm
RepIace if 7.05 mm or greater
Rocker arm (IN]EX): 11.53 mm
SUB-ROCKER ARM SHAFT AND ROCKER
ARM SHAFT INSPECTION
Inspect the rocker arm shafts and sub-rocker arm shafts for
wear or damage.
NOTE:
Measure the sIiding portion with each rocker arm.
Measure the O.D. of the foIIowing components.
SERVICE LIMIT:
Sub-rocker arm (IN]EX): 6.92 mm
RepIace if 6.92 mm or Iess
Rocker arm (IN]EX): 11.41 mm
CaIcuIate the sub-rocker arm to shaft cIearance and rocker
arm-to-shaft cIearance.
SERVICE LIMIT: 0.10 mm
ROCKER ARMS
7-7
CAMSHAFT REMOVAL
Remove the cyIinder head cover (page 7-4).
To reIease the cam chain tensioner, push down wedge B with
a fIathead screwdriver, then puII up wedge A with pIiers. In-
sert a pin into the 2 mm hoIe to secure the cam chain tensioner.
NOTE:
Camshaft removaI can be conducted with the engine instaIIed
in the frame.
Remove one of the cam sprocket boIts.
Turn the crankshaft to rotate the cam sprocket 180 degrees to
remove the other cam sprocket boIt.
NOTE:
Be carefuI not to drop the boIts into the crankcase.
Remove the pIunger and spring.
NOTE:
Be carefuI not to drop the pIunger or the spring into the crank-
case. AIso do not Iose them after removing.
PuII the cam sprocket off the camshaft fIange shouIder and
remove the cam chain from the cam sprocket.
Suspend the cam chain with a piece of wire to keep it from
faIIing into the crankcase.
Remove the camshaft and cam sprocket.
WEDGE A PIN
WEDGE B
BOLT
CHAIN
CAMSHAFT CAM SPROCKET
PLUNGER]SPRING
7-8
Remove the camshaft bearing set pins.
CAMSHAFT INSPECTION
Turn the outer race of the bearings with your finger to check
that they turn smoothIy.
RepIace the bearings if Iooseness is detected or the bearings
do not turn smoothIy.
Support both ends of the camshaft with V-bIocks and check
the camshaft runout with a diaI gauge.
ActuaI runout is 1]2 of the totaI indicator reading.
Remove the bearings from the camshaft.
Check each cam Iobe for damage.
Measure the cam Iobe height.
SERVICE LIMIT: IN: 30.583 mm
EX: 30.629 mm
SET PINS
7-9
CYLINDER HEAD REMOVAL
Remove the cyIinder head cover (page 7-4).
Remove the camshaft (page 7-7).
Remove the carburetor (page 5-4).
Remove the oiI pass pipe joint boIts and the seaIing washers.
NOTE:
The cyIinder head can be removed with the engine instaIIed
in the frame.
Remove the cam chain tensioner set pIate boIts.
Remove the tensioner set pIate.
Remove the gasket and the doweI pins
Remove the cyIinder head boIts (6 mm SH).
Remove the cyIinder head boIts]washers (10 mm).
NOTE:
Loosen the boIts in a crisscross pattern in two or more steps.
Remove the cyIinder head.
CAUTION:
BOLT
SEALING WASHERS
SET PLATE
BOLTS
BOLTS]WASHERS
BOLTS (6 mm SH)
GASKET
DOWEL PINS
7-10
CYLINDER HEAD DISASSEMBLY
Remove the foIIowing components with a vaIve spring com-
pressor:
VaIve cotters
Retainers
Springs
VaIves
Spring seats
Stem seaIs
CAUTION:
NOTE:
Mark aII parts to ensure that they are reassembIed in their
originaI Iocations.
Check the cyIinder head for warpage with a straight edge and
a thickness gauge.
CYLINDER HEAD INSPECTION
Remove carbon deposits from the combustion chamber and
exhaust ports.
CIean the cyIinder head mating surface.
CAUTION:
Check the spark pIug hoIe and vaIve seat area for crack.
VALVE SPRING COMPRESSOR
VALVE INNER SPRING
OUTER SPRING
RETAINER
STEM SEAL SPRING SEAT
CYLINDER HEAD
COTTER
7-11
VALVE SPRING INSPECTION
Inspect the vaIve springs for sagging and damage.
Measure the free Iength of the inner and outer vaIve springs.
SERVICE LIMIT: INNER: 42.51 mm
OUTER: 42.83 mm
VALVE INSPECTION
Inspect each vaIve for runout, damage, and abnormaI stem
wear.
Insert the vaIve into the vaIve guide and check the vaIve move-
ment in the vaIve guide.
Measure the vaIve stem O.D. at the sIiding portion of the vaIve
guide.
EX: 4.94 mm
VALVE GUIDE INSPECTION
Using a reamer, remove carbon deposits before checking the
vaIve guide I.D.
NOTE:
AIways rotate a reamer cIockwise when inserting or remov-
ing. Inserting or removing a reamer without rotating it, or
rotating it countercIockwise, can damage the vaIve guide in-
ner waII.
VaIve guide reamer (5.010 mm) 07984- MA60001
Measure each vaIve guide I.D.
EX: 5.03 mm
CaIcuIate the stem-to-guide cIearance.
EX: 0.09 mm
NOTE:
If the stem-to-guide cIearance exceeds the service Iimit, re-
pIace the vaIve guide. If a new vaIve guide stiII wouId not
achieve cIearance within the service Iimit, repIace the vaIve
aIso.
VALVE GUIDE REAMER
7-12
VALVE GUIDE REPLACEMENT
NOTE:
VaIves move aIong the vaIve guide as the centraI axIe. If onIy
a vaIve guide is repIaced, the vaIve and vaIve seat may not
achieve sufficient seaIing. AIways reface the vaIve seat when
a vaIve guide is repIaced.
Heat the entire cyIinder head to 100 150 C.
CAUTION:
Drive out the vaIve guides from the combustion chamber side.
VaIve guide driver 07942MA60000
CAUTION:
AppIy oiI to a new O-ring and instaII it on a new vaIve guide.
InstaII a new vaIve guide to the cyIinder head by inserting it
from the camshaft side whiIe the cyIinder head is stiII warm.
VaIve guide driver 07942MA60000
Insert the reamer from the combustion chamber side and ream
the instaIIed vaIve guide.
VaIve guide reamer (5.010 mm) 07984- MA60001
NOTE:
Be carefuI not to tiIt the reamer. If the reamer is tiIted whiIe
reaming, the vaIve guide hoIe wiII be moved off-center
causing Ieakage from the stem seaI and irreparabIe mis-
aIignment of the vaIve seat.
AIways rotate a reamer cIockwise when inserting or remov-
ing. Inserting or removing a reamer without rotating it, or
rotating it countercIockwise, can damage the vaIve guide
inner waII.
CIean the cyIinder head thoroughIy to remove aII metaI par-
ticIes.
VALVE GUIDE DRIVER
VALVE GUIDE DRIVER
VALVE GUIDE REAMER
7-13
VALVE SEAT INSPECTION AND
REFACING
VALVE SEAT INSPECTION
Remove carbon and other deposits from the vaIves.
If a rough surface or uneven wear is detected on the vaIve
face, repIace the vaIve.
AppIy a Iight coating of Prussian BIue to each cyIinder head
vaIve seat. Using a hand-Iapping tooI, Iap each vaIve and seat
without turning the vaIve and ensure that the vaIve contacts
the seat.
Remove the vaIve and inspect the vaIve seat contact surface
by checking the Prussian BIue on the vaIve face.
If vaIve seat damage is detected, reface the vaIve seat.
If uneven seat width is detected, check the stem-to-guide cIear-
ance. If the cIearance is satisfactory, repIace the vaIve guide
(page 7-12).
Measure the vaIve seat contact surface.
SERVICE LIMIT: 2.0 mm RepIace if 2.0 mm or greater
Measure the vaIve seat width.
SPECIFICATION : 1.1 1.2 mm
SERVICE LIMIT : 2.0 mm Reface if 2.0 mm or greater
If the seat width is uneven, too wide, too narrow, too high or
too Iow, reface the vaIve seat using a vaIve seat cutter.
VALVE SEAT REFACING
Use a vaIve seat cutter to reface the vaIve seats.
For detaiIs, refer to the instructions incIuded with the vaIve
seat cutter.
HAND-LAPPING TOOL
DAMAGED SEAT UNEVEN SEAT WIDTH
INTERIOR CUTTER FLAT CUTTER
SEAT CUTTER
7-14
WhiIe appIying a 4 5 kg pressure manuaIIy, rotate the vaIve
seat cutter in the same direction to reface the vaIve seat.
NOTE:
AppIy engine oiI to the vaIve seat cutter and reface the vaIve
seat whiIe removing the metaI particIes.
Use a 45-degree cutter to remove any roughness or irregu-
Iarities from the seat.
NOTE:
Reface the seat when the vaIve guide is repIaced.
Be carefuI not to grind the seat surface excessiveIy.
Use a 32-degree cutter to reface the upper part IittIe by IittIe.
Use a 60-degree cutter to reface the Iower part IittIe by IittIe.
ROUGHNESS
7-15
Use a 45-degree cutter to reface the seat untiI the seat width
reaches the specified width.
Inspect the refaced contact surface of the vaIve seat.
If the refaced contact surface is too high, cut the seat with the
32-degree cutter and then the 45-degree cutter to the speci-
fied width.
If the refaced contact surface is too Iow, cut the seat with the
60-degree cutter and then the 45-degree cutter to the speci-
fied width.
After refacing, appIy some Iapping compound to the vaIve
seat and Iap the vaIve using a hand-Iapping tooI.
CAUTION:
CIean the cyIinder head and the vaIve after Iapping.

When the refacing procedure above is compIeted, inspect the
vaIve seat contact surface again.
CYLINDER HEAD ASSEMBLY
Spring seats
New stem seaIs
VaIves
NOTE:
AppIy moIybdenum grease to the vaIve stem and vaIve
guide inner surface when inserting the vaIve.
Turn the vaIve sIowIy in order to avoid damage to the stem
seaI when inserting the vaIve.
SEAT WIDTH
CONTACT SURFACE
TOO HIGH
CONTACT TOO LOW
OLD SEAT WIDTH
OLD SEAT WIDTH
VALVE STEM SEAL
SPRING SEAT
7-16
VaIve springs
Retainers
NOTE:
InstaII the vaIve springs with their cIoser wound coiIs facing
the cyIinder head.
Compress the vaIve springs with the vaIve spring compres-
sor and instaII the vaIve cotters.
CAUTION:
CYLINDER HEAD INSTALLATION
NOTE:
Cover the cyIinder opening and oiI hoIes with a shop toweI to
prevent dirt or foreign objects from entering the engine.
InstaII the doweI pins and a new cyIinder head gasket.
GentIy tap the end of the vaIve stem to seat the cotters.
CYLINDER HEAD
VALVE SPRING COMPRESSOR
COTTER
GASKET
DOWEL PINS
7-17
CyIinder
CyIinder head boIts]washers (10 mm)
TOROUE: 4.0 kgm
NOTE:
Tighten the boIts in a crisscross pattern in two or more steps.
CyIinder head boIts (6 mm SH)
TOROUE: 1.0 kgm
Tensioner set pIate
NOTE:
SecureIy instaII the rubber part of the tensioner set pIate with
the cam chain tensioner.
TOROUE: 1.0 kgm
CAMSHAFT INSTALLATION
AppIy engine oiI to the camshaft bearings.
InstaII the oiI pass pipe joint boIt and new seaIing washers.
Tighten the oiI pass pipe joint boIt to the specified torque.
TOROUE: (7 mm) : 1.2 kgm
(8 mm) : 1.2 kgm
InstaII the carburetor (page 5-16).
BOLTS]WASHERS (10 mm)
BOLTS (6 mm SH)
SET PLATE BOLT
BOLT
SEALING WASHERS
7-18
InstaII the camshaft bearing set pins.
InstaII the spring and pIunger.
NOTE:
Be carefuI not to drop the pIunger or spring into the crank-
case.
InstaII the cam sprocket with the cam chain.
on the fIywheeI with the index notch on the Ieft crank case
cover.
SET PINS
PLUNGER]SPRING
INDEX NOTCH
T MARK
CAM SPROCKET
CAM CHAIN
7-19
InstaII the camshaft with the cam pitch facing up.
InstaII the cam sprocket to the camshaft whiIe aIigning the
timing marks on the cam sprocket with the cyIinder head top
edge.
AppIy thread Iock agent to the cam sprocket boIt.
InstaII the cam sprocket boIt and tighten to the specified
torque.
TOROUE: 2.0 kgm
NOTE:
on the fIywheeI with the index notch on the Ieft crank case
cover (where the piston is at the top dead center). Make sure
that the timing marks on the cam sprocket are aIigned with
the cyIinder head top edge.
Remove the 2 mm pin inserted into the hoIe of wedge A.
AppIy thread Iock agent to the cam sprocket boIt.
Rotate the crankshaft to turn the cam sprocket 180 degrees.
InstaII the other cam sprocket boIt and tighten to the speci-
fied torque.
TOROUE: 2.0 kgm
NOTE:
CAMSHAFT
BOLT
BOLT
WEDGE A
PIN
7-20
NOTE:
Each rocker arm has an ID mark and designated instaIIation
Iocation. InstaII each of the rocker arms in the correct posi-
tion.
InstaII the rocker arms.
ID MARKS
ROCKER ARM
SUB-ROCKER ARM EX A
ROCKER ARM B
ROCKER ARM SHAFTS
ROCKER ARM A
WAVE WASHERS
SEALING WASHERS
SUB-ROCKER ARM EX B
SEALING WASHER
WAVE WASHERS
SUB-ROCKER ARM SHAFT EX
SUB-ROCKER ARM IN
ROCKER ARM D
SEALING WASHER
ROCKER ARM C
SUB-ROCKER ARM SHAFT IN
SEALING WASHER
CYLINDER HEAD COVER ASSEMBLY
AppIy engine oiI to the rocker arm-to-shaft sIiding surface and
sub-rocker arm-to-shaft sIiding surface.
AppIy moIybdenum grease to the rocker arm sIipper surface.
7-21
AppIy engine oiI to the sIiding surface of the rocker arm shaft
and Iocking agent to the rocker arm shaft threads. InstaII new
seaIing washers.
TOROUE: 2.8 kgm
InstaII the sub-rocker arms and the wave washers.
AppIy engine oiI to the sIiding surface of the sub-rocker arm
shaft and Iocking agent to the sub-rocker arm shaft threads.
InstaII new seaIing washers.
TOROUE: 2.3 kgm
NOTE:
InstaII the intake sub-rocker arm with the IN mark facing
the vaIve.
InstaII the exhaust sub-rocker arm with the A mark fac-
ing to the Ieft and the B mark to the right.
SEALING WASHERS
ROCKER ARMS
SUB-ROCKER ARM
WAVE WASHER
IN MARK
A MARK
B MARK
SEALING WASHERS SEALING WASHERS
SUB-ROCKER ARM SHAFT SUB-ROCKER ARM SHAFT
7-22
AppIy engine oiI to a new O-ring and instaII it to the vaIve
hoIe cap.
InstaII the vaIve hoIe cap and tighten to the specified torque.
TOROUE: 1.5 kgm
CYLINDER HEAD COVER INSTAL-
LATION
Pour cIean engine oiI into the cyIinder head untiI the poured
oiI compIeteIy covers the cam top end.
InstaII doweI pins and a new cyIinder head cover gasket.
Rotate the crankshaft countercIockwise to aIign the timing
marks on the cam sprocket with the cyIinder head top edge.
Make sure that aII the cam Iobes are facing down (where the
piston is at the top dead center).
InstaII the cyIinder head cover and the cyIinder head cover
boIts (8 mm).
Connect the breather tube.
InstaII the spark pIug cap
InstaII the upper engine hanger pIate (page 6-4).
InstaII the fueI tank (page 5-23).
InstaII the seat (page 2-2).
InstaII the cyIinder head cover boIts and tighten to the speci-
fied torque.
NOTE:
Tighten the 8 mm boIts first.
Tighten the 6 mm boIts in a crisscross pattern in two or
more steps.
TOROUE: 8 mm boIt 2.4 kgm
8 mm boIt 1.2 kgm
Adjust the vaIve cIearance (page 3-12).
O-RING
VALVE HOLE CAP
GASKET
DOWEL PINS
BOLT (8 mm)
BOLT (6 mm) HEAD COVER
HANGER PLATE
PLUG CAP BREATHER TUBE
8-1
8. CYLINDER]PISTON
SERVICE INFORMATION
Be carefuI not to damage the cyIinder inner surface or the piston outer surface.
After disassembIing the parts, inspect and measure them, and then bIow them dry with compressed air.
Mark the originaI Iocation of each part in order to readiIy identify the Iocation when re-instaIIing it.
SPECIFICATIONS
TROUBLESHOOTING 8-2
CYLINDER REMOVAL 8-3
8
PISTON REMOVAL 8-4
PISTON INSTALLATION 8-6
CYLINDER INSTALLATION 8-8
Torque VaIues
CyIinder boIt (10 mm) 4.0 kgm AppIy oiI to the boIt thread and seating surface
ITEM
Unit: mm
CyIinder
Piston, piston
pin and
piston ring
73.00 73.01

18.5mm from the skirt bottom
72.950 72.970
17.002 17.008
0.03 0.06
16.994 17.000
0.002 0.014
0.016 0.040
0.15 0.30
0.30 0.45
0.20 0.70
0.015 0.05
0.015 0.05
mark facing up
mark facing up
73.11
0.05
0.05
0.10
72.87
17.05
0.1
16.97
0.05
0.09
0.30
0.45
0.86
0.12
0.12
17.06
I.D.
Taper
Out of round
Warpage
Piston O.D.
Piston pin O.D.
cIearance
Piston ring end gap
Piston ring-to-ring
groove cIearance
Piston ring mark
Top
Second
OiI (side raiI)
Top
Second
Top
Second
8-2
CYLINDER]PISTON
TROUBLESHOOTING
Low compression
Leaky cyIinder head gasket
Worn or damaged piston ring
Worn cyIinder or piston
High compression
Carbon deposits on the piston or on the combustion cham-
ber
Piston noise
Worn cyIinder, piston or piston ring
Worn piston pin hoIe or piston pin
Worn connecting rod smaII end
Noise
Damaged cyIinder or piston
8-3
CYLINDER]PISTON
CYLINDER REMOVAL
Remove the cyIinder head (page 7-9).
Cam chain guide
CyIinder boIts (6 mm SH)
CyIinder boIts (10 mm)]washers
NOTE:
Loosen the boIts in a crisscross pattern in two or more steps.
CyIinder
Gasket
DoweI pins
CYLINDER INSPECTION
Inspect the cyIinder waII for wear and damage.
Measure and record the cyIinder I.D. at a totaI of six Iocations
in both the X and Y axes (piston pin direction or perpendicu-
Iar axis) at the top, middIe, and bottom IeveIs.
Take the maximum reading to determine the cyIinder I.D.
SERVICE LIMIT: 73.11 mm Rebore or repIace if 73.11 mm or
greater
CaIcuIate the out-of-round (difference in the internaI diam-
eters between the X and Y axes) and taper (difference in the
internaI diameter between the top, middIe, and bottom IeveIs
in the X or Y directions) of the cyIinder.
Take the maximum reading to determine each vaIue.
SERVICE LIMIT:
Out of round : 0.05 mm Rebore or repIace if 0.05 mm or
greater
Taper: 0.05 mm Rebore or repIace if 0.05 mm or
greater
CAM CHAIN GUIDE
BOLTS (10 mm)]WASHERS
BOLTS (6 mm SH)
TOP
MIDDLE
BOTTOM
8-4
CYLINDER]PISTON
Check the cyIinder head for warpage with a straight edge and
a thickness gauge.
SERVICE LIMIT: 0.10 mm Resurface or repIace if 0.10 mm
or greater
PISTON REMOVAL
Piston pin cIip
Piston pin
Piston
NOTE:
Be carefuI not to drop the piston pin cIip into the crankcase.
PISTON]PISTON RING INSPECTION
Remove the piston rings.
CAUTION:
Remove any carbon deposits from the piston head and the
piston ring grooves.
Inspect the piston for damage or cracks and the ring grooves
for uneven wear.
InstaII the piston ring and measure the piston ring-to-groove
cIearance with a thickness gauge.
SERVICE LIMIT:
TOP : 0.12 mm RepIace if 0.12 mm or greater
SECOND : 0.12 mm RepIace if 0.12 mm or greater
PISTON PIN CLIP PISTON
PISTON PIN
PISTON RING
PISTON RING
8-5
CYLINDER]PISTON
Insert each piston ring into the bottom of the cyIinder from
the upper part of the piston. Make sure to keep each piston
ring horizontaIIy.
Measure the ring end gap with a thickness gauge.
SERVICE LIMIT:
TOP : 0.30 mm RepIace if 0.30 mm or greater
SECOND : 0.45 mm RepIace if 0.45 mm or greater
OIL : 0.86 mm RepIace if 0.86 mm or greater
Measure the piston O.D.
SERVICE LIMIT: 72.87 mm RepIace if 72.87 mm or Iess
NOTE:
Measure the piston diameter 18.5 mm from the bottom of the
skirt and at a right angIe to the piston pin hoIe.
Measure the piston-to-cyIinder cIearance.
Measure the piston pin hoIe I.D.
Measure the piston pin O.D. at the sIiding area of the piston
and the connecting rod smaII end.
CaIcuIate the piston-to-piston pin cIearance.
PISTON RING
CYLINDER
8-6
CYLINDER]PISTON
CONNECTING ROD SMALL END INSPEC-
TION
Measure the connecting rod smaII end I.D.
CaIcuIate the connecting rod smaII end-to-piston pin cIear-
ance.
If the cIearance reaches the service Iimit, repIace the piston
pin.
CAM CHAIN GUIDE INSPECTION
Inspect the cam chain guide rubber for excessive wear or dam-
age.
PISTON INSTALLATION
PISTON RING INSTALLATION
CIean the piston ring groove.
NOTE:
Do not use a wire brush to cIean the piston pin ring grooves
or damage the ring grooves.
AppIy engine oiI to the piston ring and instaII it to the piston.
NOTE:
Be carefuI not to damage the piston and the piston rings.
InstaII the piston rings with the manufacturers mark fac-
ing up.
Space the ring end gaps 120 degrees apart.
Do not aIign the piston ring end gap with the piston pin
hoIe or at 90 degrees to the piston pin hoIe.
Space the side raiI gaps apart from each other around a
spacer end gap.
Ensure that the rings rotate smoothIy.
CHAIN GUIDE RUBBER
MANUFACTURERS MARK PISTON RING
PISTON RING
8-7
CYLINDER]PISTON
NOTE:
Be carefuI not to drop the piston pin cIip into the crank-
case.
Do not aIign the piston pin cIip end gap with the piston
cut-out.
AppIy engine oiI to the connecting rod smaII end and the pis-
ton pin hoIe.
AppIy moIybdenum grease to the piston pin.
Piston
NOTE:
InstaII the piston with the IN mark facing the intake side.
Piston pin
New piston pin cIip
MANUFACTURERS MARK
TOP RING
TOP RING
SECOND RING
OIL RING
SECOND RING
SIDE RAILS
SPACER
OIL RING
PISTON PIN CLIP
20 mm OR MORE
20 mm OR MORE
PISTON
IN MARK
PISTON PIN
8-8
CYLINDER]PISTON
CYLINDER INSTALLATION
CIean the cyIinder mounting surface of the crankcase.
NOTE:
Be carefuI not to drop the gasket materiaIs into the crank-
case.
Be carefuI not to damage the cyIinder mounting surface.
DoweI pins
New gasket
CyIinder boIts (10 mm)]washers
TOROUE: 4.0 kgm
NOTE:
AppIy oiI to the threads and fIange surface of the cyIinder
boIt (10 mm).
Tighten the boIts in a crisscross pattern in two or more
steps.
CyIinder boIts (6 mm SH)
CyIinder
NOTE:
AppIy engine oiI to the piston outer surface and the cyIinder
inner surface before instaIIing the cyIinder.
GASKET
DOWEL PINS
CYLINDER
BOLTS (10 mm)]WASHERS
BOLTS (6 mm SH)
8-9
CYLINDER]PISTON
Cam chain guide
NOTE:
Fit the cam chain guide tab with the cyIinder cut-out.
CyIinder head (page 7-16)
Camshaft (page 7-17)
CyIinder head cover (page 7-22)
CAM CHAIN GUIDE
ALIGN
9-1
9. CLUTCH]GEARSHIFT LINKAGE
SERVICE INFORMATION
The viscosity and amount of engine oiI affect the disengaging action of the cIutch. Check the viscosity and amount of
engine oiI before inspecting the cIutch if the cIutch does not disengage smoothIy or the motorcycIe stiII creeps even
though the cIutch Iever is compIeteIy disengaged.
Remove any residuaI gasket materiaI from the crankcase mating surfaces.
Be carefuI not to damage the crankcase mating surfaces when disassembIing.
Ensure no contaminants or dirt enter the engine.
Transmission, shift drum, and shift fork maintenance work requires disassembIy of the crankcase.
SPECIFICATIONS
TROUBLESHOOTING 9-2
RIGHT CRANKCASE COVER
REMOVAL 9-3
CLUTCH REMOVAL 9-5
9
PRIMARY DRIVE GEAR 9-8
GEARSHIFT CAM 9-10
CLUTCH INSTALLATION 9-11
INSTALLATION 9-14
Torque VaIues
Right crankcase cover boIt 1.2 kgm
CIutch center Iock nut 11.0 kgm AppIy oiI to the boIt threads and fIange surface]Tighten and cauIk
Shift drum stopper arm boIt 1.2 kgm AppIy Iocking agent to the boIt threads
Primary drive gear Iock nut 9.0 kgm AppIy oiI to the boIt threads and fIange surface
Gearshift pedaI boIt 1.2 kgm
Shift return spring stopper boIt 2.4 kgm
SpeciaI TooI
CIutch center hoIder 07923-KE10000
Gear hoIder 07724-0010100
ITEM
Unit: mm
STANDARD
CIutch
Main shaft O.D. at cIutch outer guide
CIutch outer I.D.
CIutch Outer guide
10 20
37.2
2.92 3.08
25.000 25.021
24.959 24.980
19.990 20.010
19.959 19.980
SERVICE LIMIT
33.5
2.7
25.04
24.12
20.03
0.3
19.91
O.D.
I.D.
9-2
TROUBLESHOOTING
Heavy cIutch Iever operation
Damaged cIutch cabIe
Damaged cIutch Iifter mechanism
Damaged cIutch Iifter pIate bearing
WrongIy routed cIutch cabIe
CIutch does not disengage or motorcycIe creeps with
cIutch disengaged
Too much free pIay
CIutch pIate warped or distorted
Loosened cIutch center Iock nut
Too much engine oiI
CIutch sIips when acceIerating
Seized cIutch Iifter mechanism
Worn cIutch disc
Saggy cIutch spring
Too IittIe Iever free pIay
Gears do not engage smoothIy
ImproperIy adjusted cIutch Iever free pIay
Damaged or warped shift fork
Warped shift fork shaft
Transmission faiIure
Gears pop out
Damaged or warped shift fork
Warped shift fork shaft
Damaged shift drum stopper
Transmission faiIure
9-3
RIGHT CRANKCASE COVER RE-
MOVAL
Remove the under guard (page 2-7).
Remove the starter motor (page 16-7).
Undo the right step boIt and remove the right step.
Remove the oiI pipes (page 4-9).
Remove the rear master cyIinder protector pIate (page 13-
24).
Remove the return spring and swing the brake pedaI down-
ward.
Remove the oiI pass pipe (page 4-8).
Loosen the Iock nut and adjustor nut and remove the cIutch
cabIe from the cIutch arm.
Remove the right crankcase cover boIts and right crankcase
cover.
PROTECTOR PLATE
RETURN SPRING
RIGHT STEP
CABLE
CLUTCH ARM
BOLTS
9-4
Remove the gasket and doweI pin.
RIGHT CRANKCASE COVER INSPECTION
Remove the cIutch Iifter arm and spring.
Inspect the oiI seaI and repIace if damaged.
Inspect the needIe bearing and repIace if Ioose or damaged.
NOTE:
When the oiI seaI is repIaced, secureIy press the seaI into the
crankcase evenIy with the case surface.
Remove the snap ring and oiI seaI.
NOTE:
When the oiI seaI is repIaced, secureIy press the seaI into the
crankcase beIow the snap ring groove.
GASKET
DOWEL PIN
SPRING
LIFTER ARM
OIL SEAL
NEEDLE BEARING
SNAP RING
OIL SEAL
9-5
Inspect the cIutch Iifter arm and repIace if damaged.
AppIy grease to the stem O. D. of the cIutch Iifter arm.
CLUTCH REMOVAL
Remove the cIutch Iifter piece.
Undo the cIutch Iifter pIate boIts and remove the cIutch Iifter
pIate, Iifter bearing, and cIutch spring.
NOTE:
Loosen the cIutch Iifter pIate boIts in a crisscross pattern in
two or more steps.
Loosen the cauIk on the cIutch center Iock nut. Be carefuI not
to damage the mainshaft.
LIFTER PIECE
BOLTS SPRING
PLATE BEARING
NUT
9-6
WhiIe hoIding the cIutch center with the cIutch center hoIder,
remove the cIutch center Iock nut and the washer.
CIutch center
Washer
Six cIutch discs
Five cIutch pIates
Pressure pIate
Remove the cIutch outer guide.
AIign the oiI pump drive gear teeth and primary drive gear
teeth with the position mark on the crankcase as iIIustrated.
Remove the cIutch outer.
CLUTCH CENTER HOLDER
CLUTCH CENTER
PRESSURE PLATE DISCS]PLATES
POSITION MARK
CLUTCH OUTER
PRIMARY DRIVE GEAR
OIL PUMP DRIVE GEAR
CLUTCH OUTER GUIDE
9-7
CIutch pIate inspection
Check for pIate warpage on a surface pIate with a thickness
gauge.
CIutch disc inspection
RepIace the discs if they show signs of scoring or discoIora-
tion.
Measure the disc thickness.
NOTE:
CIutch discs shouId be repIaced as a set.
CIutch spring inspection
Measure the free Iength of each spring.
NOTE:
CIutch springs shouId be repIaced as a set.
CLUTCH INSPECTION
Lifter pIate bearing inspection
Rotate the Iifter pIate bearing with a finger to check the bear-
ing for Iooseness. RepIace it if Iooseness is detected.
CLUTCH DISC
CLUTCH PLATE
9-8
CIutch center inspection
Check the sIots of the cIutch center for stepped wear, damage
or crack.
CIutch outer and outer guide inspection
Check the sIots in the cIutch outer for scratch, cracks, or un-
even wear made by the cIutch discs.
Measure the I.D. of the cIutch outer.
Measure the O.D. of the cIutch outer guide.
PRIMARY DRIVE GEAR
REMOVAL
Remove the oiI pump (page 4-3).
InstaII the cIutch outer to the mainshaft.
Mainshaft inspection
Measure the mainshaft O.D. at the cIutch outer guide area.
CLUTCH CENTER
SLOT
CLUTCH OUTER
9-9
WhiIe hoIding the primary drive gear with the gear hoIder,
remove the primary drive gear Iock nut.
Remove the gear hoIder, cIutch outer, and outer guide.
Remove the Iock washer.
Remove the oiI pump drive gear and primary drive gear.
InstaII the oiI pump drive gear.
NOTE:
AIign the oiI pump drive gear cutout with the crankshaft cut-
out whiIe instaIIing the drive gear.
INSTALLATION
InstaII the primary drive gear.
NOTE:
AIign the primary drive gear cutout with the crankshaft cut-
GEAR HOLDER
LOCK NUT
LOCK WASHER PRIMARY DRIVE GEAR
OIL PUMP DRIVE GEAR
ALIGN
PRIMARY DRIVE GEAR
ALIGN
OIL PUMP DRIVE GEAR
9-10
InstaII the Iock washer with the OUT SIDE mark facing out.
InstaII the cIutch outer guide and the cIutch outer.
PIace the gear hoIder between the primary drive gear and
driven gear to hoId the primary drive gear stiII.
AppIy oiI to the primary drive gear Iock nut threads and seat-
ing surface.
InstaII the primary drive gear Iock nut and tighten it to the
specified torque.
TOROUE: 9.0 kg-m
GEARSHIFT CAM
REMOVAL
Stopper arm
Washer
Spring
Remove the gear hoIder, cIutch outer and outer guide.
InstaII the oiI pump (page 4-7).
OUT SIDE MARK
WASHER
LOCK NUT
CLUTCH OUTER
GEAR HOLDER
CLUTCH OUTER
OIL PUMP
STOPPER ARM
BOLT WASHER]SPRING
9-11
Shift cam center boIt
Shift cam
DoweI pin
INSTALLATION
InstaII the doweI pin into the gearshift drum.
InstaII the gearshift cam aIigning the gearshift cam hoIe with
the doweI pin.
InstaII and secureIy tighten the gearshift cam center boIt.
CLUTCH INSTALLATION
AppIy moIybdenum soIution to the outer surface of the cIutch
outer guide.
InstaII the cIutch outer guide.
AppIy the Iocking agent to the gearshift drum stopper arm
boIt thread.
Tighten the gearshift drum stopper arm boIt to the specified
torque.
TOROUE: 1.2 kgm
InstaII the cIutch.
InstaII the right crankcase cover (page 9-14).
NOTE:
Be carefuI not to drop the O-ring of the oiI pump when instaII-
ing the right crankcase cover.
BOLT DOWEL PIN
SHIFT CAM
GEARSHIFT
CAM
ALIGN
BOLT
DOWEL PIN
STOPPER ARM
BOLT SPRING]WASHER
CLUTCH OUTER GUIDE
9-12
AIign the oiI pump drive gear teeth and the primary drive gear
teeth with the position mark on the crankcase as iIIustrated.
InstaII the cIutch outer.
InstaII the thrust washer.
AppIy engine oiI to the cIutch discs and the cIutch pIates.
InstaII the six friction discs and five cIutch pIates aIternateIy
to the cIutch center.
InstaII the pressure pIate to the cIutch center.
InstaII the pressure pIate, cIutch discs, cIutch pIates, and cIutch
center assembIed in the above step to the cIutch outer.
InstaII the washer.
AppIy engine oiI to the new cIutch center Iock nut threads
and seating surface and instaII it.
POSITION MARK
PRIMARY DRIVE GEAR
CLUTCH OUTER
OIL PUMP DRIVE GEAR
CLUTCH CENTER
THRUST WASHER
CLUTCH DISK
PRESSURE PLATE
CLUTCH PLATE
WASHER
LOCK NUT
9-13
HoId the cIutch center with the cIutch center hoIder.
Tighten the cIutch center Iock nut to the specified torque.
TOROUE: 11.0 kgm
Remove the cIutch center hoIder and cauIk the Iock nut.
NOTE:
Be carefuI not to damage the mainshaft when cauIking the
Iock nut.
InstaII the cIutch Iifter piece.
NOTE:
Make sure that the instaIIed Iifter piece rotates smoothIy.
InstaII the right crankcase cover.
NOTE:
Be carefuI not to drop the O-ring of the oiI pump when instaII-
ing the right crankcase cover.
CIutch spring
CIutch Iifter pIate
CIutch Iifter pIate boIts
NOTE:
Tighten the cIutch Iifter pIate boIts in a crisscross pattern in
two or more steps.
CLUTCH CENTER HOLDER
CAULK
BOLTS SPRINGS
LIFTER PLATE
LIFTER PIECE
9-14
RIGHT CRANKCASE COVER IN-
STALLATION
InstaII a new gasket and the doweI pin.
InstaII the right crankcase cover.
InstaII the right crankcase cover boIts and tighten them to the
specified torque.
TOROUE: 1.2 kgm
NOTE:
Tighten the boIts in a crisscross pattern in two or more
steps.
Be carefuI not to drop the O-ring of the oiI pump when
instaIIing the right crankcase cover.
InstaII the oiI pass pipe (page 4-9).
InstaII the starter motor (page 16-13).
InstaII the cIutch cabIe to the cIutch arm.
GASKET
DOWEL PIN
BOLTS
CLUTCH ARM
CLUTCH CABLE
OIL PASS PIPE
9-15
InstaII the return spring to the brake pedaI.
InstaII the rear master cyIinder protector pIate (page 13-28).
InstaII the oiI pipes (page 4-10).
InstaII the right step.
Tighten the right step boIt to the specified torque.
TOROUE: 4.3 kgm
InstaII the under guard (page 2-7).
FiII with engine oiI (page 3-14).
After compIeting the instaIIation, the foIIowing inspection and]
or adjustment are required.
CIutch Iever free pIay (page 3-22)
Brake pedaI height adjustment (page 3-21)
RIGHT STEP
PROTECTOR PLATE
RETURN SPRING
10-1
10. CRANKSHAFT]TRANSMISSION
SERVICE INFORMATION
This section describes the crankcase separation procedure for maintenance of crankshaft components.
Prior to proceeding to the crankcase separation procedure, the foIIowing components must be removed in accordance
with the steps specified in their corresponding sections.
OIL PUMP (Section 4)
CARBURETOR (Section 5)
ENGINE (Section 6)
CYLINDER HEAD (Section 7)
CYLINDER]PISTON (Section 8)
CLUTCH]GEARSHIFT LINKAGE (Section 9)
ALTERNATOR (Section 14)
When assembIing the crankcase and the crankshaft, the crankshaft needs to be puIIed in whiIe hoIding the inner race of
the crankshaft bearing with a speciaI tooI. In order to compIete this step, a new bearing must be instaIIed into the
crankcase after removing the oId bearing on the crankshaft when the crankcase is separated.
Assure that the instaIIed crankshaft moves smoothIy after the crankcase is assembIed.
SPECIFICATIONS
TROUBLESHOOTING 10-3
CRANKCASE SEPARATION 10-4
TRANSMISSION 10-6
10
CRANKSHAFT]BALANCER SHAFT 10-12
CRANKCASE BEARING
REPLACEMENT 10-15
CRANKCASE ASSEMBLY 10-20
ITEM
Unit: mm
Crankshaft
Transmission
0.050 0.065
0 0.008
20.000 20.021
23.000 23.021
23.000 23.021
25.020 25.041
25.000 25.021
22.000 22.021
18.000 18.018
22.000 22.021
22.959 22.980
24.979 25.000
24.959 24.980
22.959 22.980
19.959 19.980
17.966 17.984
21.959 21.980
21.959 21.980
0.02 0.062
0.02 0.062
0.80
0.05
0.05
20.08
23.07
23.07
25.09
25.07
22.07
18.08
22.1
22.90
24.9
24.90
22.92
19.91
17.91
21.91
21.91
0.10
0.10
Connecting
rod big end
Run out
Gear I.D.
Bushing I.D.
Bushing O.D.
M5
M6
C1
C2
C3
C4
C1
C2
C1
C2
C3
M6
side cIearance
radiaI cIearance
Mainshaft O.D. (M6)
Countershaft
O.D.
Gear-to-shaft
cIearance
C1
C2
C4
M6
C4
10-2
ITEM
Unit: mm
Transmission 0.020 0.062
0.020 0.062
0.02 0.062
0.02 0.062
0.016 0.052
0.02 0.062
13.000 13.021
12.966 12.984
4.930 5.000
4.900 5.000
19.959 19.980
0.10
0.10
0.10
0.10
0.10
0.10
13.05
12.91
4.50
4.50
19.90
Gear-to-
bushing
cIearance
Bush-to-shaft
cIearance
M6
C1
C2
C3
C1
C2
Shift fork I.D.
bearing portion
R., Center.
L.
Torque VaIues
Crankcase boIt 1.2 kgm
Bearing set pIate boIt 1.2 kgm AppIy Iocking agent to the boIt threads
SpeciaI TooIs
Bearing remover, 15 mm 07936-KC10000
Remover shaft, 15 mm 07936-KC10100
Remover head, 15 mm 07936-KC10200
SIiding weight 07741-0010201
Shaft compressor 07936-1660120
Remover head, 13 mm 07LMC-KZ10100
Crank case assembIy tooI 07965-VM00000
CoIIar 07965-VM00100
Shaft 07965-VM00200
Adaptor 07965-VM00300
UniversaI bearing puII er 07631-0010000
Driver handIe A 07749-0010000
Outer driver, 32 x 35 mm 07746-0010100
Outer driver, 37 x 40 mm 07746-0010200
Outer driver, 42 x 47 mm 07746-0010300
Outer driver, 52 x 55 mm 07746-0010400
Outer driver, 72 x 75 mm 07746-0010600
PiIot, 15 mm 07746-0040300
PiIot, 17 mm 07746-0040400
PiIot, 20 mm 07746-0040500
PiIot, 22 mm 07746-0041000
PiIot, 28 mm 07746-0041100
10-3
TROUBLESHOOTING
Noise
Worn and]or damaged connecting rod Iarge end bearing
Worn and]or damaged connecting rod smaII end
Bent connecting rod
Worn and]or damaged crankshaft bearing
10-4
CRANKCASE SEPARATION
Remove the engine from the frame (Section 6).
Remove the foIIowing components from the engine.
CyIinder head (Section 7)
CyIinder]Piston (Section 8)
Primary drive gear (Section 9)
Cam chain tensioner
Bearing set pIate
Cam chain drive sprocket
Cam chain
Stopper pin
BOLT
CAM CHAIN TENSIONER
SET PLATE
CAM CHAIN
SPROCKET
STOPPER PIN
10-5
Remove the crankcase breather tube.
Remove the right crankcase.
Remove the Ieft crankcase boIts.
NOTE:
Loosen the boIts in a crisscross pattern in two to three steps.
PIace the Ieft crankcase side down and separate the right
crankcase from the Ieft crankcase.
CAUTION:
NOTE:
If the crankcase does not separate easiIy, Iift the right crank-
case IittIe by IittIe whiIe gentIy tapping the crankcase bosses
and the mainshaft with a pIastic hammer.
Remove the gasket and doweI pins.
BOLT
BOLT
RIGHT CRANKCASE
DOWEL PINS
GASKET
10-6
TRANSMISSION
REMOVAL]DISASSEMBLY
Separate the crankcase (page 10-4).
Remove the gearshift spindIe whiIe puIIing the gearshift pIate
in the direction of the arrow shown.
Remove the foIIowing components.
Shift fork shaft
Remove the mainshaft and countershaft as an assembIy.
Shift fork
Shift drum
GEARSHIFT
SHIFT FORK SHAFT
SHIFT FORK
SHIFT DRUM
MAINSHAFT]COUNTERSHAFT ASSEMBLY
10-7
Measure the I.D. and O.D. of the gear bushings.
SERVICE LIMITS:
I.D.: C1 : 18.08 mm RepIace if 18.08 mm or greater
C2 : 22.1 mm RepIace if 22.1 mm or greater
O.D.: M6: 22.92 mm RepIace if 22.92 mm or greater
CaIcuIate the cIearances between the M6, C1, C2, and C3 gears
and their corresponding bushings.
SERVICE LIMITS: 0.10 mm RepIace if 0.10 mm or greater
Measure the I.D. of each gear.
SERVICE LIMITS:
M5 : 20.08 mm RepIace if 20.08 mm or greater
M6 : 23.07 mm RepIace if 23.07 mm or greater
INSPECTION
Inspect the mainshaft and countershaft.
Check and repIace if uneven wear or damage is detected on
the gear teeth, engagement dogs, shift fork grooves or inner
surfaces.
Check and repIace if uneven wear or damage is detected on
the mainshaft, countershaft gears, sIiding area of the bush-
ings or spIine.
Check and repIace if uneven wear or discoIoration (seizure) is
detected on the bushings or spIine bushings.
DisassembIe the mainshaft and countershaft.
MAINSHAFT
COUNTERSHAFT
MAINSHAFT
COUNTERSHAFT
10-8
Measure the O.D. of the mainshaft and countershaft.
SERVICE LIMITS:
A : M6 gear : 19.91 mm RepIace if 19.91 mm or Iess
B : C2 bushing : 21.91 mm RepIace if 21.91 mm or Iess
C : C4 gear : 21.91 mm RepIace if 21.91 mm or Iess
D : C1 bushing : 17.91 mm RepIace if 17.91 mm or Iess
CaIcuIate the cIearance between the M6 and C4 gears and the
shaft.
CaIcuIate the cIearance between the C1 and C2 bushings and
the shaft.
Inspect the shift fork and repIace if it is bent or damaged.
Measure the I.D. of the shift fork and the thickness of the
wedge-Iike portion.
SERVICE LIMIT:
I.D. : 13.05 mm RepIace if 13.05 mm or greater
Thickness of the operation area: 4.05 mm RepIace if 4.05
mm or Iess
Inspect the shift drum and repIace if damage or uneven wear
of the shift drum guide grooves is detected.
Measure the O.D. of the shift drum right crankcase bearing
surface.
Inspect the shift fork shaft and repIace if it is bent or dam-
aged.
Measure the O.D. of the shift fork shaft.
10-9
Remove the snap ring and return spring.
Inspect the gearshift pIate cIaw and repIace if it is bent, dam-
aged or worn.
Inspect the return spring and the reset spring and repIace if
damaged.
ASSEMBLY
NOTE:
When instaIIing the snap ring, aIign the snap ring end gap
with the shaft groove as iIIustrated.
AppIy a smaII amount of moIybdenum grease to the bush-
ings and the center hoIes of the gears.
MAINSHAFT
SNAP RING
RETURN SPRING
SHIFT PLATE RESET SPRING
SNAP RING
SHAFT
MAINSHAFT]M1 (13T)
M5 (26T)
M3 (21T)]M4 (24T)
SNAP RING
M6 (27T)
M6 BUSHING
SPLINE WASHER
SNAP RING
SPLINE WASHER
M2 (17T)
10-10
INSTALLATION
AppIy engine oiI to the foIIowing components:
Mainshaft
Countershaft
AII gears
Mainshaft bearing
Countershaft bearing
Shift drum bearing
NOTE:
When instaIIing the C4 gear, aIign the cut-outs of the C4
gear thrust washer with the Iock washer tabs.
InstaII the M6 and C3 bushings with their oiI hoIes aIigning
with the mainshaft oiI hoIes.
InstaII the mainshaft and countershaft assembIy into the Ieft
crankcase.
NOTE:
Be carefuI not to damage or turn over the countershaft oiI
seaI Iip when instaIIing the mainshaft and countershaft.
C1 (36T)
COUNTERSHAFT
C5 (24T)
SPLINE WASHER
C3 (29T)
C4 (26T)
COUNTERSHAFT
C2 (32T)
C2 BUSHING
C1 BUSHING
SNAP RING
C3 SPLINE BUSHING
LOCK WASHER
SPLINE WASHER
C6 (22T)
OIL HOLES
MAINSHAFT]COUNTERSHAFT ASSEMBLY
10-11
AppIy engine oiI to the foIIowing components and instaII:
Shift fork
Shift drum
NOTE:
Each shift fork has an identification mark R , C or L .
InstaII the shift forks in the correct position.
InstaII the shift forks with their identification mark facing
up (toward the right crankcase).
Return spring
Snap ring
Reset spring
Shift fork shaft
SHIFT FORK
IDENTIFICATION MARK
SHIFT FORK SHAFT
SNAP RING RETURN SPRINGS
RESET SPRING
10-12
InstaII the gearshift spindIe whiIe puIIing the gearshift pIate
in the direction of the arrow shown.
NOTE:
InstaII the gearshift spindIe with its return spring aIigning
with the pin boIt.
Check that the gearshift spindIe oiI seaI is not curIed or
damaged after instaIIation.
InstaII the right crankcase (page 10-20).
InstaII the shift cam, the stopper arm and the gearshift pedaI,
and check the transmission for smooth shifting.
CRANKSHAFT]BALANCER SHAFT
REMOVAL
Remove the transmission (page 10-6).
Remove the Ieft crankshaft bearing with a bearing puIIer if it
is Ieft on the crankshaft.
UniversaI bearing puII er 07631-0010000
CAUTION:
Remove the crankshaft and baIancer from the Ieft crankcase

with a hydrauIic press.
NOTE:
Be carefuI not to damage the crankcase mating surfaces.
GEARSHIFT SPINDLE
TRANSMISSION
BALANCER CRANKSHAFT
UNIVERSAL BEARING PULLER
10-13
CRANKSHAFT INSPECTION
HoId the crankshaft as iIIustrated and measure the runout at
Point A and B using a diaI gauge.
Measure the side cIearance of the connecting rod big end with
a thickness gauge.
BALANCER SHAFT INSPECTION
Check the baIancer shaft gear and repIace if it is worn or dam-
aged.
Measure the runout in both X and Y directions at right angIes
to the connecting rod big end axis.
10-14
BEARING INSPECTION
Turn the inner race of the bearings with your finger to check
that it moves smoothIy.
RepIace the bearing if it does not turn smoothIy or any Ioose-
ness or damage is detected on the outer race.
INSTALLATION
CIean the crankcase with cIeaning soIvent and check for cracks
or damage.
NOTE:
Remove any residuaI gasket materiaI from the crankcase and
crankcase cover mating surfaces. Remove scratches or rough-
ness using an oiIstone.
AppIy engine oiI to the crankshaft bearing, baIancer shaft bear-
ing, and the connecting rod big end.
InstaII the crankshaft and baIancer assembIy into the right
crankcase.
AIign the index mark on the crankshaft with that on the baI-
ancer shaft gear.
BALANCER SHAFT BEARI NG
CRANKSHAFT BEARING
CRANKSHAFT
ALIGN BALANCER SHAFT
BALANCER SHAFT CRANKSHAFT
10-15
InstaII the foIIowing speciaI toII on the crankshaft.
Thread adapter 07965-VM00300
PuII the crankshaft and baIancer shaft into the Ieft crankcase
using the foIIowing speciaI tooIs.
Crankcase assembIy tooI 07965-VM00000
Shaft 07965-VM00200
CoIIar 07965-VM00100
Remove the crankcase assembIy tooI and thread adapter.
CRANKCASE BEARING REPLACE-
MENT
Remove the transmission (page 10-6).
Remove the crankshaft and the baIancer shaft (page 10-12).
Make sure that the index mark on the crankshaft is aIigned
with that on the baIancer shaft.
THREAD ADAPTER
ASSEMBLY COLLAR
ASSEMBLY SHAFT
INDEX MARK
TRANSMISSION
CRANKSHAFT
BALANCER SHAFT
10-16
CRANKSHAFT BEARING
Remove the right crankshaft bearing from the right crankcase.
Drive new crankshaft bearings into both cases using the foI-
Iowing speciaI tooIs.
Outer driver, 72 x 75 mm 07746-0010600
PiIot, 28 mm 07746-0041100
NOTE:
Drive the bearings horizontaIIy.
Drive the marking side of the bearings.
TRANSMISSION BEARING
LEFT CRANKCASE BEARING REMOVAL
Remove the Ieft mainshaft bearing using the foIIowing spe-
ciaI tooIs.
Bearing remover, 15 mm 07936-KC10000
Remover head, 15 mm 07936-KC10200
Remover shaft, 15 mm 07936-KC10100
RIGHT CRANKSHAFT BEARING
DRIVER HANDLE A
OUTER DRIVER]PILOT
MAINSHAFT BEARING
COUNTERSHAFT
BEARING BALANCER SHAFT BEARI NG
BEARING REMOVER, 15 mm
10-17
Remove the Ieft baIancer shaft bearing using the foIIowing
speciaI tooIs.
Remove the snap ring and the countershaft oiI seaI.
Remove the Ieft countershaft bearing.
LEFT CRANKCASE BEARING INSTALLATION
NOTE:
InstaII the Ieft mainshaft bearing using the foIIowing speciaI
tooIs.
Outer driver, 32 x 35 mm 07746-0010100
PiIot, 15 mm 07746-0040300
BEARING REMOVER, 13 mm
SNAP RING
OIL SEAL
COUNTERSHAFT BEARI NG
DRIVER HANDLE A
OUTER DRIVE]PILOT
10-18
InstaII the Ieft baIancer shaft bearing using the foIIowing spe-
ciaI tooIs.
Outer driver, 37 x 40 mm 07746-0010200
InstaII the Ieft countershaft bearing using the foIIowing spe-
ciaI tooIs.
Outer driver, 52 x 55 mm 07746-0010400
PiIot, 22 mm 07746-0041000
InstaII the Ieft countershaft oiI seaI.
InstaII the snap ring.
DRIVER HANDLE A
OUTER DRIVER
DRIVER HANDLE A
OUTER DRIVER]PILOT
OIL SEAL
SNAP RING
10-19
RIGHT CRANKCASE BEARING REMOVAL
Remove the right mainshaft bearing and the right counter-
shaft bearing.
Remove the right baIancer shaft bearing using the foIIowing
speciaI tooIs.
RIGHT CRANKCASE BEARING INSTALLATION
NOTE:
InstaII the right baIancer shaft bearing using the foIIowing
speciaI tooIs.
Outer driver, 37 x 40 mm 07746-0010200
InstaII the right mainshaft bearing using the foIIowing speciaI
tooIs.
Outer driver, 42 x 47 mm 07746-0010300
PiIot, 20 mm 07746-0040500
MAINSHAFT BEARING
BALANCER SHAFT
BEARING
COUNTERSHAFT BEARI NG
REMOVER HEAD, 13 mm
DRIVER HANDLE A
OUTER DRIVER
DRIVER HANDLE A
OUTER DRIVER]PILOT
10-20
InstaII the right countershaft bearing using the foIIowing spe-
ciaI tooIs.
Outer driver, 42 x 47 mm 07746-0010300
PiIot, 17 mm 07746-0040400
CRANKCASE ASSEMBLY
InstaII the crankshaft (page 10-14).
InstaII the transmission (page 10-10).
DoweI pins
New gasket
Crankcase breather tube
Left crankcase boIts
TOROUE: 1.2 kgm
NOTE:
Tighten the boIts in a crisscross pattern in two to three steps.
Right crankcase
CAUTION:
DRIVER HANDLE A
OUTER DRIVER PILOT
DOWEL PIN
GASKET
RIGHT CRANKCASE
TUBE
BOLTS
10-21
Bearing set pIate
Cam chain tensioner
AppIy thread Iock agent to the bearing set pIate boIt and
tighten to the specified torque.
TOROUE: 1.2 kgm
CyIinder head (Section 7)
CyIinder]Piston (Section 8)
Primary drive gear (Section 9)
Cam chain
Cam chain drive sprocket
NOTE:
InstaII the drive sprocket by aIigning its cutout with the crank-
shaft cutout.
Stopper pin
Right crankcase boIts
TOROUE: 1.2 kgm
BOLT
STOPPER PIN
ALIGN
CAM CHAIN DRIVE SPROCKET CAM CHAIN
CAM CHAIN TENSIONER
BOLT
SET PLATE
11-1
11. FRONT WHEEL]SUSPENSION]STEERING
SERVICE INFORMATION
SecureIy support the engine using apparatus such as a jack during maintenance of the front wheeI or suspension.
Do not depress the brake Iever after a wheeI is removed and instaIIed.
Refer to Section 13 for maintenance and inspection of the brake system.
Refer to Section 17 for inspection of Iights, meters, and switches.
Do not step on the spokes or appIy unnecessary force to a wheeI. HandIe carefuIIy to avoid damaging a wheeI.
Use the speciaIIy designated tire Ievers and rim protectors for tire removaI and instaIIation in order to avoid damaging
the wheeI rim.
SPECIFICATIONS
HANDLEBAR 11-3
11
FRONT WHEEL 11-8
FORK 11-14
STEERING STEM 11-26
ITEM
Unit: mm
Front wheeI
2.0
2.0
1.50 kg]cm
2
1.50 kg]cm
2
1.50 kg]cm
2
72.9
363.1
477 cc
90
0.1 0.2 kg-m

0.2
3.0
72.2
359.5
0.2
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
A
i
r

p
r
e
s
s
u
r
e
One
passenger
Two
passengers
Street
Highway
Street
Fork Spring free
Iength
OiI capacity
OiI IeveI
OiI type
Tube runout
A
B
11-2
Torque VaIues
Steering stem nut 10.0 kgm
Steering top thread 0.45 kgm
Spoke nippIe 0.25 0.5 kgm
Front brake disc boIt 2.0 kgm AIok boIt
Front axIe 7.5 kgm
Front axIe hoIder nut 0.45 kgm
Fork cIamp boIt (upper) 0.25 0.5 kgm
(Iower) 2.7 kgm
Fork center boIt 5.5 kgm AppIy Iocking agent to the boIt threads
Fork boIt 3.0 kgm
Front caIiper bracket boIt 3.0 kgm AppIy Iocking agent to the boIt threads
SpeciaI TooI
Steering stem socket 07916-KA50100
Steering stem driver 07946-4300101
OiI seaI remover 07948-4630100
Fork damper hoIder 07PMB-KZ40101
Fork seaI driver 07947-KA50100
Fork seaI driver attachment 07947-KF00100
Bearing remover shaft 07746-0050100
Bearing remover head, 15mm 07746-0050400
Outer driver, 32 x 35 mm 07746-0010100
PiIot, 15 mm 07746-0040300
Outer driver, 42 x 47 mm 07746-0010300
TROUBLESHOOTING
Hard steering
ExcessiveIy tightened steering top thread
Worn and]or damaged steering head bearing
Worn tire
Insufficient tire pressure
Bent forks
Bent frame
Steers to one side or does not track straight
Bent forks
Damaged steering head bearing or insufficient tightening
Uneven cushioning between Ieft and right
Bent frame
Worn or sIanted tire
Loose wheeI bearings
Bent front axIe
Front wheeI wobbIing
Distorted wheeI rim
Damaged wheeI bearing
FauIty tire
Soft front suspension
Weak cushion springs
Hard front suspension
ExcessiveIy high tire pressure
Front suspension noise
Protruding cushion case
Loose front suspension fasteners
Hesitant wheeI rotation
FauIty wheeI bearing
Bent wheeI axIe
Brake dragging (page 13-3)
FauIty speedometer gearbox
11-3
HANDLEBAR
REMOVAL
Remove the wire band and the rear view mirror.
Remove the front master cyIinder (page 13-12).
NOTE:
Keep the removed front master cyIinder in a horizontaI posi-
tion in order to prevent air entering the brake system.
XR250
Remove the headIight unit (page 17-11).
XR BAJA
Remove the right headIight unit (page 17-8).
Right handIe switch 9P (RED) coupIer (page 17-20)
Left handIe switch 9P (BLACK) coupIer (page 17-20)
Left handIe switch connector (page 17-20)
Screw
ThrottIe housing cover
ThrottIe cabIe guide
ThrottIe cabIe
ThrottIe housing
ThrottIe grip
WIRE BAND
REAR VIEW MIRROR
SCREW
THROTTLE CABLE
THROTTLE GRIP
CABLE GUIDE HOUSING
RIGHT HEADLIGHT UNI T
COVER
11-4
Screw
Right handIe switch
CIutch switch connector
BoIts
CIutch Iever bracket hoIder
CIutch Iever bracket
Screw
Left handIe switch
HandIe grip
RIGHT HANDLE SWI TCH
SCREW
BRACKET
CONNECTOR
LEFT HANDLE SWI TCH
HOLDER
BOLT
SCREW
HANDLE GRIP
11-5
Remove the handIe bar hoIder boIts.
Remove the handIe bar hoIder and handIe bar.
INSTALLATION
InstaII the handIebar.
InstaII the handIebar hoIder and secureIy tighten the front
handIebar hoIder boIts first and then the rear boIts.
NOTE:
AIign the punch mark on the handIebar with the hoIder
mating surface.
InstaII the hoIder with the punch mark facing forward.
Remove any dirt and grease from the handIe grip adhering
surfaces and compIeteIy dry the grip.
AppIy a thin coat of HONDA Bond A or CEMEDINE #540 to
the adhering surface of the grip. ImmediateIy instaII the grip
on the handIebar by rotating it before the appIied adhesive
dries.
NOTE:
Leave the instaIIed handIe grip for severaI hours untiI the ad-
hesive dries.
InstaII the Ieft handIe switch with its tab aIigned with the hoIe
on the handIebar.
HANDLEBAR BOLT
HOLDERS
HANDLEBAR BOLTS
HOLDER
PUNCH MARK
ALIGN
HANDLE GRIP
HOLE LEFT HANDLE SWI TCH
TAB
11-6
Tighten the front screw first and then the rear screw.
InstaII the cIutch Iever bracket.
InstaII the cIutch Iever bracket hoIder and tighten the boIt.
NOTE:
AIign the cIutch Iever bracket hoIder mating surface with the
punch mark on the handIebar.
InstaII the right handIe switch with its tab aIigned with the
hoIe on the handIebar.
Connect the cIutch switch connector.
SCREWS
BRACKET ALIGN
HOLDER BOLT
CONNECTOR
RIGHT HANDLE SWI TCH HOLE
TAB
11-7
InstaII the front master cyIinder (page 13-18).
InstaII the wire band and rear view mirror.
NOTE:
Route cabIes, wires, and harnesses correctIy as shown in
CABLE AND HARNESS ROUTING (page 1-19).
InstaII the throttIe housing cover and tighten the screw.
NOTE:
AIign the throttIe housing mating surface with the punch mark
on the handIebar.
AppIy grease to the inner surface of the throttIe grip and in-
staII the grip to the handIebar.
AppIy grease to the throttIe cabIe end and connect the throttIe
cabIe to the throttIe grip.
InstaII the throttIe housing.
AppIy grease to the throttIe cabIe sIiding portion and instaII
the throttIe cabIe guide.
Tighten the front screw first and then the rear screw.
SCREWS
THROTTLE GRIP
THROTTLE CABLE
THROTTLE HOUSING
CABLE GUIDE
SCREW ALIGN
COVER
WIRE BAND
REAR VIEW MIRROR
11-8
Connect the right handIe switch 9P (RED) coupIer, the Ieft
handIe switch 9P (BLACK) coupIer and the connector (page
17-20).
XR250
InstaII the headIight unit (page 17-11).
XR BAJA
InstaII the right headIight unit (page 17-8).
FRONT WHEEL
REMOVAL
Remove the screw and disconnect the speedometer cabIe.
Loosen the front axIe hoIder nuts.
Loosen the front axIe.
NOTE:
Just Ioosen the front axIe hoIder nuts.
AXLE RUNOUT INSPECTION
Set the front axIe shaft on V bIocks and measure the runout
with a diaI gauge.
The actuaI runout is 1]2 of the indicator reading.
Raise the front wheeI off the ground by secureIy Iifting the
engine.
Remove the front axIe and front wheeI.
NOTE:
Do not depress the brake Iever after the front wheeI is re-
moved.
SPEEDOMETER CABLE SCREW
FRONT AXLE NUT
FRONT WHEEL
AXLE SHAFT
FRONT AXLE
11-9
WHEEL RIM INSPECTION
SIowIy spin the wheeI and check the wheeI rim for runout
using a diaI gauge.
SERVICE LIMITS: RadiaI: 2.0 mm
AxiaI: 2.0mm
RepIace the wheeI rim if any IocaI distortion is observed.
Check that the spokes are not Ioose, bent or damaged.
WHEEL BEARING INSPECTION
Turn the inner race of the bearing with your finger to check
that it moves smoothIy. RepIace the bearing if it does not move
smoothIy or the outer race or hub of the bearing is Ioose or
damaged.
NOTE:
RepIace the wheeI bearings in pairs.
DISASSEMBLY
Speedometer gearbox
Left wheeI coIIar
WHEEL BEARING
SPEEDOMETER GEARBOX
LEFT WHEEL COLLAR
11-10
Front brake disc
Hub cover
Left dust seaI
Right dust seaI
Speedometer gear retainer
Remove the bearing and distance coIIar using the foIIowing
speciaI tooIs.
Bearing remover head, 15 mm 07746-0050400
BRAKE DISC
BOLT HUB COVER
DUST SEAL
DUST SEAL
GEAR RETAINER
REMOVER HEAD, 15 mm
REMOVER SHAFT
11-11
ASSEMBLY
AppIy grease to the wheeI bearings.
Drive the right wheeI bearing into the wheeI using the foIIow-
ing speciaI tooIs.
Outer driver, 32 x 35 mm 07746-0010100
PiIot, 15 mm 07746-0040300
NOTE:
InstaII the bearing with its seaIed side facing out.
Do not tiIt the bearing whiIe driving it into the wheeI.
RIGHT DUST SEAL
SPEEDOMETER
GEAR RETAINER
RIGHT WHEEL
BEARING
DISTANCE COLLAR
LEFT WHEEL BEARING
HUB COVER
BRAKE DISK
LEFT DUST
SEAL
BRAKE DISK BOLT
2.0 kgm
BRAKE DISK
BRAKE DISK BOLT 2.0 kgm
LEFT DUST SEAL
LEFT WHEEL BEARING
RIGHT WHEEL BEARING
RIGHT DUST SEAL
SPEEDOMETER GEAR RETAINER
DISTANCE COLLAR
DRIVER HANDLE A
OUTER DRIVER]PILOT
11-12
InstaII the distance coIIar.
Drive the Ieft wheeI bearing into the wheeI using the foIIow-
ing speciaI tooIs.
Outer driver, 32 x 35 mm 07746-0010100
PiIot, 15 mm 07746-0040300
AppIy grease to the speedometer gear retainer.
InstaII the speedometer gear retainer into the wheeI, aIigning
the retainer tabs with the wheeI hub sIots.
AppIy grease to the right dust seaI Iip and instaII it to the wheeI.
AppIy grease to the Ieft dust seaI Iip.
InstaII the Ieft dust seaI and hub cover.
DRIVER HANDLE A
OUTER DRIVER]PILOT
GEAR RETAINER
ALIGN
DUST SEAL
HUB COVER
DUST SEAL
11-13
InstaII the front brake disc.
NOTE:
InstaII the brake disc with the DRIVE mark facing out.
InstaII and tighten the new brake disc boIts to the specified
torque.
TOROUE: 2.0 kgm
InstaII the Ieft wheeI coIIar.
AppIy grease to the speedometer gearbox tangs and retainer
tangs.
InstaII the speedometer gearbox into the wheeI hub, aIigning
the gearbox tangs with the retainer tangs.
INSTALLATION
InstaII the front wheeI.
NOTE:
PIace the brake disc between the brake pads, and instaII
the front wheeI.
If the axIe hoIder is removed, reinstaII it with the mark
facing upwards.
InstaII the front axIe.
Make sure that the speedometer gearbox boss is aIigned with
the right front fork stopper.
BRAKE DISK
BOLTS DRIVE MARK
WHEEL COLLAR
GEARBOX
TANG
ALIGN
ALIGN
MARK FRONT AXLE
11-14
Tighten the front axIe to the specified torque.
TOROUE: 7.5 kgm
Remove the support under the engine. With the front brake
appIied, pump the front forks up and down severaI times and
make sure that the front axIe is secureIy seated on the axIe
hoIder.
Tighten the axIe hoIder nuts by tightening the upper nuts first,
then the Iower nuts.
TOROUE: 1.2 kgm
Connect the speedometer cabIe and secureIy tighten the
screw.
FORK
REMOVAL
Front wheeI (page 11-8)
Brake hose cIamp (Ieft side)
Front brake caIiper (Ieft side) (page 13-8)
NOTE:
Do not hang the caIipers by the brake hose.
If the brake hose is disconnected, air must be compIeteIy
bIed from the brake system after the fork instaIIation.
Screw (right side)
Speedometer cabIe cIamp (right side)
SPEEDOMETER CABLE SCREW
NUTS
CLAMP
CALIPER
SCREW
CLAMP
11-15
Loosen the upper bridge pinch boIts.
NOTE:
In order to more easiIy disassembIe the fork Ieg, Ioosen
the upper bridge pinch boIt first, then the fork boIts.
If the fork Ieg is to be disassembIed, Ioosen the upper fork
boot screw.
Loosen the Iower bridge pinch boIts and remove the fork.
DISASSEMBLY
Loosen the Iower fork boot screw.
Remove the fork boot and fork boot guide.
Remove the fork boIt from the fork tube.
Remove the fork boIt from the piston rod whiIe hoIding the
Iock nut on and between the fork spring.
Remove the spring seat A and spring A.
Remove the spring seat B and spring B.
BOLTS (UPPER)
FORK BOLTS (LOWER)
BOOT
BOOT GUIDE SCREW
FORK BOLT
FORK BOLT
SEAT A
SPRING A
SEAT B
LOCK NUT
SPRING B
11-16
Empty the fork oiI from the fork by pumping the fork 8 10
times.
Empty the fork oiI from the fork cyIinder by pumping the pis-
ton rod 8 10 times.
Remove the fork damper assembIy and the oiI Iock piece from
the fork assembIy.
Cover the bottom case caIiper bracket with a shop toweI and
hoId it in a vise.
CAUTION:
HoId the fork damper using the foIIowing speciaI tooI.
Loosen the fork center boIt and remove the center boIt and
the seaIing washer.
FORK
PISTON ROD
FORK DAMPER HOLDER
FORK DAMPER ASSEMBLY
OIL LOCK PIECE
CENTER BOLT]SEALING WASHER
11-17
In quick successive back and forth motions, puII the fork tube
out of the bottom case.
Remove the stopper ring from the bottom case groove.
CAUTION:
Remove the piston rod and spring from the fork damper.
Remove the Iock nut from the piston rod.
LOCK NUT
PISTON ROD
PISTON ROD
FORK DAMPER
SPRING
STOPPER RING
11-18
Dust seaI
OiI seaI
Back-up ring
Guide bushing
Remove the fork tube bushing by prying the sIot of the bush-
ing using a fIat-head screwdriver.
NOTE:
Do not remove the fork tube bushing unIess it is to be re-
pIaced.
Be carefuI not to damage the TefIon coating.
Do not open the sIot of the bushing more than necessary.
Set the fork tube in V bIocks and measure the runout with a
diaI gauge.
INSPECTION
Fork tube]Bottom case
Check the fork tube and repIace if it is damaged.
Check the outside and inside of the bottom case for deforma-
tion or damage and repIace if necessary.
DUST SEAL
BACK-UP RING
OIL SEAL
GUIDE BUSHING
TUBE BUSHING
BOTTOM CASE
FORK TUBE
11-19
Fork spring
Measure the fork spring free Iength.
SERVICE LIMIT: A: 72.2 mm RepIace if 72.2 mm or Iess
B: 359.5 mm RepIace if 359.5 mm or Iess
Fork damper]Piston rod]Spring
Check the fork damper piston ring for wear or damage and
repIace if necessary.
Check the ring and vaIve of the piston rod for damage.
Check the oiI Iock vaIve for wear or damage.
RepIace the piston rod assembIy if there is abnormaI wear or
damage.
Fork center boIt
Check the O-ring of the fork center boIt for degradation or
damage and repIace if necessary.
PISTON RING
RING
VALVE
O-RING
11-20
Fork tube bushing]Guide bushing
VisuaIIy inspect the sIiding surfaces of the fork tube bushing
and the guide bushing.
If the TefIon coating is worn out and any copper (goId) part
appears on the sIiding surfaces, or excessive scratches are
observed, repIace the bushing.
Check the inspection points on the back-up ring for deforma-
tion and repIace if necessary.
Remove any metaI particIes from the fork tube bushing and
guide bushing using a nyIon brush and fork oiI.
ASSEMBLY
NOTE:
Degrease and cIean the disassembIed parts thoroughIy be-
fore assembIy.
InstaII a new fork tube bushing.
NOTE:
Make sure that the sIot of the fork tube bushing has no
remaining burr.
Remove any remaining burr from the bushing using a knife
whiIe being carefuI not to damage the TefIon coating.
BUSHING
BACK-UP RING
SLIDING SURFACES
INSPECTION POINTS
FORK BOLT 3.0 kgm LOCK NUT
SPRING
SPRING SEAT A
SPRING A
SPRING SEAT B
SPRING B
FORK TUBE
FORK DAMPER
OIL LOCK PIECE
PISTON ROD
BOOT
BOTTOM
CASE
BOOT GUIDE
STOPPER RING
OIL SEAL
GUIDE BUSH
BACK-UP RING
DUST SEAL
SEALING WASHER
FORK TUBE BUSHING
FORK TUBE BUSHING
CENTER BOLT 5.5 kgm
11-21
CAUTION:
Guide bushing
Back-up ring
OiI seaI
Dust seaI
NOTE:
InstaII the oiI seaI with its marked side facing the dust seaI.
InstaII the piston rod and spring on the fork damper.
Coat the fork tube bushing and guide bushing with the rec-
ommended fork oiI and instaII the fork tube into the bottom
case.
Drive in the dust seaI to just under the edge of the stopper
ring groove using the foIIowing speciaI tooIs.
FORK SEAL DRIVER 07947-KA50100
FORK SEAL DRIVER ATTACHMENT 07497-KF00100
InstaII the stopper ring.
DUST SEAL
BACK-UP RING
OIL SEAL
GUIDE BUSHING
FORK SEAL
DRIVER
STOPPER RING
ATTACHMENT
SPRING
FORK DAMPER
PISTON ROD
DUST SEAL
STOPPER
RING
OIL SEAL
BACK-UP
RING
GUIDE
BUSHING
11-22
InstaII the Iock nut onto the piston rod.
InstaII the fork damper assembIy and oiI Iock piece into the
fork assembIy.
Cover the bottom case caIiper bracket with a shop toweI and
hoId it in a vise.
CAUTION:
RepIace the seaIing washer with a new one.
AppIy Iocking agent to the fork center boIt threads and tighten
the boIt to the specified torque.
TOROUE: 5.5 kgm
Compress the piston rod aII the way and pour the recom-
mended fork oiI into the piston rod untiI the oiI fIows out of
the damper rod end.
Pour the remaining amount of the recommended fork oiI into
the fork. Pump the fork tube and piston rod sIowIy 8 10 times
to bIeed air from the fork.
Pump the fork tube and piston rod sIowIy 8 10 times again
and Ieave it for 5 minutes.
LOCK NUT
PISTON ROD
FORK DAMPER ASSEMBLY
OIL LOCK PIECE
FORK DAMPER HOLDER
SEALING WASHER CENTER BOLT
FORK TUBE
PISTON ROD
11-23
Check the fork oiI IeveI once the oiI IeveI has settIed.
RECOMMENDED OIL: Honda UItra Cushion oiI #5
OIL CAPACITY: 477 cc
OIL LEVEL: 90 mm
NOTE:
Compress the fork aII the way when measuring the fork oiI
IeveI.
Compress the piston rod aII the way, position the fork ver-
ticaIIy, and check the fork oiI IeveI.
Attach a wire more than 60 mm Iong under the Iock nut to
puII up the piston rod.
InstaII fork spring B.
SIowIy puII the piston rod up by puIIing the attached wire
upward.
InstaII the spring seat B, fork spring A and spring seat A.
Remove the attached wire and manuaIIy tighten the Iock nut
untiI it makes contact with the end.
WIRE
LOCK NUT
SPRING B
SEAT A
SPRING A
LOCK NUT
SEAT B
OIL LEVEL
11-24
RepIace the fork boIt O-ring with a new one and appIy the
recommended fork oiI to the O-ring.
HoId the Iock nut and tighten the fork boIt to the piston rod
untiI it makes contact with the Iock nut.
HoId the Iock nut and tighten the fork boIt to the specified
torque.
TOROUE: 1.5 kg-m
InstaII the fork boIt into the fork tube.
InstaII the fork boot guide.
InstaII the fork boot with the breather hoIes facing down.
Attach the fork boot to the boot guide with the fork boot hoIes
facing out.
SecureIy tighten the Iower fork boot screw.
BOLT
O-RING
LOCK NUT
FORK BOLT
HOLES
BOOT
BOOT
HOLES
SCREW
BOOT GUIDE
11-25
INSTALLATION
InstaII the fork and tighten the Iower bridge pinch boIts to the
specified torque.
TOROUE: 2.7 kgm
If the fork has been disassembIed and reassembIed, tighten
the fork boIt to the specified torque.
TOROUE: 3.0 kgm
Tighten the upper bridge pinch boIts to the specified torque.
TOROUE: 3.2 kgm
PuII up the fork boot untiI it makes contact with the bottom
bridge and secureIy tighten the upper fork boot screw.
Screw (right side)
Speedometer cabIe cIamp (right side)
Brake hose cIamp (Ieft side)
BOLTS (LOWER) FORK
SCREW
SCREW
CABLE CLAMP
SCREW
CALIPERS
BOLTS (UPPER)
11-26
STEERING STEM
REMOVAL
HandIebar (page 11-3)
Front fender (page 2-2)
BoIts
Speedometer cabIe
Speed sensor
Upper and Iower bridge pinch boIts
Brake hose guide (Ieft side)
Steering top thread
Steering stem nut
Washer
Fork (page 11-14)
Top bridge
BOLTS
SPEED
SENSOR
SPEEDOMETER CABLE
HOSE GUIDE
BOLTS
FORK STEM NUT]WASHER
TOP BRIDGE
TOP THREAD
11-27
InstaII the upper and Iower outer races of the steering head
using the foIIowing speciaI tooIs.
Outer driver, 42 x 47 mm 07746-0010300
STEERING HEAD BEARING REPLACEMENT
NOTE:
AIways repIace the bearings and bearing outer races as a
set.
Remove the upper and Iower races of the steering head
using the foIIowing speciaI tooI.
Remove the steering stem.
RepIace the upper bearing if damaged.
RepIace the bearing outer race of the steering head pipe if
damaged.
Upper dust seaI
Upper bearing
RepIace the upper bearing if damaged.
DUST SEAL
UPPER BEARING
UPPER BEARING
STEERING STEM
OIL SEAL REMOVER
DRIVER HANDLE A
OUTER DRIVER
11-28
Remove the Iower bearing and dust seaI using a tooI such as
a chiseI.
CAUTION:
Press a new dust seaI, the Iower bearing inner race and Iower
bearing into the steering stem.
INSTALLATION
LOWER BEARING]DUST SEAL
STEM NUT
STEERING
STEM DRIVER
STEERING STEM
UPPER OUTER RACE
STEERING TOP THREAD
DUST SEAL
UPPER BEARING
LOWER OUTER RACE
LOWER BEARING
DUST SEAL
11-29
AppIy grease to the upper and Iower bearings.
Steering stem
Upper bearing
Dust seaI
Steering top thread
TOROUE: 0.45 kgm
Turn the stem Iock-to-Iock at Ieast five times to seat the bear-
ings and tighten the steering top thread again to the specified
torque.
TOROUE: 0.45 kgm
Top bridge
Fork (page 11-25)
Washer
Steering stem nut
TOROUE: 10.0 kgm
DUST SEAL
UPPER BEARING STEERING STEM
STEERING STEM SOCKET
TOP THREAD
FORK STEM NUT]WASHER
TOP BRIDGE
11-30
Brake hose guide (Ieft side)
TOROUE: UPPER : 3.2 kgm
LOWER : 2.7 kgm
Speed sensor
Speedometer cabIe
BoIts
HOSE GUIDE
BOLTS
BOLTS
SPEED SENSOR
SPEEDOMETER CABLE
12-1
12. REAR WHEEL]SUSPENSION
SERVICE INFORMATION
SecureIy support the engine using apparatus such as a jack during maintenance of the rear wheeI or suspension.
Do not depress the brake Iever after a wheeI is removed and instaIIed.
Refer to Section 13 for maintenance and inspection of the brake system.
Do not step on the spokes or appIy unnecessary force to a wheeI. HandIe carefuIIy to avoid damaging a wheeI.
Use the speciaIIy designated tire Ievers and rim protectors for tire removaI and instaIIation in order to avoid damaging
the wheeI rim.
SPECIFICATIONS
REAR WHEEL 12-3
12
REAR CUSHION 12-9
CUSHION LINKAGE 12-13
SWINGARM 12-17
ITEM
Unit: mm
Rear wheeI
2.0
2.0
1.50 kg]cm
2
1.50 kg]cm
2
1.50 kg]cm
2
30 40
520MOZ9]102LE
520VC5]102LE
181 7.5 kg when compressed to 10 mm

Ioosen it back untiI 9 - 12 cIicks are
the matching notch.
Ioosen it back untiI 8 - 11 cIicks are
the matching notch.
0.2
3.0
10
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
A
i
r

p
r
e
s
s
u
r
e
One
passenger
Two
passengers
Street
Highway
Street
RepIacement
chain]Iink
Rear damper compression pressure
RK
DID
Rear
position
position
12-2
Torque VaIues
Driven sprocket nut 3.3 kgm
Rear brake disc boIt 4.3 kgm AIok BoIt
Rear axIe nut 9.5 kgm
Spoke nippIe 0.25 0.5 kgm
Rear brake hose guide screw 0.43 kgm AppIy Iocking agent to the threads
Rear cushion boIt (upper) 4.5 kgm
(Iower) 4.5 kgm
Cushion connecting rod nut (on cushion arm side) 5.0 kgm AppIy grease to the threads and seating surface
(on frame side) 4.5 kgm
Cushion arm nut (on swingarm side) 7.0 kgm
Swingarm pivot nut 9.0 kgm
Chain cover boIt 1.2 kgm
SpeciaI TooI
NeedIe bearing remover 07931-MA70000
NeedIe bearing remover 07946-KA50000
Bush driver pin 07GMD-KT80100
SphericaI bearing driver 07HMF-KS60100
Retainer wrench B 07710-0010200
Retainer wrench body 07710-0010401
Outer driver, 24 x 26 mm 07746-0010700
Outer driver, 37 x 40 mm 07746-0010200
Outer driver, 42 x 47 mm 07746-0010300
PiIot, 17 mm 07746-0040400
TROUBLESHOOTING
Rear wheeI vibration
Distorted wheeI rim
Damaged wheeI bearings
FauIty tire
FaiIure or Iack of Iubrication on pivots or sIiding surfaces
InsufficientIy tightened rear axIe
Low tire pressure
Hesitant wheeI rotation
FauIty wheeI bearing
Bent rear axIe
Brake dragging (page 13-3)
Soft rear suspension
Weak cushion springs
FauIty rear cushion damper
Hard rear suspension
Distorted rear cushion damper rod
ExcessiveIy high tire pressure
FaiIure or Iack of Iubrication on pivots or sIiding sur-
faces
Rear suspension noise
Protruding rear cushion
Loose rear suspension fasteners
12-3
REAR WHEEL
REMOVAL
Raise the rear wheeI off the ground by secureIy Iifting the
engine.
Loosen the rear axIe nut and fuIIy sIacken the adjuster pIate.
Remove the stopper pIate from the stopper pin.
Move the rear wheeI forward for maximum drive chain sIack.
Remove the drive chain from the driven sprocket.
PuII the rear wheeI back untiI it reaches the swingarm tab.
Remove the rear brake caIiper.
NOTE:
moved.
Do not hang the brake caIipers by the brake hose.
Remove the rear wheeI.
To disassembIe the rear wheeI, remove the foIIowing compo-
nents:
AxIe nut
Washer
Adjuster pIate
Stopper pIate
AxIe shaft
AXLE RUNOUT INSPECTION
Set the rear axIe shaft on V bIocks and measure the runout
with a diaI gauge.
AXLE NUT STOPPER PLATE
ADJUSTER PLATE STOPPER PIN
DRIVE CHAIN
REAR WHEEL CALIPER
TAB
12-4
WHEEL RIM INSPECTION
SIowIy spin the wheeI and check the wheeI rim for runout
using a diaI gauge.
SERVICE LIMITS: RadiaI: 2.0 mm RepIace if 2.0 mm or
greater
AxiaI : 2.0mm RepIace if 2.0 mm or
greater
RepIace the wheeI rim if any IocaI distortion is observed.
Check that the spokes are not Ioose, bend or damaged.
WHEEL BEARING INSPECTION
Turn the inner race of the bearing with your finger to check
that it moves smoothIy. RepIace the bearing if it does not move
smoothIy or the outer race or hub of the bearing is Ioose or
damaged.
NOTE:
RepIace the wheeI bearings in pairs.
DISASSEMBLY
Right wheeI coIIar
Left wheeI coIIar
WHEEL BEARING
RIGHT WHEEL COLLAR
LEFT WHEEL COLLAR
12-5
Rear brake disc boIts
Rear brake disc
Right dust seaI
Driven sprocket boIts]nuts
Washers
Driven sprocket
Left dust seaI
BOLTS
BRAKE DISC
DUST SEAL
BOLTS]NUTS]WASHERS
DRIVEN SPROCKET
DUST SEAL
12-6
speciaI tooIs.
ASSEMBLY
REMOVER SHAFT
REMOVER HEAD
LEFT WHEEL BEARING
DRIVEN SPROCKET
DISTANCE COLLAR
RIGHT WHEEL BEARING
LEFT DUST SEAL
DRIVEN SPROCKET BOLT
BRAKE DISK
DRIVEN SPROCKET NUT 3.3 kgm
DRIVEN SPROCKET
RIGHT DUST SEAL
DRIVEN SPROCKET BOLTS]NUTS
BRAKE DISK BOLT
4.3 kgm
BRAKE DISK
LEFT WHEEL
BEARING
LEFT DUST SEAL
DISTANCE COLLAR
BRAKE DISK BOLT
4.3 kgm
RIGHT WHEEL BEARING
RIGHT DUST SEAL
3.3 kgm
12-7
AppIy grease to the wheeI bearings.
ing speciaI tooIs.
Outer driver, 42 x 47 mm 07746-0010300
PiIot, 17 mm 07746-0040400
NOTE:
ing speciaI tooIs.
Outer driver, 37 x 40 mm 07746-0010200
PiIot, 17 mm 07746-0040400
AppIy grease to the Ieft dust seaI Iip.
InstaII the Ieft dust seaI.
InstaII the driven sprocket.
InstaII the driven sprocket boIts.
InstaII the sprocket washers and nuts and tighten the nuts to
the specified torque.
TOROUE: 3.3 kgm
DRIVER HANDLE A
OUTER DRIVER]PILOT
DRIVER HANDLE A
OUTER DRIVER]PILOT
DUST SEAL
BOLTS]NUTS
DRIVEN SPROCKET
12-8
AppIy grease to the right dust seaI Iip.
InstaII the right dust seaI.
InstaII the rear brake disc.
NOTE:
torque.
TOROUE: 4.3 kgm
InstaII the right wheeI coIIar.
DUST SEAL
BOLTS
DRIVE MARK
BRAKE DISC
LEFT WHEEL COLLAR
RIGHT WHEEL COLLAR
12-9
INSTALLATION
If the rear wheeI was disassembIed, instaII the foIIowing com-
ponents.
AxIe nut
Washer
Right adjuster pIate
Stopper pIate
AxIe shaft
InstaII the rear wheeI on the swingarm tab.
InstaII the rear caIiper to the axIe shaft and aIign the bracket
with the sIide raiI on the sIiding arm.
InstaII the drive chain to the driven sprocket.
Move the rear wheeI forward and instaII the stopper pIate
over the stopper pin.
Adjust the drive chain sIack (page 3-17).
Tighten the rear axIe nut to the specified torque.
TOROUE: 9.5 kgm
REAR CUSHION
REMOVAL
Remove the air cIeaner case (page 5-19).
engine.
Cushion arm boIt]nut (on swingarm side)
Cushion connecting rod boIt]nut (on cushion arm side)
NUT]WASHER ADJUSTER PLATE
TAB STOPPER PLATE
DRIVE CHAIN
DRIVEN SPROCKET
STOPPER PLATE
NUT STOPPER PIN
CUSHION ARM BOLT]NUT (SWINGARM SIDE)
CUSHION CONNECTING ROD
BOLT]NUT (CUSHION ARM SIDE)
12-10
Rear cushion boIt]nut (upper)
Rear cushion]cushion arm
Rear cushion boIt]nut (Iower)
Cushion arm
Rear cushion
INSPECTION
Check the damper case for deformation, oiI Ieaks, or a bent
rod, and repIace if necessary.
Check the damper unit for deterioration or damage and re-
pIace if necessary.
Make sure that the damper unit operates smoothIy.
DAMPER UNIT DEGASSING
FoIIow the precautions beIow since the damper unit contains
highIy pressurized nitrogen gas.
Remove the vaIve cap and push the vaIve core to reIease the
gas.
Remove the vaIve core after the gas has been compIeteIy re-
Ieased and dispose of the unit.
BOLT]NUT (UPPER)
REAR CUSHION]CUSHION ARM
BOLT]NUT (LOWER) CUSHION ARM
REAR CUSHION
VALVE CAP
12-11
SPHERICAL BEARING REPLACEMENT
Remove the coIIar and dust seaI.
Remove the stopper ring.
COLLAR
Remove the sphericaI ring using the foIIowing speciaI tooI
and a hydrauIic press.
AppIy grease to a new sphericaI bearing.
SecureIy instaII the stopper ring into the ring groove.
Press the sphericaI ring untiI it reaches the stopper ring using
the foIIowing speciaI tooI and a hydrauIic press.
DUST SEAL
STOPPER RING
SPHERICAL BEARING DRIVER
SPHERICAL BEARING
DRIVER
SPHERICAL BEARING
COLLAR
STOPPER RING
12-12
AppIy grease to a new dust seaI and instaII it to the damper
unit.
NOTE:
InstaII the dust seaI with its groove facing out.
InstaII the coIIar.
INSTALLATION
Cushion arm
TOROUE: 4.5 kgm
COLLAR
Rear cushion]cushion arm
Rear cushion boIt]nut (upper)
TOROUE: 4.5 kgm
TOROUE: 5.0 kgm
TOROUE: 7.0 kgm
InstaII the air cIeaner case (page 5-22).
DUST SEAL
BOLT]NUT (LOWER)
CUSHION ARM
REAR CUSHION]CUSHION ARM
BOLT]NUT (UPPER)
12-13
CUSHION LINKAGE
REMOVAL
engine.
Cushion connecting rod boIt]nut (on fame side)
Washer
Cushion connecting rod
CUSHION ARM
engine.
Swingarm (page 12-17)
Cushion arm
BOLT]NUT (FRAME SIDE)]WASHER
DISASSEMBLY
Dust seaIs
CoIIars
CUSHION ARM
Dust seaIs
CoIIar
SphericaI bearing coIIars
Cushion arm
BOLT]NUT (LOWER)
CUSHION ARM
DUST SEALS COLLARS
DUST SEALS SPHERICAL BEARING COLLARS
CUSHION ARM COLLAR
12-14
INSPECTION
Check the cushion connecting rod for cracks or damage and
repIace if necessary.
Check the dust seaI for deterioration or damage and repIace
if necessary.
Check the coIIar for damage and repIace if necessary.
Check the needIe bearing for damage and repIace if neces-
sary.
CUSHION ARM
Check the cushion arm for cracks or damage and repIace if
necessary.
Check the dust seaI for deterioration or damage and repIace
if necessary.
Check the coIIar for damage and repIace if necessary.
Check the needIe bearing for damage and repIace if neces-
sary.
Check the sphericaI bearing for damage and repIace if neces-
sary.
Check the sphericaI bearing coIIar for damage and repIace if
necessary.
DUST SEALS
NEEDLE BEARING REPLACEMENT
Remove the needIe bearing from the cushion connecting rod
using the foIIowing speciaI tooI and a hydrauIic press.
Bush driver pin 07GMD-KT80100
AppIy grease to a new needIe bearing.
InstaII the needIe bearing to the cushion connecting rod us-
ing the foIIowing speciaI tooIs and a hydrauIic press.
Outer driver, 24 x 26 mm 07746-0010700
PiIot, 17 mm 07746-0040400
NOTE:
InstaII the needIe bearing with the mark facing out.
Press the needIe to the specified depth.
COLLARS
CUSHION ROD
CUSHION ARM COLLAR
BUSH DRIVER PIN
DRIVER HANDLE A
OUTER DRIVER
PILOT
NEEDLE BEARING
12-15
CUSHION ARM
Remove the needIe bearing from the cushion arm using the
foIIowing speciaI tooI and a hydrauIic press.
InstaII the needIe bearing into the cushion arm using the foI-
Iowing speciaI tooI and a hydrauIic press.
NOTE:
NEEDLE BEARING REMOVER
SPHERICAL BEARING REPLACEMENT
Remove the sphericaI bearing from the cushion arm using
AppIy grease to a new sphericaI bearing.
InstaII the sphericaI bearing into the cushion arm using the
NOTE:
Press the sphericaI bearing to the specified depth.
NEEDLE BEARING
SPHERICAL BEARING
12-16
ASSEMBLY
CoIIars
Dust seaIs
CUSHION ARM
Cushion arm
SphericaI bearing coIIars
CoIIar
Dust seaIs
INSTALLATION
CUSHION ARM
Cushion arm
TOROUE: 4.5 kgm
Swingarm (page 12-22)
Cushion connecting rod boIt]nut]washer (on frame side)
TOROUE: 4.5 kgm
NOTE:
AppIy grease to threads and seating surfaces of the cushion
connecting rod boIt and nut (on cushion arm side) before in-
staIIing them.
TOROUE: 5.0 kgm
COLLARS
DUST SEALS
CUSHION ARM COLLAR
BOLT]NUT (LOWER)
CUSHION ARM
CUSHION CONNECTING ROD BOLT]
NUT]WASHER (FRAME SIDE)
CUSHION CONNECTING ROD BOLT]
NUT (CUSHION ARM SIDE)
12-17
SWINGARM
REMOVAL
Rear wheeI (page 12-3)
Screws
Brake hose guide
BoIts
Chain cover
SCREWS
Chain guide screws]nuts
Chain guide sIider
RepIace the chain guide sIider if it is damaged or worn.
GUIDES
CHAIN COVER
BOLTS
CHAIN GUIDE SLIDER
SCREWS]NUTS
PROTECTOR PLATE
CUSHION CONNECTING ROD BOLT]NUT (CUSHION
ARM SIDE)
12-18
Swingarm pivot nut
Swingarm pivot boIt
Swingarm
PIVOT NUT
DISASSEMBLY
BoIts
Brake disc cover
BoIts
Chain guide
Chain sIider screw
NOTE:
It is difficuIt to undo the chain sIider screw since Iocking agent
has been appIied to the threads.
Chain sIider
RepIace the chain sIider if it is damaged or worn.
RETURN SPRING
SWINGARM
PIVOT BOLT
CHAIN GUIDE DISC COVER
BOLTS BOLTS
CHAIN SLIDER SCREW
12-19
Dust seaI cap
Dust seaIs
CoIIars
INSPECTION
RepIace the dust seaI cap if it is deteriorated or damaged.
RepIace the dust seaI if it is deteriorated or damaged.
RepIace the coIIar if it is damaged.
RepIace the needIe bearing if it is damaged.
RepIace the swingarm if it is damaged.
DUST SEAL CAP
Remove the outer needIe bearing from the swingarm using
the foIIowing speciaI tooI.
NeedIe bearing remover 07931-MA70000
Remove the inner needIe bearing from the swingarm using
DUST SEALS
COLLARS
DUST SEAL CAP
DUST SEALS
COLLARS
12-20
InstaII the inner needIe bearing to the swingarm using the
NOTE:
InstaII the outer needIe bearing to the swingarm using the
NOTE:
NEEDLE BEARING
NEEDLE BEARING
ASSEMBLY
SCREWS 0.43 kgm
SCREW
CHAIN SLIDER
DUST SEAL CAP
BRAKE HOSE GUIDE
SWINGARM
NEEDLE BEARINGS
COLLARS
12-21
CoIIars
Dust seaIs
Dust seaI cap
NOTE:
AppIy grease to the Iips of the dust seaIs and dust seaI cap
before instaIIation.
Chain sIider
NOTE:
AIign the swingarm tab with the chain sIider hoIe.
DUST SEAL CAP
Chain sIider screw
NOTE:
CIean and appIy Iocking agent to the sIider screw threads
before instaIIation.
Chain guide
BoIts
Brake disc cover
BoIts
DUST SEALS
COLLARS
ALIGN CHAIN SLIDER
SCREW
CHAIN GUIDE DISC COVER
BOLTS BOLTS
12-22
INSTALLATION
AppIy a thin coat of grease to the sIiding surfaces of the
swingarm pivot boIt.
InstaII the swingarm and the swingarm pivot boIt.
InstaII the swingarm pivot nut and tighten it to the specified
torque.
TOROUE: 9.0 kgm
InstaII the brake pedaI return spring.
SWINGARM
InstaII the cushion arm boIt]nut (on swingarm side) and tighten
the nut to the specified torque.
TOROUE: 7.0 kgm
InstaII the cushion connecting rod boIt]nut (on cushion arm
side) and tighten the nut to the specified torque.
TOROUE: 5.0 kgm
InstaII the rear master cyIinder protector pIate (page 13-28).
InstaII the chain guide sIider.
InstaII the chain guide screws]nuts.
PIVOT BOLT
PIVOT NUT
RETURN SPRING
PROTECTOR PLATE
CUSHION CONNECTING ROD BOLT]NUT (CUSHION
ARM SIDE)
CHAIN GUIDE SLIDER
SCREWS]NUTS
12-23
InstaII the chain cover, aIigning the chain cover sIot with the
swingarm tab.
Tighten the chain cover boIts to the specified torque.
TOROUE: 1.2 kgm
CHAIN COVER
InstaII the brake hose guide, appIy Iocking agent to the screw
threads and tighten the screws to the specified torque.
TOROUE: 0.43 kgm
InstaII the rear wheeI (page 12-9).
ALIGN
BOLTS
SCREWS
GUIDE
13-1
13. BRAKE SYSTEM
BRAKE FLUID REPLACEMENT]AIR
BLEEDING 13-4
BRAKE PAD REPLACEMENT 13-6
FRONT BRAKE CALIPER 13-8
13
FRONT MASTER CYLINDER 13-12
REAR BRAKE CALIPER 13-19
REAR MASTER CYLINDER 13-24
BRAKE PEDAL 13-29
3.5 kgm
1.8 kgm
0.6 kgm
1.0 kgm
0.25 kgm
3.5 kgm
13-2
BRAKE SYSTEM
SERVICE INFORMATION
Do not aIIow any contaminant or water to enter the reservoir when adding brake fIuid.
Do not mix different brands or grades of brake fIuid. Mixing different brands or grades may cause a chemicaI reaction.
Do not reuse used brake fIuid.
Keep brake fIuid away from other motorcycIe components. Brake fIuid may cause painted, pIastic or rubber compo-
nents to deteriorate.
Do not reuse the seaIing washer.
CIean the removed brake components with brake fIuid and check that air fIows through aII ports sing compressed air.
BIeed the hydrauIic system if it is contaminated with air during maintenance work such as brake hose removaI.
AIways repIace brake pads in pairs.
SPECIFICATIONS
Brake fIuid
Brake pad wear
Brake disc runout
Mater cyIinder I.D.
Master piston O.D.
CaIiper piston O.D.
DOT 4
10 20
10 20
3.5
4.5
12.700 12.743
14.000 14.043
12.657 12.684
13.957 13.984
27.000 27.050
27.000 27.050
26.935 26.968
26.935 26.968
FR
RR
FR
RR
FR
RR
FR
RR
FR
RR
To the service
Iimit groove
0.15
3.0
4.0
12.76
14.06
12.64
13.95
27.10
27.10
26.89
26.89
Unit: mm
13-3
BRAKE SYSTEM
Torque VaIues
Brake hose boIt 3.5 kgm
Brake hose guide screw 0.43 kgm AppIy Iocking agent to the threads
Reservoir cover screw 0.2 kgm
Front master cyIinder hoIder boIt 1.4 kgm
Front brake Iight switch screw 0.12 kgm
Front brake Iever pivot boIt 0.6 kgm
nut 0.6 kgm
Rear master cyIinder boIt 1.4 kgm AppIy Iocking agent to the threads
Push rod Iock nut 1.8 kgm
Front caIiper bracket boIt 3.0 kgm AppIy Iocking agent to the threads
Front caIiper pad pin 1.8 kgm
Front caIiper pad pin pIug 0.25 kgm
Front caIiper bIeeder vaIve 0.6 kgm
Front caIiper pin boIt A 2.3 kgm AppIy Iocking agent to the threads
Front caIiper pin boIt B 1.3 kgm AppIy Iocking agent to the threads
Rear caIiper pad pin 1.0 kgm
Rear caIiper pad pin pIug 0.25 kgm
Rear caIiper bIeeder vaIve 0.6 kgm
Rear caIiper pin boIt 2.8 kgm
Rear caIiper bracket pin boIt 1.2 kgm AppIy Iocking agent to the threads
SpeciaI TooI
Snap ring pIiers 07914-3230001
TROUBLESHOOTING
Poor braking
Air bubbIes in the brake system
Deteriorated brake fIuid due to moisture absorption
Contaminated brake pads and]or disc
Worn caIiper piston seaI
Worn master cyIinder piston cup
Worn brake pads
Contaminated caIiper
CaIiper not sIiding properIy
Uneven brake pads]disc wear
Low brake fIuid IeveI
CIogged fIuid passage
Warped or deformed brake disc
Stuck or worn caIiper piston
Stuck or worn master cyIinder piston
Worn disc
Contaminated master cyIinder
Bent brake Iever
Stiff brake Iever (pedaI) or hard to return
Stuck or worn caIiper piston
CIogged fIuid passage
Worn caIiper piston seaI
Stuck or worn master cyIinder piston
Bent brake Iever (pedaI)
Brake snagging or uneven braking
MisaIigned disk or wheeI
Contaminated brake pads and]or disc
Brake drag
Contaminated or worn brake pads and]or disc
Uneven or stepped wear of brake pads]disc
13-4
BRAKE SYSTEM
BRAKE FLUID REPLACEMENT]AIR
BLEEDING
BRAKE FLUID DRAINING
Front
Remove the screw and reservoir cover.
Rear
Remove the reservoir tank bracket boIt.
Remove the reservoir cap.
NOTE:
Do not aIIow any contaminant or water to enter the reser-
voir when adding brake fIuid.
Do not mix different brands or grades of brake fIuid. Mix-
ing different brands or grades may cause a chemicaI reac-
tion.
Keep brake fIuid away from other motorcycIe components.
Brake fIuid may cause painted, pIastic or rubber compo-
Keep the reservoir top surface in a horizontaI position to
remove the reservoir cover.
Use DOT 4 brake fIuid for both front and rear brake sys-
tems.
Attach a cIear pIastic tube to the bIeeder vaIve, open the
bIeeder vaIve on the caIiper and operate the brake Iever or
pedaI.
Repeat the above procedure untiI aII brake fIuid is compIeteIy
drained out.
Tighten the bIeeder vaIve and fiII the reservoir with the speci-
fied brake fIuid to the upper IeveI Iine.
BIeed the brake system.
Front
InstaII the diaphragm, diaphragm pIate and reservoir cover.
Tighten the screw to the specified torque.
TOROUE: 0.2 kgm
SCREWS CAP
COVER BOLT
BLEEDER VALVE
UPPER LEVEL
SCREWS COVER
PLATE DIAPHRAGM
13-5
BRAKE SYSTEM
Rear
InstaII the diaphragm, diaphragm pIate and reservoir cover.
SecureIy tighten the reservoir tank bracket boIt.
AIR BLEEDING
NOTE:
Keep a cIose eye on the brake fIuid IeveI during the bIeeding
procedure. FiII the reservoir with brake fIuid before the fIuid
IeveI reaches the Iower IeveI Iine.
FiII the reservoir with the specified brake fIuid to the upper
IeveI Iine.
Keep operating the brake Iever or pedaI untiI air bubbIes stop
appearing.
Connect one end of a cIear pIastic tube to the bIeeder vaIve
and the other to a container.
1. Operate the brake Iever (or pedaI) severaI times, Ioosen
the bIeeder vaIve haIf a turn whiIe hoIding the brake Iever
(or pedaI) in the depressed position, and then tighten the
vaIve again.
NOTE:
Keep hoIding the brake Iever (or pedaI) untiI you tighten the
bIeeder vaIve.
2. SIowIy reIease the brake Iever (or pedaI) and Ieave it for a
few seconds.
3. Repeat Steps 1 and 2 above untiI air bubbIes stop coming
out from the bIeeder vaIve.
Tighten the bIeeder vaIve to the specified torque.
TOROUE: 0.6 kgm
FiII the reservoir with the specified brake fIuid to the upper
IeveI Iine and instaII the reservoir cover (or the reservoir cap).
BOLT CAP
PLATE DIAPHRAGM
<FRONT> BLEEDER VALVE
<REAR> BLEEDER VALVE
13-6
BRAKE SYSTEM
BRAKE PAD REPLACEMENT
Push back the caIiper piston to instaII new brake pads.
Pad pin pIug
Pad pin
Brake pads
NOTE:
AIways repIace the brake pads in pairs.
Make sure that the pad spring and the retainer are correctIy
pIaced and instaII new pads onto the brake caIiper.
NOTE:
Ensure that the pads are secureIy aIigned with the retainer.
PLUGS
PAD PINS
PADS
PADS
13-7
BRAKE SYSTEM
InstaII the pad pin and tighten it to the specified torque.
TOROUE : Front : 1.8 kgm
Rear : 1.0 kgm
InstaII the pad pin pIug and tighten it to the specified torque.
TOROUE : Front : 0.25 kgm
Rear : 0.25 kgm
BRAKE DISC INSPECTION
Measure the brake disc thickness.
SERVICE LIMIT : Front : 3.0 mm RepIace if 3.0 mm or Iess
Rear : 4.0 mm RepIace if 4.0 mm or Iess
Measure the brake disc warpage.
SERVICE LIMIT : 0.15 mm RepIace if 0.15 mm or greater
PAD PINS
PAD PIN PLUG
13-8
BRAKE SYSTEM
FRONT BRAKE CALIPER
REMOVAL
NOTE:
CIean the removed brake components with brake fIuid and
check that air fIows through aII ports using compressed
air.
Keep aII disassembIed components organized and away
from contaminants.
Drain the brake fIuid (page 13-4).
Brake hose boIt
SeaIing washers
Front brake caIiper bracket boIts
Front brake caIiper assembIy
DISASSEMBLY
Remove the front brake caIiper bracket from the caIiper.
CaIiper pin boot
Retainer
NOTE:
Do not remove the bracket pin unIess it is to be repIaced.
HOSE BOLT
SEALING WASHERS
BOLTS
CALIPER ASSEMBLY
BRACKET
CALIPER
RETAINER
BOOT
13-9
BRAKE SYSTEM
Bracket pin boot
Pad spring
NOTE:
Do not remove the caIiper pin unIess it is to be repIaced.
Wrap the caIiper with a shop rag in order to prevent the pis-
ton and the brake fIuid contained from coming off, and pIace
the caIiper with the piston facing down.
SIowIy bIow Iow-pressure air into the brake hose connecting
port to remove the piston from the caIiper.
Remove the piston seaIs and dust seaIs.

CAUTION:
CIean the caIiper cyIinder and piston using cIean brake fIuid
and remove any dirt from the grooves.
INSPECTION
RepIace the piston and]or the cyIinder if damaged or
scratched.
BOOT
PAD SPRING
PISTON SEAL
DUST SEAL
PISTONS
13-10
BRAKE SYSTEM
ASSEMBLY
Measure the I.D. of the cyIinder bores.
Measure the O.D. of the piston.
RETAINER
CALIPER BRACKET
CALIPER BOOT
DUST SEAL BLEEDER VALVE 0.6 kgm
PISTON SEAL
BRACKET PIN BOOT
PAD PIN 1.8 kgm
PISTON
PAD PIN PLUG 0.25 kgm
PAD SPRING
3.5 kgm
13-11
BRAKE SYSTEM
NOTE:
AIways repIace the piston seaIs and dust seaIs with new
ones.
RepIace the boot if it is deteriorated or damaged.
AppIy siIicon grease to the boot inner waII.
Make sure that each part is free from dirt or dust before
reassembIy.
AppIy the specified brake fIuid to the piston seaIs and dust
seaIs.
AppIy the specified brake fIuid to the pistons.
New piston seaIs
New dust seaIs
Piston
Pad spring
Bracket pin boot
Retainer
CaIiper pin boot
InstaII the front brake caIiper bracket to the caIiper.
PISTON SEAL DUST SEAL
PISTON
BOOT
PAD SPRING
RETAINER
BOOT
BRACKET
CALIPER
13-12
BRAKE SYSTEM
INSTALLATION
InstaII the front brake caIiper assembIy.
CIean the front brake caIiper bracket boIts and appIy Iocking
agent to the threads.
Tighten the front brake caIiper bracket boIt to the specified
torque.
TOROUE: 3.0 kgm
InstaII the brake hose by tightIy fitting the hose on the caIiper.
CAUTION:
InstaII new seaIing washers and tighten the brake hose boIt
to the specified torque.
TOROUE: 3.5 kgm
FiII with brake fIuid and bIeed air from the brake system (page
13-4).
FRONT MASTER CYLINDER
REMOVAL
NOTE:
air.
from contaminants.
Remove the rear view mirror (page 11-3).
Reservoir cover screws
Reservoir cover
Diaphragm pIate
Diaphragm
BOLTS
CALIPER ASSEMBLY
BOLT
SEALING WASHERS
SCREW
COVER PLATE
DIAPHRAGM
13-13
BRAKE SYSTEM
Stop Iight switch connector
Brake hose boIt
SeaIing washers
Brake hose
Front master cyIinder hoIder boIts
Front master cyIinder hoIder
Front master cyIinder assembIy
DISASSEMBLY
Front brake Iever pivot nut
CoIIar
CONNECTOR
HOSE
SEALING WASHERS
BOLT
MASTER CYLINDER ASSEMBLY
BOLT
HOLDER
COLLAR
NUT
13-14
BRAKE SYSTEM
KnuckIe guard
Front stop Iight switch screw
Front stop Iight switch
Remove the boot and snap ring.
NOTE:
Be carefuI not to damage the boot.
Piston assembIy
Spring
NOTE:
CIean the removed brake components using brake fIuid
and check that air fIows through aII ports using compressed
air.
from contaminants.
Do not remove the piston cup from the piston. RepIace the
entire piston assembIy.
RepIace the spring if it is damaged.
KNUCKLE GUARD
BOLT
SCREW STOP LIGHT SWITCH
SNAP RING PLIERS SNAP RING
BOOT
PISTON
SPRING
13-15
BRAKE SYSTEM
INSPECTION
Check the piston and cyIinder for scratch and repIace if nec-
essary.
Measure the I.D. of the cyIinder bore.
SERVICE LIMIT : 12.76 mm RepIace if 12.76 mm or greater
SERVICE LIMIT : 12.64 mm RepIace if 12.64 mm or Iess
PISTON
13-16
BRAKE SYSTEM
NOTE:
RepIace the piston assembIy and spring as a set.
RepIace the boot if it is deteriorated or damaged.
reassembIy.
AppIy the specified brake fIuid to the piston cups.
Spring
Piston assembIy
InstaII the snap ring.
InstaII the boot.
NOTE:
SNAP RING
PISTON
RESERVOIR COVER
BOOT
SPRING
DIAPHRAGM PLATE
BRAKE LEVER
BRAKE LEVER PIVOT BOLT
0.6 kgm
DIAPHRAGM
FRONT STOP LIGHT SWITCH
KNUCKLE GUARD
COLLAR
BRAKE LEVER PIVOT NUT 0.6 kgm
SPRING
PISTON
SNAP RING PLIERS SNAP RING
BOOT
ASSEMBLY
0.2 kgm
1.4 kgm
3.5 kgm
0.12 kgm
13-17
BRAKE SYSTEM
InstaII the front brake Iight switch aIigning the front stop Iight
switch tab with the hoIe on the master cyIinder.
InstaII the front stop Iight switch screw and tighten it to the
specified torque.
TOROUE: 0.12 kgm
InstaII the knuckIe guard
Tighten the front brake Iever pivot boIt to the specified torque.
TOROUE: 0.6 kgm
InstaII the coIIar.
Tighten the front brake Iever pivot nut to the specified torque.
TOROUE: 0.6 kgm
STOP LIGHT SWITCH
ALIGN
SCREW
KNUCKLE GUARD
BOLT
COLLAR
NUT
13-18
BRAKE SYSTEM
INSTALLATION
Front master cyIinder assembIy
Front master cyIinder hoIder
NOTE:
InstaII the hoIder with its UP mark facing up.
AIign the mating surfaces of the hoIder and master cyIin-
der with punch mark on the handIe bar.
Front master cyIinder hoIder boIts
TOROUE: 1.4 kgm
NOTE:
Tighten the upper hoIder boIt first.
New seaIing washers
Brake hose
NOTE:
InstaII the brake hose untiI it reaches the master cyIinder stop-
per.
Brake hose boIt
TOROUE: 3.5 kgm
Stop Iight switch connector
MASTER CYLINDER ASSEMBLY BOLTS
HOLDER
UP MARK
BRAKE HOSE
SEALING WASHERS
BOLT
CONNECTORS
13-19
BRAKE SYSTEM
Diaphragm
Diaphragm pIate
Reservoir cover
TOROUE: 0.2 kgm
FiII with brake fIuid and bIeed air from the system (page 13-
4).
REAR BRAKE CALIPER
REMOVAL
PuII the rear wheeI back untiI it comes to the swingarm tab
(page 12-3).
Remove the rear brake caIiper.
Brake hose boIt
SeaIing washers
Rear brake caIiper assembIy
DISASSEMBLY
Remove the rear brake caIiper bracket from the caIiper.
SCREWS COVER
PLATE DIAPHRAGM
CALIPER ASSEMBLY
CALIPER ASSEMBLY
SEALING WASHERS
BOLT
BRACKET
CALIPER
13-20
BRAKE SYSTEM
CaIiper pin boot
Retainer
NOTE:
Do not remove the bracket pin unIess it is to be repIaced.
Bracket boot
Pad spring
NOTE:
Do not remove the caIiper pin unIess it is to be repIaced.
Wrap the caIiper with a shop rag in order to prevent the pis-
ton and the brake fIuid contained from coming off, and pIace
the caIiper with the piston facing down.
SIowIy bIow Iow-pressure air into the brake hose connecting
port to remove the piston from the caIiper.
Remove the piston seaIs and the dust seaIs.

CAUTION:
CIean the caIiper cyIinder and piston using cIean brake fIuid
and remove any dirt from the grooves.
RETAINER
BOOT
BOOT
PAD SPRING
PISTON SEAL
DUST SEAL
13-21
BRAKE SYSTEM
INSPECTION
Check the piston and cyIinder for damage or scratch and re-
pIace if necessary.
Measure the I.D. of the cyIinder bore.
PISTON
13-22
BRAKE SYSTEM
NOTE:
AIways repIace the piston seaI and dust seaI with new ones.
RepIace the boot with a new one if it is deteriorated or
damaged.
reassembIy.
AppIy the specified brake fIuid to the piston seaIs and dust
seaIs.
AppIy the specified brake fIuid to the pistons.
Piston seaI
Dust seaI
Piston
Pad spring
Bracket pin boot
RETAINER
CALIPER PIN BOOT
DUST SEAL
BLEEDER VALVE 0.6 kgm
PISTON
PISTON SEAL
CALIPER BRACKET
PAD PIN 1.0 kgm
BRACKET PIN BOOT
PAD SPRING
PAD PIN PLUG 0.25 kgm
PISTON SEAL
PISTON
DUST SEAL
BRACKET PIN BOOT
PAD SPRING
ASSEMBLY
3.5 kgm
13-23
BRAKE SYSTEM
Retainer
CaIiper pin boot
InstaII the rear brake caIiper bracket to the caIiper.
InstaII the brake hose by tightIy fitting the hose on the caIiper.
CAUTION:
InstaII new seaIing washers and tighten the brake hose boIt
to the specified torque.
TOROUE: 3.5 kgm
InstaII the rear brake caIiper to the axIe shaft and aIign the
bracket with the swingarm sIide raiI.
Adjust the drive chain sIack (page 3-17).
13-4).
RETAINER
BOOT
BRACKET
CALIPER
SEALING WASHERS BOLT
CALIPER
13-24
BRAKE SYSTEM
REAR MASTER CYLINDER
REMOVAL
NOTE:
air.
from contaminants.
Cotter pin
Joint pin
Brake hose boIt
SeaIing washers
Brake hose
Reservoir tank boIt
Rear master cyIinder protector pIate
Rear master cyIinder assembIy
COTTER PIN
JOINT PIN
BRAKE HOSE BOLT
SEALING WASHERS
MASTER CYLINDER ASSEMBLY
BOLT
HOLDER BOLTS PROTECTOR PLATE
13-25
BRAKE SYSTEM
DISASSEMBLY
Reservoir tank
Snap ring
Joint pipe
O-ring
Boot
NOTE:
Snap ring
Push rod assembIy
Piston assembIy
Piston cup
Spring
NOTE:
air.
from contaminants.
Do not remove the piston cup from the piston. RepIace the
entire piston assembIy.
RepIace the spring, if damage is found.
RESERVOIR TANK
JOINT PIPE SNAP RING
O-RING
SNAP RING PLIERS BOOT
SNAP RING
SPRING PISTON CUP
PUSH ROD ASSEMBLY
PISTON
13-26
BRAKE SYSTEM
INSPECTION
Check the piston and cyIinder for damage or scratch and re-
pIace if necessary.
Measure the I.D. of the cyIinder bores.
PISTON
13-27
BRAKE SYSTEM
NOTE:
RepIace the master piston assembIy and spring as a set.
RepIace the boot with a new one if it is deteriorated or
damaged.
reassembIy.
AppIy the specified brake fIuid to the piston cup.
Spring
Piston cup
Piston assembIy
Push rod assembIy
Snap ring
Boot
NOTE:
JOINT PIPE
RESERVOIR CAP
SNAP RING
DIAPHRAGM PLATE
DIAPHRAGM
O-RING
RESERVOIR TANK
SNAP RING
SPRING
BOOT
PISTON CUP
PISTON
PUSH ROD ASSEMBLY
COTTER PIN
JOINT PIN
SPRING PISTON CUP
PUSH ROD ASSEMBLY
PISTON
SNAP RING PLIERS BOOT
SNAP RING
ASSEMBLY
3.5 kgm
1.8 kgm
13-28
BRAKE SYSTEM
New O-ring
Joint pipe
Snap ring
Reservoir tank
INSTALLATION
AppIy Iocking agent to the threads of the rear master cyIinder
hoIder boIt.
Rear master cyIinder assembIy
Rear master cyIinder protector pIate
TOROUE: 1.4 kgm
Reservoir tank boIt
Brake hose
NOTE:
InstaII the brake hose aIigning it with the master cyIinder stop-
per.
New seaIing washers
Brake hose boIt
TOROUE: 3.5 kgm
O-RING SNAP RING
JOINT PIPE
RESERVOIR TANK
MASTER CYLINDER ASSEMBLY BOLT
HOLDER BOLTS PROTECTOR PLATE
BOLT BRAKE HOSE
SEALING WASHERS
ALIGN
13-29
BRAKE SYSTEM
Joint pin
New cotter pin
13-4).
BRAKE PEDAL
REMOVAL
Cotter pin (master cyIinder side)
Cotter pin (brake pedaI side)
Washer
Joint pin
Brake pedaI
Dust seaI
INSTALLATION
AppIy grease to the brake pedaI pivot.
Dust seaI
Brake pedaI
Joint pin
JOINT PIN
COTTER PIN
WASHER
COTTER PIN (BRAKE PEDAL SIDE)
COTTER PIN (MASTER CYLINDER SIDE)
SPRING
DUST SEAL
JOINT PIN PEDAL
SPRING
DUST SEAL
JOINT PIN PEDAL
13-30
BRAKE SYSTEM
Washer
New cotter pin (brake pedaI side)
New cotter pin (master cyIinder side)
WASHER
COTTER PIN (BRAKE PEDAL SIDE)
COTTER PIN (MASTER CYLINDER
SIDE)
14-1
14. CHARGING SYSTEM]ALTERNATOR
SERVICE INFORMATION
CAUTION:
NOTE:
The MF battery must be changed when it reaches the end of its usefuI Iife.
Turn the main switch OFF before removing any eIectricaI parts.
When storing a vehicIe with its battery stiII mounted, disconnect the () cabIe of the battery.
A fast charger is for emergency use. It may shorten the batterys usefuI Iife.
The battery may be damaged or its capabiIity and usefuI Iife may be reduced if charged and discharged to the extreme
(fuII discharge and charge) repeatedIy or if Ieft fuIIy discharged. The capabiIity of the battery naturaIIy degrades in
approximateIy two to three years even under normaI usage. AIthough the voItage of a battery with Iow capabiIity (Iow
capacity) can be restored if it is recharged, its voItage faIIs significantIy and immediateIy as soon as a Ioad is appIied
and the battery quickIy discharges.
Overcharge symptoms may occur visuaIIy due to faiIure of the battery itseIf. If a short circuit occurs in one Iayer of the
battery and the voItage between the battery terminaIs does not rise, the reguIator does not operate and the battery
suffers from over voItage, which speeds up reduction of the eIectroIyte.
A new MF battery that is onIy fiIIed with eIectroIyte may not be abIe to perform properIy depending on the storage
conditions. In the foIIowing cases, recharge the battery separateIy after fiIIing with eIectroIyte.
If the open voItage (between the terminaIs) is Iess than 12.4 V ten minutes after fiIIing with eIectroIyte: Perform
normaI charging untiI the battery open voItage reaches 12.8 V.
If the eIectroIyte temperature is beIow 0 C: charge the battery with standard charging current for two to three hours.
Inspection of the charger shouId be conducted based on the sequence of the faiIure diagnostic chart (page 14-3).
For the Iayout of the eIectricaI parts, see the iIIustration on page 14-0.
BATTERY 14-5
14
CHARGING SYSTEM INSPECTION 14-7
REGULATOR]RECTIFIER 14-8
ALTERNATOR 14-9
14-2
TOROUE VALUES
L, crankcase cover boIt 1.2 kgm
Stator boIt 1.0 kgm AppIy a Iocking agent to the threads.
FIywheeI boIt 10.5 kgm AppIy grease to the threads and fIange surface.
One-way cIutch outer boIt 1.6 kgm AppIy a Iocking agent to the threads.
Change pedaI boIt 1.2 kgm
PuIse generator socket boIt 0.5 kgm AppIy a Iocking agent to the threads.
CIamp socket boIt 0.5 kgm AppIy a Iocking agent to the threads.
NeutraI switch nut 0.15 kgm
SPECIAL TOOLS
FIywheeI hoIder 07725 0040000
FIywheeI puIIer 07733 0020001
SPECIFICATIONS
ITEM SPECIFICATIONS
AIternator
ReguIator]rectifier
Battery
Three-phase system
0.204 kW]5,000 rpm
0.1 1.0
Thyristor type
14.0 14.8 V
12 V 9 Ah
0.5 A]5 10 h
5.0 A]0.5 h
2.0 mA maximum
12.8 V minimum
12.3 V maximum
Type
Output
Charging coiI resistor (20 C)
Type
ControI voItage
Capacity
Charging current
Leakage current
Standard
Fast
VoItage
(20 C)
FuII charging
Lack of charging
14-3
DIAGNOSIS
Charging faiIure (reaches to the controI voItage by exceeding the rated speed)
InstaII a battery in good order and check the
charging conditions (page 14-7).
Disconnect the reguIator]rectifier 2P (naturaI)
coupIer and check the voItage of the battery wire
(page 14-8).
Perform the battery Ieak test (page 14-7).
CONNECTION: Red]White (+), Green ()
STANDARD: Battery voItage
Disconnect the AIternator 3P (BIack) coupIer and
measure the resistance of the charging coiI at
AIternator side.
Standard: 0.1 1.0 (20 C)
NormaI
NormaI
Reaches to the controI voItage by
exceeding the rated speed.
ReguIator]rectifier fauIty.
AbnormaI
Battery fauIty.
NormaI
AbnormaI
Short circuit in the wire
harness.
Main switch fauIty.
Short circuit in the wire harness.
PoorIy connected coupIer or connectors.
AbnormaI
Stator fauIty.
Short circuit in the wire harness.
NormaI
14-4
InstaII a battery in good order and check the
charging conditions (page 14-7).
Disconnect the reguIator]rectifier 2P (naturaI)
coupIer and check the continuity between
ground wire and body ground wire (page 14-8).
CONNECTION: Green Body ground
STANDARD: CONTINUITY
ReguIator]rectifier fauIty.
AbnormaI
Open circuit in the wire harness.
PoorIy connected coupIer.
NormaI
ControI voItage exceeds the standard vaIue greatIy
NormaI
Battery fauIty.
ControI voItage exceeds the
standard vaIue greatIy.
14-5
BATTERY
REMOVAL
NOTE:
Main switch must be turned OFF before performing the ser-
vice.
Remove the side cover (page 2-2).
Remove the terminaI boIt and disconnect the battery () cabIe.
Remove the terminaI cover.
Remove the terminaI boIt and disconnect the battery (+) cabIe.
Remove the battery hoIder boIts and remove the battery
hoIder.
Remove the battery.
INSTALLATION
NOTE:
After the instaIIation, appIy cIean grease to the battery termi-
naI.
INSPECTION
Measure the voItage between battery terminaIs and check the
charging conditions.
FuIIy charged: 12.8 V minimum
Lack of charging: 12.3 V maximum
Charge the battery additionaIIy, if the battery is charged in-
sufficientIy.
NOTE:
When inspecting the voItage after charging, measure the voIt-
age between terminaIs more than 30 minutes after the compIe-
tion of charging. The voItage between the terminaIs varies
significantIy after the charging is compIeted and thus proper
inspection cannot be performed.
CHARGING BATTERY
Charge the battery based on the charging current and hours
Iisted on the battery body.
Remove the battery from the body.
TERMINAL BOLTS
BATTERY BOLT
TERMINAL COVER
(+) CABLE
() CABLE
HOLDER
BATTERY
14-6
Connect the battery charger (+) cabIe to the battery (+) termi-
naI.
Connect the battery charger () cabIe to the battery () termi-
naI.
CHARGING CURRENT]HOURS: STANDARD: 0.5 A]5 10 h
FAST: 5.0 A]0.5 h
Remove the boIts and cIamp and remove the battery case.
INSTALLATION
InstaII the battery case and cIamp, then tighten the boIts se-
cureIy.
InstaII the fuse box and tighten the screw secureIy.
InstaII the starter reIay.
InstaII the battery (page 14-5).
NOTE:
Route the wires and harnesses through correct Iocation as
shown in CABLE AND HARNESS ROUTING (page 1-19).
FUSE BOX
BATTERY CASE
REMOVAL
Remove the battery (page 14-5).
Remove the starter reIay.
Remove the screw and remove the fuse box.
SCREW STARTER RELAY
CLAMP
BOLT BATTERY CASE
FUSE BOX
SCREW STARTER RELAY
14-7
CHARGING SYSTEM INSPECTION
LEAK TEST
Turn the main switch OFF and disconnect the battery () cabIe.
Connect an ammeter between the battery () terminaI and ()
cabIe.
Measure the Ieak current with the main switch turned OFF.
CAUTION:
LEAK CURRENT: 2.0 mA maximum

When the Ieak current Iarger than the measurement vaIue
fIows, short circuit may exist.
Disconnect the coupIer or connector sequentiaIIy and Iook
for the short circuit Iocation whiIe measuring the current.
CHARGING CONDITION INSPECTION
InstaII the fuIIy charged battery.
InstaII a voItmeter between the battery terminaIs after the
engine is warm up.
NOTE:
Make sure not to short the wires during the measurement.
If the battery terminaI is disconnected or connected whiIe
the current is fIowing, overvoItage may occur and damage
the tester or eIectricaI parts. AIways turn the key switch
OFF before performing such service work.
Inspection must be done with fuIIy charged battery.
InstaII the engine tachometer.
Start the engine and set the head Iight to Lo beam.
Increase the engine speed graduaIIy and check for the voIt-
age between battery terminaIs when the engine runs at speci-
fied speed (5,000 rpm).
CONTROL VOLTAGE: 14.0 14.8 V] 5000 rpm
When the voItage rises from the battery voItage to the con-
troI voItage, the charging condition is correct.
NOTE:
The speed at which the voItage starts to rise cannot be checked
as it varies with the temperature of the AIternator and the
Ioad of the eIectricaI parts.
When the battery fuIIy discharges frequentIy with correct
charging condition, the battery may be out of usage Iife.
() CABLE
() TERMINAL
() TERMINAL
() CABLE
BATTERY
NORMAL CHARGING VOLTAGE
CONTROL
VOLTAGE
BATTERY
VOLTAGE
ENGINE SPEED
14-8
If the foIIowing conditions occur, charging system may be
fauIty. Inspect each part.
1. The voItage does no reach to the controI voItage even if
the engine speed is raised (page 14-3).
Open or short circuit in the charging system, poor con-
nection of the coupIer
Open or short circuit in the AIternator
FauIty reguIator]rectifier
2. The controI voItage exceeds the standard vaIue significantIy
(page 14-4)
FauIty battery
FauIty reguIator]rectifier
FauIty reguIator]rectifier earth
REGULATOR]RECTIFIER
SYSTEM INSPECTION
Remove the AIternator 3P (bIack) coupIer and the reguIator]
rectifier 2P (naturaI) coupIer. Check for Iooseness or damage
of the coupIer.
Measure the foIIowing items between the AIternator coupIer
and wire harness side coupIer of the reguIator]rectifier.
ABNORMAL CHARGING VOLTAGE
3P (BLACK) COUPLER
If aII harness side inspections are normaI, check for fauIty
connection of the reguIator]rectifier coupIer. If there is no ab-
normaIity, repIace the reguIator]rectifier.
If there is an abnormaIity in the charging coiI wire inspection,
inspect the AIternator (page 14-9).
REMOVAL and INSTALLATION
Open the cover and disconnect the AIternator 3P (bIack) cou-
pIer and the reguIator]rectifier 2P (naturaI) cooper.
Item
Battery wire
(red]white)
Earth wire (green)
Charging coiI wire
(yeIIow)
Judgment
There shouId be battery voItage
between red]white (+) wire and
green () wire.
There shouId be continuity between
green wire and body ground wire.
There shouId be the foIIowing
resistance between yeIIow termi-
naIs.
0.1 1.0 (20 C)
ENGINE SPEED
3P (BLACK) CONNECTOR
14-9
Remove the boIts and the reguIator]rectifier.
InstaIIation is the reverse order of removaI.
ALTERNATOR
INSPECTION
NOTE:
Inspection can be done without removing the AIternator from
the engine.
Disconnect the AIternator 3P (bIack) coupIer.
Measure the resistance between the yeIIow terminaIs of the
engine side coupIer.
STANDARD: 0.1 1.0 (20 C)
If the resistance between terminaIs is abnormaI, repIace the
stator.
Check for no continuity between the yeIIow terminaI of the
engine side coupIer and body ground.
If there is continuity between the yeIIow terminaI and the body
ground, repIace the stator.
BOLTS
3P (BLACK) COUPLER
REMOVAL
Remove the drive sprocket cover (page 6-2).
Remove the stator reduction gear (page 16-6).
Remove the boIt and the change pedaI.
BOLT CHANGE PEDAL
REGULATOR]RECTIFIER
3P (BLACK) COUPLER
14-10
Remove the foIIowing parts.
PuIse generator]neutraI switch 3P (naturaI) coupIer
Seat (page 2-2)
AIternator 3P (bIack) coupIer
Nut
Washer
NeutraI switch cord
L, crankcase cover boIt
L, crankcase cover
3P (BLACK) COUPLER
NUT CORD
WASHER
BOLT L, CRANKCASE COVER
14-11
Gasket
Knock pin
PuIse generator socket boIts
PuIse generator connector
PuIse generator
KNOCK PIN
CIamp socket boIt
CIamp
Grommet
Stator boIts
Stator
BOLT
STATOR
BOLT
GASKET
CONNECTOR
PULSE GENERATOR
GROMMET BOLT
CLAMP
14-12
Stator idIe gear
Washer
FIywheeI boIt.
FIywheeI Assy.
FIywheeI puIIer 07733 0020001
Woodruff key
NOTE:
When removing the woodruff key, make sure not to damage
the key groove or crankshaft. And make sure not to Iose it
after removing.
NeedIe bearing
Washer
IDLE GEAR
WASHER
BOLT
FLYWHEEL HOLDER
FLYWHEEL PULLER
FLYWHEEL ASSY.
WOODRUFF KEY NEEDLE BEARING
WASHER
14-13
DISASSEMBLY
Remove the stator driven gear whiIe turning it counter cIock-
wise.
Washer
One-way cIutch outer boIts
One-way cIutch Assy.
STARTER DRIVEN GEAR
WASHER
FLYWHEEL HOLDER
BOLT
ONE-WAY CLUTCH ASSY.
14-14
ASSEMBLY
One-way cIutch
CIean up the one-way cIutch and appIy engine oiI to the sprag.
Orient the fIange side of one-way cIutch to the fIywheeI side
and instaII the one-way cIutch to the one-way cIutch outer.
ONE-WAY CLUTCH
ONE-WAY CLUTCH
STARTER DRIVE GEAR
ONE-WAY CLUTCH
FLYWHEEL
ONE-WAY CLUTCH BOLT 1.6 kg-m
WASHER
STARTER CLUTCH OUTER
CLUTCH OUTER
14-15
InstaII the one-way cIutch Assy. to the fIywheeI.
CIean up the threads of one-way cIutch outer boIt and appIy a
Iocking agent to the threads.
Use the foIIowing tooIs to fix the fIywheeI.
InstaII the one-way cIutch outer boIt and tighten to the speci-
fied torque.
TOROUE: 1.6 kgm
InstaII the washer.
InstaII the starter drive gear whiIe turning it counter cIock-
wise.
ONE-WAY CLUTCH ASSY.
FLYWHEEL
FLYWHEEL HOLDER
BOLT
WASHER
STARTER DRIVEN GEAR
14-16
INSTALLATION
InstaII the washer.
AppIy engine oiI to the needIe bearing and instaII it.
CIean up and degrease the taper portion of the crankshaft.
InstaII the woodruff key.
Set the woodruff key of the crankshaft to the key groove of
fIywheeI and instaII the fIywheeI.
Use the foIIowing tooIs to fix the fIywheeI.
AppIy oiI to the threads and fIange surface of fIywheeI boIt.
Tighten the fIywheeI to the specified torque.
TOROUE: 10.5 kgm
InstaII the starter idIe gear and washer.
WOODRUFF KEY NEEDLE BEARING
WASHER
BOLT
FLYWHEEL HOLDER
IDLE GEAR
WASHER
14-17
CIean up the threads of the stator boIts and appIy a Iocking
InstaII the foIIowing parts.
Stator
Stator boIts
TOROUE: 1.0 kgm
Grommet
NOTE:
AppIy a seaIing agent to the crescent portion of grommet
and instaII it to the L, crankcase cover secureIy.
CIean up the threads of the crank socket boIts and appIy a
Iocking agent to the threads.
CIamp
CIamp socket boIt
TOROUE: 0.5 kgm
BOLT
STATOR
GROMMET
BOLT
CLAMP
GROMMET
CLAMP SOCKET BOLT 0.5 kgm
CLAMP
PULSE GENERATOR SOCKET BOLT 0.5 kgm
PULSE GENERATOR
STATOR
STATOR BOLT
1.0 kgm
14-18
PuIse generator
PuIse generator connector
NOTE:
Before instaIIing the puIse generator socket boIts, cIean up
the threads and appIy a Iocking agent to threads.
TOROUE: 0.5 kgm
New gasket
Knock pin
L, crankcase cover
L, crankcase cover boIts
TOROUE: 1.2 kgm
CONNECTOR
NeutraI switch cord
Washer
Nuts
TOROUE: 0.15 kgm
NOTE:
Route the neutraI switch cord through correct Iocation as
BOLT
PULSE GENERATOR
GASKET
KNOCK PIN
L, CRANKCASE COVER
BOLT
NUT CORD
WASHER
14-19
AIternator 3P (bIack) coupIer
PuIse generator]neutraI switch 3P (naturaI) coupIer
Seat (page 2-2)
NOTE:
Route the wires and harnesses through correct Iocation as
InstaII the change pedaI and tighten the change pedaI boIt to
TOROUE: 1.2 kgm
InstaII the drive sprocket cover (page 6-5).
InstaII the starter reduction gear (page 16-6).
3P (BLACK) COUPLER
SEAT
BOLT
CHANGE PEDAL
15-1
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION 15-6
IGNITION COIL 15-8
PULSE GENERATOR INSPECTION 15-9
IGNITION TIMING 15-9
SERVICE INFORMATION
When servicing the ignition system, aIways foIIow the steps in the troubIeshooting sequence on page 15-3.
For the Iayout of eIectricaI parts, see the iIIustration on page 15-0.
Ignition timing cannot be adjusted since the eIectronic spark advance device is buiIt into the ignition system unit.
HandIe the CDI unit carefuIIy since it may be damaged if dropped or exposed to strong impact. AIso, if either the coupIer
or connector is disconnected or reconnected when current is present, a voItage surge may occur and damage the
circuits within the unit. AIways perform any servicing with main switch turned OFF.
A fauIty ignition system is often reIated to poorIy connected coupIers or connecters. Check those connections before
performing each service.
Use a good condition battery whiIe servicing. Ignition may not occur since a Iow capacity battery consumes power
when rotating the seIf-starter and reduces the cranking speed.
Use a spark pIug of the correct heat range. Using a spark pIug with an incorrect heat range can damage the engine.
This manuaI mainIy describes inspection by peak voItage. AIso, the inspection by coiI resistance is Iisted however,
correct judgment may not be obtained.
This motorcycIe uses an ignition cut off type side stand. This device operates the ignition system when the gear is in
neutraI and]or the side stand is in the retracted position.
15
15. IGNITION SYSTEM
15-2
IGNITION SYSTEM
SERVICE SPECIFICATIONS
TOROUE
Timing hoIe cap 1.0 kgm AppIy grease to the threads and fIange surface.
SPECIAL TOOLS
Peak voItage adaptor 07HGJ-0020100
PuIse generator
ITEM SPECIFICATIONS
Ignition type
Spark pIug
CDI
Standard
NGK
CR8 EH-9
CR7 EH-9
CR9 EH-9
NIPPON DENSO
U24FER9
U22FER9
U27FER9
Spark pIug gap
Ignition timing
0.8 0.9 mm
8 BTDC]1,300 rpm
1,900 200 rpm
4,300 rpm
MP13
0.1 - 0.3
7.2 - 11.0 k
3.5 - 4.7 k
100 V minimum
460 580
0.7V minimum
F mark
advance
Type Ignition coiI
Resistance
at 20 C
Primary coiI
Secondary coiI with
a pIug cap
Secondary coiI
without a pIug cap
Peak voItage
Resistance at 20 C
Peak voItage
15-3
IGNITION SYSTEM
NormaI
AbnormaI
AbnormaI
TROUBLESHOOTING
Inspect the foIIowing before diagnosing the system.
FauIty connection of spark pIug cap or spark pIug wire.
Water got into the spark pIug cap
FauIty connection of the ignition system coupIers or connectors.
No spark at pIug
Inspect the operation of starter motor (page 16-
2).
Measure the ignition coiI primary voItage (page
15-6).
Remove CDI unit coupIer.
Measure the puIse generator peak voItage at the
harness side of CDI unit (page 15-7).
CONNECTION: BIue]YeIIow (+) Body ground ()
STANDARD: 0.7 V MINIMUM
NormaI
FauIty or discharged battery
FauIty starting unit
CDI unit fauIty.
AbnormaI
CONNECTION: BIack]YeIIow (+) Body ground ()
STANDARD: 100 V MINIMUM
NormaI
FauIty spark pIug or ignition coiI secondary cur-
rent Ieaking.
Ignition coiI fauIty.
15-4
IGNITION SYSTEM
NormaI
AbnormaI
AbnormaI
NormaI
AbnormaI
Disconnect the puIse generator coupIer.
Measure the puIse generator peaI voItage (page
15-7).
Turn the main switch ON and inspect the opera-
tion of side stand warning Iight.
Disconnect the side stand switch coupIer.
Check for the continuity of side stand switch
(page 17-22).
SIDE STAND RETRACTED STATE:
Green]White Green CONTINUITY
SIDE STAND PARKING STATE:
YeIIow]BIack Green CONTINUITY
NormaI
PuIse generator fauIty.
Side stand switch fauIty.
Open or short circuit in yeIIow]bIack terminaI cord.
BIown side stand warning Iight buIb.
Disconnected or poorIy connected side stand
switch coupIer.
Open or short circuit in bIue]yeIIow terminaI cord.
IGNITION CUTOFF SYSTEM INSPECTION
15-5
IGNITION SYSTEM
NormaI
AbnormaI
Inspect the continuity at CDI unit coupIer harness
side.
NeutraI switch fauIty.
Open circuit in fresh green cord.
Diode fauIty.
Open circuit in green]white terminaI cord.
CONNECTION:
Green]White terminaI (+) Body ground
Transmission in neutraI position: Continuity
Transmission not in neutraI position:
No continuity
CDI unit fauIty.
15-6
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
NOTE:
If there is no spark at the pIug, check aII connections for
Ioose or poor contact before measuring each peak voIt-
age.
The dispIay vaIue differs and the correct vaIue cannot be
measured since the impedance of the muItimeter varies
depending upon the type of muItimeter. Use a digitaI muI-
timeter with a minimum impedance of 10 M ]V DC.
Connect the peak voItage adapter to the digitaI muItimeter.
Peak voItage adapter 07HGJ 0020100
IGNITION COIL PRIMARY PEAK VOLTAGE
NOTE:
Check aII connections before inspection. If the system is
disconnected, an incorrect voItage might be measured.
Check cyIinder compression and that the spark pIug is in-
staIIed correctIy. If the spark pIug cap is disconnected and
the voItage is measured, a higher peak voItage might be
obtained.
Leave the spark pIug in the engine as normaI spark test and
instaII a good pIug to the pIug cap and ground it to the en-
gine.
Turn the main switch ON and set the kiII switch to RUN.
Open the rubber cover of the ignition coiI and connect the
peak voItage adapter between the primary cord terminaI and
body ground with the cord connected to the ignition coiI.
Use the starter motor to crank the engine and measure the
peak voItage.
PEAK VOLTAGE: 100 V minimum
If the measured vaIue is abnormaI inspect the items shown
in the troubIeshooting tabIe.
PEAK VOLTAGE
ADAPTER
GOOD SPARK PLUG
(+) PROBE: BLACK]YELLOW IGNITION COIL
() PROBE: BODY GROUND
15-7
IGNITION SYSTEM
PULSE GENERATOR PEAK VOLTAGE
NOTE:
obtained.
Remove the CDI unit 4P (naturaI) coupIer.
Connect the tester probe of the peak voItage adapter to the
harness side of the foIIowing terminaI.
CONNECT TERMINAL: BIue]YeIIow (+) Body ground ()
Crank the engine with starter motor and measure the peak
voItage.
PEAK VOLTAGE: 0.7 V minimum
Measure the peak voItage at puIse generator]neutraI switch
3P (naturaI) coupIer again if the peak voItage measured at
CDI unit 4P (naturaI) coupIer terminaI is abnormaI.
Disconnect the puIse generator]neutraI switch 3P (naturaI)
coupIer.
Connect the tester probe of peak voItage adapter to the foI-
Iowing terminaI at the harness side.
peak voItage.
PEAK VOLTAGE: 0.7 V MINIMUM
If the voItage measured at the CDI unit coupIer terminaI is
abnormaI and the voItage measured at the generator cou-
pIer is normaI, check for open circuit in wire harness or
contact faiIure in coupIer.
If both voItages are abnormaI, repIace the puIse generator
(page 14-9).
(+) PROBE: BLUE]YELLOW 4P (NATURAL) COUPLER
(+) PROBE: BLUE]YELLOW 3P (NATURAL) COUPLER
15-8
IGNITION SYSTEM
IGNITION COIL
INSPECTION
Disconnect the ignition coiI primary side connector.
Measure the ignition coiI primary side resistance between
terminaIs.
STANDARD: 0.1 0.3 (20 C)
Measure the ignition coiI secondary side resistance between
green terminaI and spark pIug cap.
STANDARD: 7.2 11.0 k (20 C)
If the measured vaIue is out of the standard vaIue range, re-
move the spark pIug cap and measure the ignition coiI sec-
ondary resistance between spark pIug cord and green termi-
naI.
STANDARD: 3.5 4.7 k (20 C)
REMOVAL]INSTALLATION
Remove the ignition coiI primary side connector.
Remove the spark pIug cap from the pIug.
Remove the boIt and remove the ground cord and ignition
coiI.
NOTE:
When instaIIing, tighten the ground cord with the boIt.
IGNITION COIL
GREEN TERMINAL
PLUG CAP
GREEN TERMINAL
SPARK PLUG CORD
IGNITION COIL
CONNECTOR GROUND CORD
PLUG CAP
BOLT
15-9
IGNITION SYSTEM
PULSE GENERATOR INSPECTION
INSPECTION
NOTE:
The puIse generator can be inspected whiIe it is mounted on
the engine.
Disconnect the CDI unit 4P (naturaI) coupIer.
Measure the resistance of the puIse generator between the
CDI unit 4P (naturaI) coupIer bIue]yeIIow terminaI and body
ground.
STANDARD: 460 580 (20 C)
If the measured vaIue is abnormaI, inspect the puIse genera-
tor separateIy.
coupIer.
Measure the resistance between the puIse generator side bIue]
yeIIow terminaI and body ground.
STANDARD: 460 580 (20 C)
If the measured vaIue is abnormaI, repIace the puIse genera-
tor (page 14-9).
IGNITION TIMING INSPECTION
NOTE:
Ignition timing inspection shouId be done after the engine
is warm up.
The ignition timing cannot be adjusted since the eIectronic
advance angIe device is used.
If the ignition timing is abnormaI, inspect the CDI unit and
puIse generator. If the device is fauIty, repIace it.
Read the timing Iight operation manuaI and use the Iight
correctIy.
Warm up the engine.
Remove the timing hoIe cap.
Stop the engine and connect the timing Iight to the spark pIug
cord.
InstaII the engine tachometer.
TIMING HOLE CAP
TIMING LIGHT
15-10
IGNITION SYSTEM
Start the engine and make sure that F mark on the fIywheeI
is in Iine with the aIignment mark on the L, crank case cover
at idIing speed (1,300 100 rpm).
Increase the engine speed graduaIIy to 4,300 rpm, and make
sure that the aIignment mark on the L, crank case cover is
within the range of advance mark.
AppIy engine oiI to the new O-ring.
AppIy grease to the threads and fIange surface of the timing
hoIe cap and tighten the cap to the specified torque.
TOROUE: 1.0 kg-m
ALIGNMENT MARK
ALIGNMENT MARK
ADVANCE MARK
O-RING
F MARK
TIMING HOLE CAP
16-1
16. STARTING SYSTEM
SERVICE INFORMATION
When servicing the starter system, aIways foIIow the steps in the troubIeshooting sequence on page 16-2.
For the Iayout of starting system parts, see the iIIustration on page 16-0.
If the battery is discharged, the rotating power of the starter motor is Iost and the engine cannot be cranked. In case of
starter faiIure, first connect a good condition battery and check if the cause is a discharged battery.
The starter motor coiI may burn out if subject to excessive current through the motor by forcibIy turning the starter
motor when the engine cannot be cranked.
SPECIFICATIONS
STARTER REDUCTION GEAR 16-6
16
STARTER MOTOR 16-7
STARTER MOTOR RELAY SWITCH 16-14
ITEM STANDARD
Unit: mm
SERVICE LIMIT
8.5
16-2
STARTING SYSTEM
TROUBLESHOOTING
Before servicing, check whether the main fuse (20A) or sub fuse (15A) has bIown.
Check for any disconnection or Iooseness of the battery or starter motor cabIe connections.
If the battery is discharged, the rotating power of the starter motor is Iost and the engine cannot be cranked. In case of
starter faiIure, first connect a good battery and check if the cause is a discharged battery.
Before any starter motor inspection, make sure that of side stand and transmission gear are in positions in which the
engine can be started.
If the gear is in neutraI, the starter motor can be turned regardIess of the positions of the side stand switch or cIutch
switch.
If the gear is in any position other than neutraI, see the foIIowing tabIe.
Check for poorIy connected battery terminaI or
short circuit.
Check for poorIy connected starter reIay switch
4P coupIer.
AbnormaI
NormaI
PoorIy connected connectors in the battery termi-
naI.
Gear position (other than
neutraI)
CIutch Iever
HeId position
ReIeased position
HeId position
ReIeased position
Starter motor
Turns
Does not turn
Turns
Does not turn
Side stand
Retracted position
Parking position
Starter does not turn
NormaI
AbnormaI
PoorIy connected starter reIay switch 4P coupIer.
16-3
STARTING SYSTEM
Check for poorIy connected starter motor cabIe
terminaI or short circuit.
AbnormaI
PoorIy connected starter motor cabIe or open cir-
cuit.
No noise
NormaI
Make sure that a cIicking noise occurs in the
starter reIay when the main switch is ON, kiII
switch is RUN, and the starter switch is pressed.
Noise occurs
Check whether the motor turns when the starter
motor (+) cabIe is disconnected and is contacted
with the battery () terminaI. (Do not use smaII
cord since Iarge current fIows.)
Turns
No turn
Starter motor fauIty.
PoorIy connected starter
motor cabIe.
Operation faiIure of the
starter motor reIay switch.
Remove the starter motor reIay switch 4P
coupIer and check the ground wire.
1. Green]red terminaI and ground wire of neutraI
switch. (Perform the inspection whiIe cIutch
Iever is not heId and the gear is in the neutraI
position.)
CONNECTION TERMINAL: Green]Red ()
Body ground (+)
2. Green]red terminaI and ground wire of side
stand switch. (Perform the inspection whiIe
cIutch Iever is heId, gear is in any position
other than the neutraI position, and the side
stand is retracted position.)
CONNECTION TERMINAL: Green]Red ()
Body ground (+)
Continuity
No continuity
CIutch switch diode fauIty.
CIutch switch fauIty.
CoupIer, connector fauIty.
Open circuit in wire harness.
16-4
STARTING SYSTEM
Connect the starter reIay 4P coupIer. Turn the
main switch ON and the kiII switch RUN. Press
the starter switch and inspect the starter reIay
voItage at the starter reIay switch coupIer.
(Connect (+) to yeIIow]red and () to body
ground.)
CONNECTION TERMINAL: YeIIow]Red (+)
Body ground ()
STANDARD: BATTERY VOLTAGE
No voItage
Main switch or starter switch fauIty.
PoorIy connected coupIer or connecter.
Open circuit in starter switch wire.
There is voItage.
Remove the starter reIay switch.
Connect a fuIIy charged battery to the starter
reIay switch as shown the foIIowing drawing.
Check for continuity between the terminaIs with
the battery connected.
BATTERY CONNECTION: YeIIow]Red (+)
Green]Red ()
Starter motor turns when the gear is in the neutraI position. However, starter motor does not turn when the gear is
any position other than neutraI even when the side stand is retracted and the cIutch Iever is heId.
Check whether the side stand indicator Iights up
when the main switch is ON and the side stand is
in the parking position.
NormaI
PoorIy connected starter reIay 4P coupIer.
AbnormaI
Starter reIay switch fauIty.
Does not
Iight up
Warning Iight buIb bIown.
PoorIy connected side stand switch coupIer.
Lights up
16-5
STARTING SYSTEM
Inspect the cIutch switch.
AbnormaI
CIutch switch fauIty.
NormaI
Inspect the side stand switch.
SIDE STAND RETRACTED STATE: Continuity for
Green]White Green
SIDE STAND PARKING STATE: Continuity for
YeIIow]BIack Green
AbnormaI
NormaI
PoorIy connected side stand switch coupIer, cIutch
switch connector.
Rotating power of the starter motor is weak (cannot be
cranked)
Battery Iow capacity (fuIIy discharged)
PoorIy connected battery terminaI cabIe
PoorIy connected starter motor cabIe
Starter motor fauIty
Worn or damaged brush
Starter motor turns with no Ioad
Motor reverse rotation
Motor case is assembIed reverseIy.
Motor terminaIs are connected reverseIy.
Starter cIutch sIip
Starter motor is normaI but does not crank
Crankshaft does not turn due to a engine faiIure.
FauIty starter reduction gear.
Damaged starter idIe gear.
16-6
STARTING SYSTEM
STARTER REDUCTION GEAR
REMOVAL
NOTE:
PIace a cIean oiI pan under the engine to receive engine oiI
since it comes out when the starter reduction gear cover is
removed.
BoIts
Starter reduction gear cover
O-ring
Starter reduction gear shaft
Starter reduction gear
INSPECTION
Inspect the starter reduction gear and shaft.
Worn or damaged starter reduction gear RepIace
Worn or damaged starter reduction gear shaft RepIace
INSTALLATION
AppIy engine oiI to the starter reduction gear]shaft.
Starter reduction gear
Starter reduction gear shaft
BOLT
COVER
O-RING
SHAFT
GEAR
GEAR
SHAFT
16-7
STARTING SYSTEM
AppIy engine oiI to the new O-ring and instaII it to the starter
reduction gear cover.
InstaII the starter reduction gear cover.
AIign the mark of the starter reduction gear cover with
the position shown on the photo.
InstaII the boIt and tighten it secureIy.
STARTER MOTOR
REMOVAL
Rubber cap
Starter motor cabIe nut
Starter motor cabIe
Starter motor boIts
Ground cabIe
Starter motor
O-ring
COVER
O-RING
MARK
BOLTS
RUBBER CAP
GROUND CABLE
NUT
BOLTS
STARTER MOTOR
O-RING
16-8
STARTING SYSTEM
DISASSEMBLY
AssembIy boIt
PIate
O-ring
Front cover
O-ring
Lock washer
InsuIated washer
Thrust washers
NOTE:
To reassembIe the thrust washers in their originaI positions,
note their order and number.
Rear cover Assy.
O-ring
Thrust washers
NOTE:
To reassembIe the thrust washers in their originaI positions,
note their order and number.
Armature
Starter motor case
BOLT
O-RING
PLATE
O-RING
THRUST WASHER
LOCK WASHER
INSULATED WASHER
FRONT COVER
REAR COVER ASSY.
THRUST WASHER
O-RING
STARTER MOTOR CASE
ARMATURE
16-9
STARTING SYSTEM
TerminaI nut
Washer
InsuIated washer
Shim
O-ring
Brush hoIder Assy.
TerminaI boIt stopper
Rear cover
Brush spring
TerminaI boIt
Brush hoIder
NUT
WASHER
INSULATED WASHER
SHIM
O-RING
BRUSH HOLDER ASSY. REAR COVER
STOPPER
BOLT BRUSH HOLDER
SPRING
16-10
STARTING SYSTEM
INSPECTION
Inspect the armature.
UnevenIy worn or damaged commutator surface RepIace
Burnout commutator surface (discoIored) RepIace
MetaI particIes adhered to areas between segments CIean
up
Check for continuity of armature.
Between segments: Continuity
Between segment and armature shaft: No continuity
RepIace the armature if there is abnormaIity.
Measure the brush Iength.
SERVICE LIMIT: REPLACE IF LESS THAN 8.5 mm
Check for continuity of rear cover Assy.
Between the starter motor terminaI and brush: Continuity
Between the starter motor terminaI and rear cover: No conti-
nuity
RepIace parts if there is abnormaIity.
NO CONTINUITY CONTINUITY
REAR COVER ASSY.
16-11
STARTING SYSTEM
ASSEMBLY
Brush hoIder
TerminaI boIt
Brush spring
Rear cover
TerminaI boIt stopper
Brush hoIder Assy.
NOTE:
AIign the tang of brush hoIder with the rear cover sIot and
instaII it.
New O-ring
Shim
InsuIated washer
Washer
TerminaI nut
BOLT BRUSH HOLDER
SPRING
ALIGN
BRUSH HOLDER ASSY. STOPPER
REAR COVER
SHIM
O-RING
INSULATED WASHER
NUT
WASHER
16-12
STARTING SYSTEM
Starter motor case
Armature
Thrust washer
NOTE:
ReinstaII the thrust washers in their originaI positions in the
order and numbers that are noted when disassembIing.
New O-ring
Rear cover Assy.
NOTE:
AIign the protrusion of rear cover Assy. with the motor case
notch and assembIy them.
Thrust washers
NOTE:
ReinstaII the thrust washers in their originaI positions in the
order and numbers that are noted when disassembIing.
InsuIated washer
Lock washer
NOTE:
AIign a protrusion of the Iock washer with a notch of the front
cover and assembIy them.
New O-ring
Front cover
NOTE:
AIign matching marks of the front cover and motor case.
STARTER MOTOR CASE
ARMATURE
REAR COVER ASSY.
ALIGN
O-RING
THRUST WASHERS
O-RING
THRUST WASHERS
LOCK WASHER
INSULATED WASHER
ALIGN
ALIGN
FRONT COVER
16-13
STARTING SYSTEM
New O-ring
PIate
AssembIy boIts
INSTALLATION
AppIy engine oiI to the new O-ring.
New O-ring.
Starter motor
Ground cabIe
Starter motor boIts
NOTE:
Tighten the starter boIt together with the oiI pass pipe cIamp
and ground cabIe.
Starter motor cabIe
Starter motor cabIe nut
Rubber cap
NOTE:
Route the cabIes through correct Iocation as shown on the
wiring drawing (page 1-19).
InstaII the rubber cap secureIy after the instaIIation.
InstaII the exhaust pipe (page 2-8)
BOLT
O-RING PLATE
O-RING
STARTER MOTOR
GROUND CABLE
STARTER MOTOR CABLE
BOLT
NUT
RUBBER CAP
16-14
STARTING SYSTEM
STARTER RELAY SWITCH
INSPECTION
NOTE:
Before inspection, make sure that battery is in good condi-
tions.
Inspect whether a cIicking noise occurs in the starter reIay
when the main switch is ON, kiII switch is RUN, and the starter
switch is pressed.
VOLTAGE INSPECTION
Disconnect the starter reIay switch 4P coupIer.
Connect the voItmeter to the harness side connector of 4P
coupIer.
Measure the voItage when the main switch is turned ON ,
the kiII switch is turned RUN , and the starter switch is
pressed.
CONNECTION: YeIIow]Red (+) Body ground ()
CONTINUITY INSPECTION
Disconnect the starter reIay switch 4P coupIer.
Check for continuity at the harness side of the 4P coupIer ter-
minaI.
CONNECTION: Green]Red Body ground
STANDARD:
CIutch Iever puIIed: Continuity
Gear in neutraI: Continuity
OPERATION INSPECTION
Remove the starter reIay switch.
Connect fuIIy charged battery to the starter reIay switch.
Check for continuity between the terminaIs.
BATTERY CONNECTION: YeIIow]Red (+) Green]Red ()
(+) PROBE: YELLOW]RED
BODY GROUND
GREEN]RED TERMINAL
BATTERY
17-1
17. LIGHT, METER, SWITCH
SERVICE INFORMATION
HaIogen headIight buIbs become very hot whiIe in use. When repIacing the buIb, be carefuI not to aIIow any oiI to
contaminate the surface from your bare hands or gIoves. Such contaminated areas become hot spots and may ther-
maIIy deform the gIass surface, thus damaging the buIb.
Note the foIIowing precautions when repIacing the buIb:
Never repIace the buIb whiIe the headIight is on. AIways turn the main switch OFF and repIace the buIb after it has
cooIed down.
When repIacing the buIb, aIways wear new gIoves and avoid any oiI from coming into contact with the gIass.
If any oiI adheres to the gIass, use an aIcohoI- or thinner-dampened cIoth to cIean off the oiI.
After repIacing the buIb, ensure the dust cover is properIy instaIIed.
Continuity inspection of switches can be performed once the parts are instaIIed.
First, check that there is no abnormaIity with the battery when using a battery to perform the inspection.
BULB REPLACEMENT 17-4
HEADLIGHT (XR BAJA) 17-4
HEADLIGHT (XR 250) 17-11
DIGITAL METER 17-11
SPEED SENSOR 17-14
THROTTLE SENSOR 17-16
17
MAIN SWITCH 17-18
HANDLEBAR SWITCH 17-19
STOPLIGHT SWITCH 17-21
CLUTCH SWITCH 17-21
NEUTRAL SWITCH 17-21
SIDE STAND SWITCH 17-22
HORN 17-23
17-2
LIGHT, METER, SWITCH
Disconnect the battery (+) terminaI to reset the
digitaI meter forcedIy.
After a few seconds, connect the battery (+)
terminaI and check whether the digitaI meter
dispIays.
DigitaI meter fauIty.
NO DISPLAY
TROUBLESHOOTING
Turn the main switch ON and inspect whether aII segments on the digitaI meter are dispIayed for two to three sec-
onds. After a voItage is appIied to the speed sensor, the digitaI meter reverts to its normaI dispIay.
When the battery terminaI is disconnected, the data (such as miIeage and time) in the digitaI meter is cIeared. For
detaiIs on how to reset the digitaI meter, see the operation manuaI.
If the dispIay on the digitaI meter is abnormaI, often the cause is a poorIy connected battery (+) cabIe or coupIer. Before
servicing, check whether the connecters are poorIy connected.
DIGITAL METER DOES NOT DISPLAY
NOTE:
Before troubIeshooting, measure the battery voItage.
If the battery voItage is 7 V maximum, the digitaI meter does not dispIay.
If the battery voItage is 3 V maximum, the data (such as miIeage and time) in the digitaI meter is cIeared.
Inspect the sub fuses 15 A (for stop, horn, taiI,
turn signaI, and meter) within the fuse box and
repIace abnormaI fuses such as bIown out fuse.
Inspect the circuits and repIace the fuse.
FUSE BLOWN
OUT
Inspect the sub fuses 15 A (for cIock) within the
fuse box and repIace abnormaI fuses such as
bIown out fuse.
Inspect the circuits and repIace the fuse.
FUSE BLOWN
OUT
NO FUSE BLOWN OUT
Disconnect the digitaI meter 4P coupIer.
Turn the main switch ON and measure the
voItage between the harness side of 4P coupIer
and 3P coupIer.
CONNECT: BIack]Brown (+) Green ()
Open or short circuit between the bIack]brown ter-
minaI and green terminaI.
Measure the voItage between the harness side of
4P coupIer and 3P coupIer.
CONNECT: Red]Green (+) Green ()
Open or short circuit between the red]green termi-
naI and green terminaI.
Sub fuse 5 A bIown out.
ABNORMAL
ABNORMAL
NO FUSE BLOWN OUT
NORMAL
NORMAL
17-3
Turn the main switch ON and measure the
voItage at the meter side of 3P coupIer.
CONNECT: BIack]BIue (+) BIue]BIack ()
STANDARD: 9 11 V
Sub fuses (15 A, 5 A) bIown out.
Open or short circuit between the bIack]brown ter-
minaI and green terminaI.
Open or short circuit between the red]green termi-
naI and green terminaI.
NORMAL
ABNORMAL
NO VEHICLE SPEED COUNTED OR NO MILEAGE COUNTED
Connect the digitaI meter 3P coupIer.
Connect the voItage meter (anaIog) to the 3P
coupIer with the digitaI meter 3P coupIer con-
nected.
Turn the main switch ON .
Inspect the voItage and the number of times the
tester needIe fIuctuates when the front wheeI is
graduaIIy rotated one fuII turn.
CONNECTION: White]BIue (+) BIue] BIack ()
STANDARD VOLTAGE: 3 5 V
NUMBERS OF NEEDLE FLUCTUATION: 15 TIMES
Speed sensor fauIty.
ABNORMAL
NORMAL
Disconnect the battery (+) terminaI to reset the
digitaI meter forcedIy.
After a few seconds, connect the battery (+)
terminaI and check whether the digitaI meter
dispIays again.
ABNORMAL
17-4
BULB REPLACEMENT
HEADLIGHT BULB (XR BAJA)
Remove the dust cover.
Turn the buIb socket counter cIockwise and remove it.
Remove the headIight buIb and repIace it with new one.
InstaII the headIight buIb to the headIight unit.
NOTE:
When instaIIing the buIb, aIign a protruding portion of the
buIb with a sIot of the headIight unit.
InstaII the buIb socket to the headIight unit and turn the socket
counter cIockwise to Iock it.
DUST COVER
BULB SOCKET
HEADLIGHT BULB
BULB SOCKET
ALIGN
17-5
InstaII the dust cover.
NOTE:
Turn the TOP mark up.
HEADLIGHT BULB (XR250)
Remove the headIight (page 17-11).
Turn the buIb socket counter cIockwise and remove it.
Remove the headIight buIb and repIace it with new one.
InstaII the headIight buIb to the headIight unit.
NOTE:
When instaIIing the buIb, aIign a protruding portion of the
buIb with a sIot of the headIight unit.
When instaIIing the dust cover, turn the TOP mark up.
TAIL]STOP LIGHT
Loosen the screw and remove the taiI]stop Iight Iens.
TOP MARK
DUST COVER
ALIGN
TOP MARK
DUST COVER
BULB SOCKET
BULB
SCREW
LENS
17-6
Turn the taiI]stopIight buIb counter cIockwise to remove it.
TURN SIGNAL BULB
Use a narrow () driver to pry the turn signaI case and re-
move the turn signaI Iens.
NOTE:
Make sure not to damage the Iens or the case.
Turn the turn signaI buIb counter cIockwise and remove it.
INDICATOR BULB
Remove the piIot box (page 17-12).
Remove the buIb socket.
BULB
LENS
BULB
BULB SOCKET
17-7
Remove the buIb from buIb socket and repIace it with new
one.
METER LIGHT BULB
Remove the digitaI meter (page 17-12).
Remove the nut and washer and remove the digitaI meter
from meter Iower case.
Remove the buIb socket.
Remove the buIb from buIb socket and repIace the buIb with
new one.
BULB
NUT
CASE
WASHER
BULB SOCKET
BULB
17-8
HEADLIGHT (XR: BAJA)
HEADLIGHT UNIT
REMOVAL
Remove the screws and remove the headIight unit from the
head Iight case.
Disconnect the headIight unit 3P (naturaI) coupIer.
INSTALLATION
The InstaIIation is in the reverse order of removaI.
NOTE:
When instaIIing the headIight unit, aIign its protrusion with a
sIot of the headIight case.
HEADLIGHT GUARD
RemovaI
Remove the headIight unit.
Disconnect the foIIowing coupIers and connector.
R. front turn signaI 2P (bIack) coupIer
R. handIe switch 9P (red) coupIer
L. handIe switch 9P (bIack) coupIer
L. handIe switch connector
Main switch 2P (bIack) coupIer
SCREW
ALIGN
HEADLIGHT UNIT
9P (BLACK)
COUPLER
2P (BLACK)
COUPLER
CONNECTOR
2P (BLACK) COUPLER
9P (RED) COUPLER
17-9
Disconnect the foIIowing coupIers.
PiIot box 6P (bIue) coupIer
L. turn signaI 2P (bIack) coupIer
DigitaI meter 4P (bIack) coupIer
DigitaI meter 3P (bIue) coupIer
Remove the digitaI meter (page 17-13).
Remove wires and harnesses from the head Iight case.
Remove the headIight guard boIts]nuts and remove the head-
Iight guard.
3P (BLACK)
COUPLER
4P (BLACK) COUPLER
2P (BLACK)
COUPLER
6P (BLUE)
COUPLER
3P (BLUE) COUPLER
HEADLIGHT CASE
BOLT]NUT
HEADLIGHT GUARD
17-10
InstaIIation
InstaIIation is in the reverse order of the removaI.
TOROUE: HEADLIGHT GUARD NUT: 0.5 kgm
NOTE:
Ensure the wires and harnesses are correctIy routed as per
the wiring diagram (page 1-19).
DIGITAL METER
DISASSEMBLY]ASSEMBLY
HEADLIGHT GUARD
L. TURN SIGNAL
L. HEADLIGHT CASE
R. HEADLIGHT CASE
R. TURN SIGNAL
PILOT BOX
17-11
HEADLIGHT (XR250)
REMOVAL
Remove the boIts.
Remove the headIight by removing a protruding portion at
the Iower side of headIight from the steering stem.
Disconnect the headIight connector.
INSTALLATION
Connect the head Iight connector.
InstaII the headIight by aIigning a protruding portion at the
Iower side of headIight with the steering stem.
Tighten the boIts secureIy.
DIGITAL METER
INSPECTION
Inspect the main fuse 20 A in the starter reIay switch, if the
fuse is bIown, repIace it with new one.
Inspect the sub fuses 15 A (for stop, horn, taiI, turn signaI and
meter) in the fuse box, if the fuse is bIown, repIace it with
new one.
Inspect the sub fuse 5 A (for cIock) in the fuse box, if the fuse
is bIown, repIace it with new one.
XR BAJA:
Remove the L. headIight unit (page 17-18).
XR 250:
Disconnect the digitaI meter 4P (XR BAJA: bIack, XR 250:
brown) coupIer.
Disconnect the digitaI meter 3P (bIue) coupIer.
Turn the main switch ON and measure the voItage at the
harness side of 4P (bIack) coupIer and 3P (bIue) coupIer.
CONNECT: BIack]Brown (+) Green ()
If there is any abnormaIity in the above inspections, check for
open or short circuit between the bIack]brown terminaI and
green terminaI.
If there is no abnormaIity in the circuit between the bIack]
brown terminaI and green terminaI, remove the battery (+)
terminaI to reset the digitaI meter forcedIy.
If the abnormaIity continues after reconnecting the battery
(+) terminaI, repIace the digitaI meter.
BOLT
HEADLIGHT
PROTRUDING PORTION
CONNECTOR
4P (BLACK) COUPLER
3P (BLUE) COUPLER
3P (BLUE) COUPLER
4P (BROWN) COUPLER
17-12
brown) coupIer.
Disconnect the digitaI meter 3P (bIue) coupIer.
Measure the voItage at the harness side of 4P (bIack) coupIer
and 3P (bIue) coupIer.
CONNECT: Red]Green (+) Green ()
If there is any abnormaIity in the above inspections, check for
open or short circuit between the red]green terminaI and green
terminaI or inspect the sub fuse 5A.
If there is no abnormaIity of the circuit between the red]green
terminaI and green terminaI, remove the battery (+) terminaI
to reset the digitaI meter forcedIy.
If the abnormaIity continues after reconnecting the battery
(+) terminaI, repIace the digitaI meter.
INSTALLATION
PILOT BOX
XR BAJA:
Remove the R.]L. headIight unit (page 17-8).
Disconnect the piIot box 6P (bIue) coupIer.
Disconnect the main switch 2P (bIack) coupIer.
XR 250:
Disconnect the piIot box 6P (bIue) coupIer.
4P (BLACK) COUPLER
3P (BLUE) COUPLER
3P (BLUE) COUPLER
4P (BROWN) COUPLER
2P (BLACK) COUPLER
6P (BLUE) COUPLER
2P (BLACK) COUPLER
6P (BLUE) COUPLER
17-13
Remove the boIts and remove the piIot box.
DIGITAL METER
Remove the piIot box.
XR BAJA:
Remove the foIIowing coupIers.
XR 250:
DigitaI meter 4P (brown) coupIer
Remove the boIts and remove the digitaI meter.
PILOT BOX
BOLTS
3P (BLACK) COUPLER
4P (BLACK) COUPLER
3P (BLUE) COUPLER
3P (BLACK) COUPLER
3P (BLUE) COUPLER
4P (BROWN) COUPLER
DIGITAL METER
BOLT
17-14
INSTALLATION
NOTE:
SPEED SENSOR
INSPECTION
XR: BAJA
Disconnect the digitaI meter 3P (bIack) coupIer.
XR: 250
Turn the main switch ON and measure the voItage at the
meter side of 3P (bIack) coupIer.
CONNECTION: BIack]BIue (+) BIue]BIack ()
STANDARD: 9 11 V
If there is any abnormaIity in the above inspection, inspect
the digitaI meter.
DIGITAL METER
PILOT BOX
3P (BLACK) COUPLER
3P (BLACK) COUPLER
3P (BLACK) COUPLER
17-15
Connect the digitaI meter 3P (bIack) coupIer.
Connect the voItage meter (anaIog) to the 3P (bIack) coupIer
with 3P (bIack) coupIer connected.
Turn the main switch ON .
Inspect the voItage and the number of times the tester needIe
fIuctuates when the front wheeI is graduaIIy rotated one fuII
turn.
CONNECTION: White]BIue (+) BIue] BIack ()
STANDARD VOLTAGE: 3 5 V
NUMBER OF NEEDLE FLUCTUATIONS: 15 TIMES
If there is any abnormaIity in the above inspection, repIace
the speed sensor.
XR: BAJA
XR: 250
Remove the speedometer cabIe.
Remove the boIts and remove the speed sensor.
NOTE:
3P (BLACK) COUPLER
3P (BLACK) COUPLER
3P (BLACK) COUPLER
CABLE
BOLTS
SPEED SENSOR
17-16
THROTTLE SENSOR
INSPECTION
XR BAJA:
Disconnect the digitaI meter 4P (bIack) coupIer and 3P (bIue)
coupIer.
XR 250:
Disconnect the digitaI meter 4P (brown) coupIer and 3P (bIue)
coupIer.
INPUT VOLTAGE
Turn the main switch ON , and measure the voItage at the
meter side of 4P (XR BAJA: bIack, XR 250: brown) coupIer
and 3P (bIue) coupIer.
CONNECTION: YeIIow]Red (+) BIue]Green ()
STANDARD: 4.5 5.5 V
If there is any abnormaIity in the above inspection, inspect
the digitaI meter (page 17-11).
OUTPUT VOLTAGE
Connect the digitaI meter 4P (XR BAJA: bIack, XR 250: brown)
and 3P (bIue) coupIers. Turn the main switch ON and mea-
sure the voItage with the 3P (bIue) coupIer connected.
CONNECTION: YeIIow]BIue (+) BIue]Green ()
MEASUREMENT CONDITION:
THROTTLE FULLY OPENED
THROTTLE STOP SCREW FULLY LOOSENED (FULLY
CLOSED)
Compare the measured vaIues with those obtained from the
formuIa shown on the next page and determine whether the
output voItages are correct.
4P (BLACK) COUPLER
3P (BLUE) COUPLER
3P (BLUE) COUPLER
4P (BROWN) COUPLER
3P (BLUE) COUPLER
4P (BLACK) COUPLER
3P (BLUE) COUPLER
17-17
THROTTLE FULLY OPENED:
Assuming that the input voItage previousIy measured is Va,
and the voItage obtained from the formuIa for the fuIIy opened
throttIe is Vo:
Va x 0.786 = Vo
then provided that the actuaIIy measured Vo vaIue when
the throttIe is fuIIy opened is within ten percent ( 10%) of the
caIcuIated vaIue, there is no probIem with the voItage.
CLOSED):
Assuming that the input voItage previousIy measured is Va,
and the voItage obtained from the formuIa for the Ioosened
(fuIIy cIosed) throttIe is Vc:
Va x 0.1 = Vc
then provided that the actuaIIy measured Vc vaIue when
the throttIe is fuIIy cIosed is within ten percent ( 10%) of the
caIcuIated vaIue, there is no probIem with the voItage.
AIso, retest using an anaIog tester and check that the voItage
indicator needIe fIuctuates as the throttIe is graduaIIy opened.
If any abnormaIity is reveaIed through the above inspections,
check for continuity.
brown) and 3P (bIue) coupIers, and measure the voItage at
the harness side of the 4P (XR BAJA: bIack, XR 250: brown)
and 3P (bIue) coupIers.
CONNECTION: YeIIow]Red BIue]Green
STANDARD : 4 6 k (20 C)
CONNECTION: YeIIow]BIue BIue]Green
STANDARD:
THROTTLE FULLY OPENED: 3.6 5.4 k (20 C)
THROTTLE STOP SCREW FULLY LOOSENED
(FULLY CLOSED): 0.4 0.6 k (20 C)
If any abnormaIity is reveaIed by the above inspections, per-
form the same inspection on the 3P coupIer of the throttIe
sensor.
Disconnect the throttIe sensor 3P (naturaI) coupIer.
Measure the resistance at the throttIe sensor side of the 3P
(naturaI) coupIer.
CONNECTION: YeIIow]Red BIue]Green
STANDARD : 4 6 k (20 C)
CONNECTION: YeIIow]BIue BIue]Green
STANDARD:
If there is any abnormaIity in the above inspections, repIace
the throttIe sensor.
If there is no abnormaIity in the above inspections, repIace
the wire harness.
4P (BLACK) COUPLER
3P (BLACK) COUPLER
3P (NATURAL ) COUPLER
17-18
MAIN SWITCH
INSPECTION
XR BAJA:
Remove the R. head Iight unit (page 17-8).
XR 250:
Remove the head Iight (page 17-11).
Remove the main switch 2P (bIack) coupIer.
Check for continuity at the main switch side of the 2P (bIack).
the main switch.
Remove the main switch from the piIot box whiIe pressing
the projection of the main switch.
NOTE:
When instaIIing, aIign a protruding portion of the main switch
with a sIot of piIot box.
ON
OFF
LOCK
COLOR
BAT 1
R
BAT 2
R]BI
2P (BLACK) COUPLER
2P (BLACK) COUPLER
MAIN SWITCH PROJECTION
PILOT BOX
MAIN SWITCH
ALIGN
PILOT BOX
17-19
HANDLEBAR SWITCHES
INSPECTION
XR BAJA:
Remove the R. headIight unit (page 17-18).
Remove the foIIowing coupIers and connector.
L. handIe switch connector
XR 250:
Remove the headIight (page 17-11)
Perform the foIIowing continuity inspections in the coupIers
at the R. handIe switch side.
KILL SWITCH
STARTER SWITCH
the R. handIe switch (page 11-3).
FREE
PUSH
COLOR
BAT 3
BI]Bu
ST
Y]R
OFF
ON
COLOR
BAT 5
BI]R
1G
BI]W
HL
Bu]W
9P (BLACK) COUPLER
9P (RED) COUPLER
CONNECTOR
6P (BLACK) COUPLER
6P (RED) COUPLER 4P (BLACK) COUPLER
R. HANDLE SWITCH
17-20
Perform the foIIowing continuity inspections in the coupIers
and connectors at the L. handIe switch side.
HORN SWITCH
DIMMER SWITCH
TURN SIGNAL SWITCH
the L. handIe switch (page 11-3).
BRAKE LIGHT SWITCH
FRONT
Disconnect the front brake Iight switch connector and check
for continuity.
Check that there is continuity when the front brake Iever is
puIIed.
Check that there is no continuity when the front brake Iever is
reIeased.
the front brake Iight switch (page 13-13).
REAR
Disconnect the rear brake Iight switch 2P (white) coupIer.
Check that there is continuity when the rear brake pedaI is
depressed.
Check that there is no continuity when the rear brake pedaI is
reIeased.
the rear brake Iight switch.
FREE
PUSH
COLOR
BAT 6
BI]Br
HO
Lg
H
(N)
L
COLOR
HI
Bu
HL
Bu]W
LO
W
L
N
R
COLOR
L
O]W
W
Gr
R
Lb]W
L. HANDLE SWITCH
FRONT BRAKE LIGHT SWITCH
2P (WHITE) COUPLER
17-21
CLUTCH SWITCH
Disconnect the cIutch switch connector.
Check that there is continuity when the cIutch Iever is puIIed.
Check that there is no continuity when the cIutch Iever is re-
Ieased.
the cIutch switch.
NEUTRAL SWITCH
INSPECTION
Disconnect the puIse generator]neutraI switch 3P (naturaI) cou-
pIer.
Check for continuity at the switch side terminaI of the 3P (natu-
raI) coupIer.
CONNECTION: LIGHT GREEN]RED BODY GROUND
STANDARD:
GEAR IS IN NEUTRAL: CONTINUITY
GEAR IS IN ANY POSITION OTHER THAN NEUTRAL:
NO CONTINUITY
the neutraI switch.
Remove the drive sprocket cover (page 6-2).
Nut
Washer
NeutraI switch cord
Remove the neutraI switch cover.
CLUTCH SWITCH
NUT CORD
WASHER
COVER
17-22
Remove the neutraI switch.
NOTE:
Ensure the neutraI switch cord is correctIy routed as per the
wiring diagram (page 1-19).
SIDE STAND SWITCH
INSPECTION
Disconnect the side stand switch 3P (bIack) coupIer.
Perform the foIIowing continuity inspection at the side stand
switch side of the 3P (bIack) coupIer.
the side stand switch.
Disconnect the side stand switch 3P (bIack) coupIer from the
stay.
Disconnect the side stand switch 3P (bIack) coupIer.
Remove the air cIeaner case]sub frame (page 5-19).
Side stand retracted state
Side stand parking state
G]W Y]BI G
NEUTRAL SWITCH
3P (BLACK) COUPLER
SIDE STAND
3P (BLACK) COUPLER
17-23
BoIts
Side stand switch cover
Side stand switch boIt
Side stand switch
NOTE:
When instaIIing, aIign the side stand switch pin with the
side stand hoIe.
When instaIIing, aIign the side stand switch notch with the
side stand return spring pin.
Ensure the side stand switch cord is correctIy routed as per
the wiring drawing (page 1-19).
HORN
Disconnect the horn connector.
Remove the boIt and remove the horn.
Connect a fuIIy charged battery to the horn terminaIs, and
check whether it operates.
If there is any abnormaIity in the above inspection, repIace
the horn.
BOLT
COVER
BOLT
SIDE STAND SWITCH
ALIGN
ALIGN SIDE STAND SWITCH
HORN
19-1
19. TROUBLESHOOTING
This chapter describes the troubIeshooting for major faiIures reIated to the whoIe engine operation range. For the faiIure
not mentioned in this chapter, refer to the troubIeshooting in each chapter.
ENGINE DOES NOT START OR IS HARD TO START
ENGINE DOES NOT START OR IS
HARD TO START 19-1
POOR PERFORMANCE AT LOW AND
IDLE SPEED 19-2
19
ENGINE IS FAULTY AT MIDDLE AND
HIGH SPEED 19-3
POOR POWER AND LACK OF SPEED AT
HIGH SPEED 19-4
CAN BE CRANKED
Starting system fauIty (Chapter 16)
Engine burn-out
CANNOT BE
CRANKED
NORMAL
Wet pIug due to an incorrect starting opera-
tion
Mixture is too rich (Chapter FueI System )
NOTE:
RepIace the spark pIug with a good one and turn
the fueI cock OFF, then try to restart the engine
with throttIe wideIy opened.
FauIty ignition system (Chapter 15)
WET PLUG
STRONG SPARK
WEAK OR
NO SPARK
THERE IS GASOLINE
NO OR LITTLE
GASOLINE
DRAINED
FueI system fauIty
COMPRESSION NORMAL
NO OR LOW
COMPRESSION
CyIinder head reIated parts fauIty (Chapter 7)
CyIinder and piston reIated parts fauIty (Chap-
ter 8)
FIRES GasoIine deteriorated
Choke operation fauIty
Mixture is too Iean (Chapter FueI System )
Secondary air aspirated
Carburetor cIogged
Loosen the drain screw of the carburetor and
check to see if there is sufficient gasoIine in the
fIoat chamber (use a drain pan to receive the
gasoIine).
Remove the spark pIug and check its condition.
Check to see if the engine can be cranked by
the starter motor.
Ignition timing fauIty (Chapter 15)
VaIve cIearance incorrectIy adjusted
Perform a spark test for the spark pIug.
Inspect the cyIinder compression.
NO FIRE
Remove the spark pIug and fiII smaII amount of
gasoIine into the cyIinder, then restart the
engine.
19-2
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
NORMAL
Ignition timing fauIty (Chapter 15) ABNORMAL
PiIot screw incorrectIy adjusted BETTER
NORMAL
ABNORMAL
InsuIator band screw Ioosened
InsuIator damaged
InsuIator O-ring worn-out
ABNORMAL Ignition system fauIty (Chapter 15)
Inspect the ignition timing
Ignition timing fauIty (Chapter 15)
Carburetor cIogged (perform overhauI)
VaIve cIearance incorrectIy adjusted
SYMPTOM UNCHANGED
Adjust the carburetor piIot screw
Check to see if secondary air is aspirated.
NORMAL
Perform the spark pIug test.
19-3
TROUBLESHOOTING
ENGINE IS FAULTY AT MIDDLE AND HIGH SPEED
NOTHING CHANGED
CIogged fueI tank cap vent hoIe TEMPORARILY
RECOVERED
Spark pIug fauIty
Incorrect spark pIug heat vaIue
BURNED OR
CONTAMI-
NATED
NORMAL
RECOVERED CIogged air cIeaner
Rich mixture (Chapter of FUEL SYSTEM)
WORN OUT Worn out camshaft
Degraded gasoIine
NORMAL
ABNORMAL FauIty ignition system (Chapter 15)
NOTHING CHANGED
INCORRECT FauIty vaIve timing
NORMAL
Remove the air cIeaner eIement and check to
see if the engine condition is recovered.
Check the spark pIug eIectrode
Open the fueI tank cap once and check the
engine condition.
Inspect the ignition timing
Check the vaIve timing
NORMAL
Check to see if cam nose is worn out
19-4
TROUBLESHOOTING
POOR POWER AND LACK OF SPEED AT HIGH SPEED
WHEEL SPINS FREELY
Brake dragging (Chapter 13)
Drive chain too tight
Worn or damaged wheeI bearing
IncorrectIy instaIIed wheeI
HEAVY TO
SPIN
Raise the front wheeI and spin it by hand.
Check to see if it spins smoothIy.
Deteriorated gasoIine
PRESSURE NORMAL
Pressure Ieaked out.
FauIty tire vaIve
Punctured tire
PRESSURE
TOO LOW
Check tire pressure
NORMAL
FauIty ignition timing (Chapter 15) INCORRECT Check ignition timing.
NORMAL
CIutch sIip (Chapter 9) SLIP Check for a cIutch sIip.
NORMAL
Too match oiI friction TOO MUCH
OIL
Check the amount of engine oiI.
FLOWS SMOOTHLY
CIogged fueI tube
CIogged fueI tank cap vent hoIe
CIogged fueI strainer screen
CIogged fueI vaIve
DOES NOT
FLOW
SMOOTHLY
Disconnect the fueI tube at the carburetor side
and check to see if the gasoIine fIows out. (use
a drain pan to receive gasoIine).
NOT CLOGGED
CIean up CLOGGED Check carburetor cIogging.
NORMAL
VaIve timing fauIty INCORRECT Check vaIve timing
VaIve spring fauIty INCORRECT
NORMAL
Inspect vaIve spring.
19-5
TROUBLESHOOTING
SI (InternationaI System of Units)
This service manuaI uses SI (InternationaI System of Units) newIy in addition to conventionaI metric unit.
What is SI unit7
SI is the abbreviation of InternationaI System of Units (Syst me InternationaI dUnit s) and is a unit system determined
internationaIIy to standardize various unit systems that have been used.
The metric system that has been used conventionaIIy in Japan has represented the Iength as meter (m) , mass as
kiIogram (kg) , and time as second (s) basicaIIy. The SI unit is the extended unit of this metric system.
In conventionaI unit system, the units of mass (kg) and force (kg or kgf) are used together. However, in SI unit, mass
(kg) and force (N) are distinguished cIearIy. The size of force is discriminated from mass and is represented by the unit of
N (newton). The weight in SI unit is a magnitude of gravity force that acts on a substance and is caIcuIated by a muItipIi-
cation of a mass and the standard gravity force, so differs from the concept of conventionaI weight.
Notation of SI unit
In this manuaI, SI unit is notated as foIIows:
SI unit is Iisted primary in conjunction with the conventionaI unit that is encIosed in parentheses. The conversion resuIt
is rounded and Iisted.
ExampIe: <pressure> 98 kPa (1.0 kgf]cm
2
)
ConventionaI unit
SI unit (1kgf]cm
2
= 98.0665 kPa)
If a conventionaI unit of force is used, a unit for kgf (weight kiIogram) is used to discriminate from the kg (mass
kiIogram) in SI unit.
ExampIe: <torque> 10 N-m (1.0 kgfm)
kgf (weight kiIogram) = conventionaI unit for force
Notation exampIe of SI unit and conventionaI unit
Item
Pressure
Torque
VoIume
Force
Notation exampIe
200 kPa (2.00 kgf]cm
2
)
33 kPa (250 mmHg)
18 N-m (1.8 kgfm)
419 cm
3
(419 cc) or Iitter
12 N (1.2 kgf)
Remarks
1 kgf]cm
2
= 98.0665 kPa (kiIopascaI), 1 kPa = 1,000 Pa (pascaI)
1 mm Hg = 133.322 Pa = 0.133322 kPa
1 kgfm = 9.80665 N-m (newton meter)
1 cm
3
= 1 cc
1 Iitter = 1,000 cm
3
1 kgf = 9.80665 N (newton)
In principIe, the vaIues and units Iisted in this manuaI are those Iisted in the notification materiaIs such as specification
tabIes or inspection and maintenance charts.
20-1
XR BAJA (T) SUPPLEMENT
CARBURETOR IDENTIFICATION NUMBER
20
20. XR BAJA (T) SUPPLEMENT
SPECIFICATIONS (XA BAJA) 20-2
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER COLOR LABEL
SERVICE DATA 20-4
TOROUE VALUES 20-11
20-2
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda MD30
2,140 mm
820 mm
1,220 mm
1,405 mm
MD17E
0.249 Iitter
GasoIine
65 kg
70 kg
135 kg
2 persons
92 kg
153 kg
245 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
270 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Intake vaIve opens at 1mm Iift
Intake vaIve cIoses at 1mm Iift
Exhaust vaIve opens at 1mm Iift
Exhaust vaIve cIoses at 1mm Iift
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5mm
9.3:1
28 PS]8,000 rpm
2.6 kg-m]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
14 Iitter
VE88B
32 mm
20-3
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
8 BTDC]1,300 rpm
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Gearshift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.000 (13]39)
WHEELS Caster
TraiI
Tire pressure Front
Rear
25 40
94 mm
1.50 kg]cm
2
1.50 kg]cm
2
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1100001 ~
MD17E 1750001 ~
20-4
at draining
at disassembIy
1.7 Iitter
1.4 Iitter
API Service CIassification SE or SF
grade engine oiI
0.15
0.15 0.22
0.02 0.09
Tip cIearance
Body cIearance
Side cIearance
OiI pump rotor
0.20
0.25
0.12
LUBRICATION SYSTEM
SERVICE DATA
Unit: mm
Type
Setting mark
Venturi diameter
PiIot screw opening
FIoat IeveI
IdIe speed
Main jet
SIow jet
Carburetor VE 88B
VE 88B A
2-1]4 turns out
18.5 mm
1,300 100 rpm
#138
#45
2 6 mm
Unit: mm
FUEL SYSTEM
20-5
Warpage
VaIve seat width
Cam Iobe height
Runout
VaIve stem O.D.
VaIve guide I.D.
VaIve seat width
Free Iength
Rocker arm I.D.
Sub-rocker arm I.D.
ITEM
Unit: mm
CyIinder compression 667 kPa (6.8 kgf]cm
2
)
0.10 0.02 mm
0.12 0.02 mm
1.1 1.2
30.672 30.872
30.719 30.919
4.975 4.990
4.955 4.970
5.000 5.012
5.000 5.012
0.010 0.037
0.030 0.057
1.1 1.2
1.1 1.2
43.44
44.03
11.500 11.518
7.000 7.015
7.000 7.015
11.466 11.484
6.972 6.987
6.972 6.987
0.016 0.052
0.013 0.043
VaIve spring
0.10
2.0
30.583
30.629
0.04
4.96
4.94
5.03
5.03
0.06
0.09
2.0
2.0
42.51
42.83
11.53
7.05
7.05
11.41
6.92
6.92
0.10
0.10
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
Inner
Outer
IN
EX
IN
EX
CyIinder head
Camshaft
VaIve and
vaIve guide
Rocker arm
Sub-rocker
arm
20-6
ITEM
Unit: mm
ITEM
Unit: mm
STANDARD
CIutch
CIutch outer I.D.
CIutch Outer guide
10 20
37.2
2.92 3.08
25.000 25.021
24.959 24.980
19.990 20.010
19.959 19.980
CyIinder
Piston, piston
pin and
piston ring
73.00 73.01

18.5mm from the skirt bottom
72.950 72.970
17.002 17.008
0.03 0.06
16.994 17.000
0.002 0014
0.016 0.040
0.15 0.30
0.30 0.45
0.20 0.70
0.015 0.05
0.015 0.05
mark facing up
mark facing up
73.11
0.05
0.05
0.10
72.87
17.05
0.1
16.97
0.05
0.09
0.30
0.45
0.86
0.12
0.12
17.06
CYLINDER]PISTON
I.D.
Taper
Out of round
Warpage
Piston O.D.
Piston pin O.D.
cIearance
Piston ring end gap
Piston ring-to-ring
groove cIearance
Piston ring mark
SERVICE LIMIT
33.5
2.7
25.04
24.12
20.03
0.3
19.91
Top
Second
OiI (side raiI)
Top
Second
Top
Second
O.D.
I.D.
20-7
ITEM
Unit: mm
Crankshaft
Transmission
0.050 0.065
0 0.008
20.000 20.021
23.000 23.021
23.000 23.021
25.020 25.041
25.000 25.021
22.000 22.021
18.000 18.018
22.000 22.021
22.959 22.980
24.979 25.000
24.959 24.980
22.959 22.980
19.959 19.980
17.966 17.984
21.959 21.980
21.959 21.980
0.02 0.062
0.02 0.062
0.020 0.062
0.020 0.062
0.02 0.062
0.02 0.062
0.016 0.052
0.02 0.062
13.000 13.021
12.966 12.984
4.930 5.000
4.900 5.000
19.959 19.980
0.80
0.05
0.05
20.08
23.07
23.07
25.09
25.07
22.07
18.08
22.1
22.90
24.90
24.90
22.92
19.91
17.91
21.91
21.91
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
13.05
12.91
4.50
4.50
19.90
Connecting
rod big end
Runout
Gear I.D.
Bushing I.D.
Bushing O.D.
M5
M6
C1
C2
C3
C4
C1
C2
C1
C2
C3
M6
side cIearance
radiaI cIearance
Mainshaft O.D. (M6)
Countershaft
O.D.
Gear-to-shaft
cIearance
Gear-to-
bushing
cIearance
Bush-to-shaft
cIearance
C1
C2
C4
M6
C4
M6
C1
C2
C3
C1
C2
Shift fork I.D.
bearing portion
R., Center.
L.
20-8
ITEM
Unit: mm
Front wheeI
2.0
2.0

2
)
2
)
2
)
64.8
374.4
467 4 cm
3
101
0.1 0.2 kgfm

0.2
3.0
64.2
370.7
0.2
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
One
passenger
Two
passengers
Street
Highway
Street
Fork Spring free
Iength
OiI capacity
OiI IeveI
OiI type
Tube runout
A
B
ITEM
Unit: mm
Rear wheeI
2.0
2.0

2
)
2
)
2
)
30 40
520MOZ9]102LE
520VC5]102LE
188.5 mm
strength position first, and then Ioosen it
back untiI 9 12 cIicks are heard where the
punch mark meets the matching notch.
back untiI 10 13 cIicks are heard where
the punch mark meets the matching
notch.
0.2
3.0
10
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
One
passenger
Two
passengers
Street
Highway
Street
RepIacement
chain]Iink
Rear cushion spring mount Iength
RK
DID
Rear
(XR 250)
Rear
(XR BAJA)
position
position
position
position
20-9
Brake fIuid
Brake pad wear
Brake disc runout
Mater cyIinder I.D.
Master piston O.D.
CaIiper piston O.D.
DOT 4
10 20
10 20
3.5
4.5
12.700 12.743
14.000 14.043
12.657 12.684
13.957 13.984
27.000 27.050
27.000 27.050
26.935 26.968
26.935 26.968
FR
RR
FR
RR
FR
RR
FR
RR
FR
RR
To the service
Iimit groove
0.15
3.0
4.0
12.76
14.06
12.64
13.95
27.10
27.10
26.89
26.89
Unit: mm
BRAKE SYSTEM
ITEM STANDARD
AIternator
ReguIator]rectifier
Battery
TripIe phase AC
0.204 kW]5,000 rpm
0.1 1.0
14.0 14.8 V
12 V 4 Ah
0.5 A]5 10 h
5.0 A]0.5 h
2.0 mA maximum
12.8 V minimum
12.3 V maximum
Type
Output
20 C
Type
VoItage range
Capacity
Charging current
Leakage current
Standard
Fast
VoItage at
20 C
FuII charging
Lack of charging
20-10
PuIse generator
ITEM SPECIFICATIONS
Ignition type
Spark pIug
CDI
Standard
IGNITION SYSTEM
NGK
CR8 EH-9
CR7 EH-9
CR9 EH-9
NIPPON DENSO
U24FER9
U22FER9
U27FER9
Spark pIug gap
Ignition timing
0.8 0.9 mm
8 BTDC]1,300 rpm
1,900 200 rpm
4,300 rpm
MP13
0.1 0.3
7.2 11.0 k
3.5 4.7 k
100 V minimum
460 580
0.7 V minimum
F mark
advance
Type Ignition coiI
Resistance
at 20 C
Primary coiI
Secondary coiI with
a pIug cap
Secondary coiI
without a pIug cap
Peak voItage
Resistance at 20 C
Peak voItage
ITEM STANDARD
Unit: mm
SERVICE LIMIT
8.5
ITEM SPECIFICATIONS
Fuse
Light]buIb
20 A
5 A x 2, 15 A x 3
12 V 35]36.5 W
12 V 5]21 W
12 V 5 W
12 V 15 W
12 V 15 W
12 V 2 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
Primary
Secondary
TaiI]brake Iights
License Iight
NeutraI indicator
20-11
above.
NOTES: 1 . AppIy a Iocking agent to the threads.
2 . Left hand screws.
3 . CauIk the boIt head.
4 . AppIy oiI to the threads and seating surface.
5 . AppIy cIean engi ne oiI to the O-ring.
6 . AppIy grease to the threads and seating surface.
7 . U-nut.
8 . ALOC boIt (RepIace with a new one when removed).
9 . CastIe nut
FASTENERS TYPE
TIGHTENING TOROUE
Nm (kgfm)
TIGHTENING TOROUE
Nm (kgfm)
5 (0.5)
10 (1.0)
22 (2.2)
34 (3.5)
54 (5.5)
5 mm screw
FASTENERS TYPE
4 (0.4)
9 (0.9)
12 (1.2)
26 (2.7)
39 (4.0)
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Maintenance:
VaIve hoIe cap
Timing hoIe cap
Crankshaft hoIe cap
Lubrication System:
(8 mm)
Spark pIug
(8 mm)
(10 mm)
Cam sprocket boIt
Rocker arm shaft
(EX)
CyIinder]Piston:
CyIinder boIt
1
4
1
1
2
1
2
1
13
1
2
4
2
2
4
2
2
2
4
11
1
1
1
1
1
Note 6
Note 6
Note 4
Note 1
Note 1
Note 1
Note 4
Note 3, 4
Note 4
25 (2.5)
15 (1.5)
10 (1.0)
8 (0.8)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
22 (2.2)
10 (1.0)
39 (4.0)
20 (2.0)
27 (2.8)
22 (2.2)
24 (2.4)
26 (2.6)
10 (1.0)
39 (4.0)
12 (1.2)
108 (11.0)
12 (1.2)
24 (2.4)
88 (9.0)
12 (1.2)
12
36
14
30
7
8
6
10
6
8
6
10
7
14
12
7
8
6
10
6
16
6
10
18
6
ENGINE
TOROUE VALVES
20-12
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Crankcase boIt
AIternator:
Stator boIt
FIywheeI boIt
CIamp socket boIt
Others:
Drive sprocket boIt
NeutraI switch
NeutraI switch nut
11
1
8
3
1
6
2
1
2
1
1
Note 1
Note 1
Note 4
Note 1
Note 1
Note 1
12 (1.2)
12 (1.2)
12 (1.2)
10 (1.0)
103 (10.5)
16 (1.6)
5 (0.5)
5 (0.5)
10 (1.0)
12 (1.2)
1.5 (0.15)
6
6
6
6
12
6
5
5
6
10
4
ENGINE (continued)
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Exhaust pipe joint nut
(Rear)
Maintenance:
Lubrication system:
OiI strainer nut
FueI system:
FueI strainer cup
FueI cock Iock nut
Engine mount:
Engine hanger nut
Steering stem nut
Steering top thread
Spoke nippIe
Front axIe
(Iower)
Fork center boIt
Fork boIt
1
2
4
2
2
1
1
1
1
1
1
1
4
6
1
1
31
4
1
4
4
4
2
2
Note 8
Note 7
Note 1
26 (2.6)
42 (4.3)
10 (1.0)
12 (1.2)
20 (2.0)
32 (3.3)
32 (3.3)
39 (4.0)
37 (3.8)
54 (5.5)
26 (2.7)
26 (2.7)
64 (6.5)
26 (2.7)
98 (10.0)
4.4 (0.45)
2.45 4.9 (0.25 0.5)
20 (2.0)
74 (7.5)
12 (1.2)
32 (3.3)
26 (2.7)
54 (5.5)
29 (3.0)
8
8
6
6
8
8
8
10
12
27
18
18
10
8
24
26
BC3.2
6
12
6
8
8
19
36
FRAME
20-13
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Driven sprocket nut
Rear axIe nut
(Lower)
(on the frame)
Swingarm pivot nut
Chain cover boIt
Brake System:
Brake hose boIt
nut
Push rod Iock nut
Others:
Right step boIt
nut
HandIe Iock screw
HeadIight guard nut
Speed sensor nut
6
4
1
1
1
1
1
1
1
2
4
2
2
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
Note 7
Note 8
Note 7
Note 7
Note 7
Note 7
Note 6, 7
Note 7
Note 7
Note 1
Note 1
Note 1
Note 1
Note 1
Note 1
Note 7
32 (3.3)
42 (4.3)
93 (9.5)
44 (4.5)
44 (4.5)
44 (4.5)
49 (5.0)
69 (7.0)
88 (9.0)
12 (1.2)
34 (3.5)
4.2 (0.43)
1.5 (0.15)
12 (1.2)
1.2 (0.12)
6 (0.6)
6 (0.6)
14 (1.4)
18 (1.8)
29 (3.0)
18 (1.8)
2.5 (0.25)
6 (0.6)
22 (2.2)
12 (1.2)
18 (1.8)
2.5 (0.25)
6 (0.6)
27 (2.8)
12 (1.2)
42 (4.3)
10 (1.0)
39 (4.0)
23 (2.3)
5 (0.5)
12 (1.2)
8
8
16
10
10
10
10
12
14
6
10
5
4
6
4
6
6
6
8
8
10
10
8
8
8
10
10
8
12
8
10
10
10
8
6
18
FRAME (continued)
21-1
21
21. XR 250]XR BAJA (V) SUPPLEMENT
SPECIFICATIONS (XA 250) 21-3
SERVICE DATA 21-7
TOROUE VALUES 21-14
CABLE & HARNESS ROUTING (XR 250) 21-17
CARBURETOR INSULATOR 21-18
PILOT SCREW ADJUSTMENT 21-19
OIL PUMP 21-20
ENGINE OIL INSPECTION 21-22
PRIMARY DRIVE GEAR 21-24
HEADLIGHT (XR 250) 21-26
VALVE REPLACEMENT (XR 250) 21-27
WIRING DIAGRAM (XR 250) 21-29
21-2
XR 250]XR BAJA (V) SUPPLEMENT
ENGINE SERIAL NUMBER
CARBURETOR SERIAL NUMBER
FRAME SERIAL NUMBER
COLOR LABEL
21-3
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda MD30
2,140 mm
820 mm
1,195 mm
1,420 mm
MD17E
0.249 Iitter
GasoIine
60 kg
69 kg
129 kg
2 persons
90 kg
149 kg
239 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
270 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
9.7 Iitter
VE88
32 mm
21-4
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
8 BTDC]1,300 rpm
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Gearshift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.076 (13]40)
WHEELS Caster
TraiI
Tire pressure Front
Rear
25 40
94 mm
1.50 kg]cm
2
1.50 kg]cm
2
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1200001 ~
MD17E 1800001 ~
21-5
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda MD30
2,140 mm
820 mm
1,220 mm
1,420 mm
MD17E
0.249 Iitter
GasoIine
65 kg
71 kg
136 kg
2 persons
92 kg
154 kg
246 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
270 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
14 Iitter
VE88
32 mm
21-6
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
CDI
8 BTDC]1,300 rpm
CR8 EH-9 (NGK) or U24FER9 (DENSO)
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Shift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
Wet muIti-pIate
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
Left shift pedaI
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.076 (13]40)
WHEELS Caster
TraiI
Tire pressure Front
Rear
25 40
94 mm
1.50 kg]cm
2
1.50 kg]cm
2
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1200001 ~
MD17E 1800001 ~
21-7
at draining
at disassembIy
1.7 Iitter
1.4 Iitter
grade engine oiI
0.15
0.15 0.22
0.02 0.09
Tip cIearance
Body cIearance
Side cIearance
OiI pump rotor
0.20
0.25
0.12
LUBRICATION SYSTEM
SERVICE DATA
Unit: mm
Type
Setting mark
Venturi diameter
PiIot screw opening
FIoat IeveI
IdIe speed
Main jet
SIow jet
Carburetor VE 88C
VE 88C A
2-1]4 turns out
18.5 mm
1,300 100 rpm
#138
#45
2 6 mm
Unit: mm
FUEL SYSTEM
21-8
Warpage
VaIve seat width
Cam Iobe height
Runout
VaIve stem O.D.
VaIve guide I.D.
VaIve seat width
Free Iength
Rocker arm I.D.
Sub-rocker arm I.D.
ITEM
Unit: mm
2
)
0.10 0.02 mm
0.12 0.02 mm
1.1 1.2
30.672 30.872
30.719 30.919
4.975 4.990
4.955 4.970
5.000 5.012
5.000 5.012
0.010 0.037
0.030 0.057
1.1 1.2
1.1 1.2
43.44
44.03
11.500 11.518
7.000 7.015
7.000 7.015
11.466 11.484
6.972 6.987
6.972 6.987
0.016 0.052
0.013 0.043
VaIve spring
0.10
2.0
30.583
30.629
0.04
4.96
4.94
5.03
5.03
0.06
0.09
2.0
2.0
42.51
42.83
11.53
7.05
7.05
11.41
6.92
6.92
0.10
0.10
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
Inner
Outer
IN
EX
IN
EX
CyIinder head
Camshaft
VaIve and
vaIve guide
Rocker arm
Sub-rocker
arm
21-9
ITEM
Unit: mm
ITEM
Unit: mm
STANDARD
CIutch
CIutch outer I.D.
CIutch Outer guide
10 20
37.2
2.92 3.08
25.000 25.021
24.959 24.980
19.990 20.010
19.959 19.980
CyIinder
Piston, piston
pin and
piston ring
73.00 73.01

72.950 72.970
17.002 17.008
0.03 0.06
16.994 17.000
0.002 0.014
0.016 0.040
0.15 0.30
0.30 0.45
0.20 0.70
0.015 0.05
0.015 0.05
mark facing up
mark facing up
73.11
0.05
0.05
0.10
72.87
17.05
0.1
16.97
0.05
0.09
0.30
0.45
0.86
0.12
0.12
17.06
CYLINDER]PISTON
I.D.
Taper
Out of round
Warpage
Piston O.D.
Piston pin O.D.
cIearance
Piston ring end gap
Piston ring-to-ring
groove cIearance
Piston ring mark
SERVICE LIMIT
33.5
2.7
25.04
24.12
20.03
0.3
19.91
Top
Second
OiI (side raiI)
Top
Second
Top
Second
O.D.
I.D.
21-10
ITEM
Unit: mm
Crankshaft
Transmission
0.050 0.065
0 0.008
20.000 20.021
23.000 23.021
23.000 23.021
25.020 25.041
25.000 25.021
22.000 22.021
18.000 18.018
22.000 22.021
22.959 22.980
24.979 25.000
24.959 24.980
22.959 22.980
19.959 19.980
17.966 17.984
21.959 21.980
21.959 21.980
0.02 0.062
0.02 0.062
0.020 0.062
0.020 0.062
0.02 0.062
0.02 0.062
0.016 0.052
0.02 0.062
13.000 13.021
12.966 12.984
4.930 5.000
4.900 5.000
19.959 19.980
0.80
0.05
0.05
20.08
23.07
23.07
25.09
25.07
22.07
18.08
22.1
22.90
24.90
24.90
22.92
19.91
17.91
21.91
21.91
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
13.05
12.91
4.50
4.50
19.90
Connecting
rod big end
Run out
Gear I.D.
Bushing I.D.
Bushing O.D.
M5
M6
C1
C2
C3
C4
C1
C2
C1
C2
C3
M6
side cIearance
radiaI cIearance
Mainshaft O.D. (M5)
Countershaft
O.D.
Gear-to-shaft
cIearance
Gear-to-
bushing
cIearance
Bush-to-shaft
cIearance
C1
C2
C4
M5
C4
M6
C1
C2
C3
C1
C2
Shift fork I.D.
bearing portion
R., L.
Center.
21-11
ITEM
Unit: mm
Front wheeI

2
)
2
)
2
)
44.1
391.8
460 4 cm
3
108
0.1 0.2 kg-m

0.2
2.0
2.0
3.0
43.7]45.1
387.9]386.4
0.2
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
One
passenger
Two
passengers
Street
Highway
Street
Fork Spring free
Iength
OiI capacity XR250]XR BAJA
OiI IeveI XR250]XR BAJA
OiI type
Tube runout
A XR250]XR BAJA
B XR250]XR BAJA
ITEM
Unit: mm
Rear wheeI

2
)
2
)
2
)
30 40
520MOZ9]104LE
520VC5]104LE
188.5 mm
the matching notch.
the matching notch.
0.2
2.0
2.0
3.0
10
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
One
passenger
Two
passengers
Street
Highway
Street
RepIacement
chain]Iink
Rear cushion spring Ioading Iength
RK
DID
Rear
position
position
45.6
390.3
458 4 cm
3
110
21-12
Brake fIuid
Brake pad wear
Brake disc runout
Mater cyIinder I.D.
Master piston O.D.
CaIiper piston O.D.
DOT 4
10 20
10 20
3.5
4.5
12.700 12.743
14.000 14.043
12.657 12.684
13.957 13.984
27.000 27.050
27.000 27.050
26.935 26.968
26.935 26.968
FR
RR
FR
RR
FR
RR
FR
RR
FR
RR
To the service
Iimit groove
0.15
3.0
4.0
12.76
14.06
12.64
13.95
27.10
27.10
26.89
26.89
Unit: mm
BRAKE SYSTEM
ITEM STANDARD
AIternator
ReguIator]rectifier
Battery
TripIe phase AC
0.204 kW]5,000 rpm
0.1 1.0
14.0 14.8 V
12 V 4 Ah
0.5 A]5 10 h
5.0 A]0.5 h
2.0 mA maximum
12.8 V minimum
12.3 V maximum
Type
Output
20 C
Type
VoItage range
Capacity
Charging current
Leakage current
Standard
Fast
VoItage at
20 C
FuII charging
Lack of charging
21-13
PuIse generator
ITEM SPECIFICATIONS
Ignition type
Spark pIug
CDI
Standard
IGNITION SYSTEM
NGK
CR8 EH-9
CR7 EH-9
CR9 EH-9
DENSO
U24FER9
U22FER9
U27FER9
Spark pIug gap
Ignition timing
0.8 0.9 mm
8 BTDC]1,300 rpm
1,900 200 rpm
4,300 rpm
MP13
0.1 0.3
7.2 11.0 k
3.5 4.7 k
100 V minimum
460 580
0.7 V minimum
F mark
advance
Type Ignition coiI
Resistance
at 20 C
Primary coiI
Secondary coiI with
a pIug cap
Secondary coiI
without a pIug cap
Peak voItage
Resistance at 20 C
Peak voItage
ITEM STANDARD
Unit: mm
SERVICE LIMIT
8.5
ITEM SPECIFICATIONS
Fuse
Light]buIb
20 A
5 A x 2, 15 A x 3
XR BAJA: 12 V 35]36.5 W XR250: 12 V 60]55 W
12 V 5]21 W
12 V 5 W x 2
12 V 15 W
12 V 15 W
12 V 2 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
Primary
Secondary
TaiI]brake Iights
License Iight
NeutraI indicator
21-14
above.
5 . AppIy cIean engine oiI to the O-ring.
7 . U-nut.
9 . CastIe nut
TOROUE VALUES
FASTENERS TYPE
TIGHTENING TOROUE
Nm (kgfm)
TIGHTENING TOROUE
Nm (kgfm)
5 (0.5)
10 (1.0)
22 (2.2)
34 (3.5)
54 (5.5)
5 mm screw
FASTENERS TYPE
4 (0.4)
9 (0.9)
12 (1.2)
26 (2.7)
39 (4.0)
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Maintenance:
VaIve hoIe cap
Timing hoIe cap
Crankshaft hoIe cap
Lubrication System:
(8 mm)
Spark pIug
(8 mm)
(10 mm)
Cam sprocket boIt
Rocker arm shaft
(EX)
CyIinder]Piston:
CyIinder boIt
1
4
1
1
2
1
2
1
13
1
2
4
2
2
4
2
2
2
4
11
1
1
1
1
1
Note 6
Note 6
Note 4
Note 1
Note 1
Note 1
Note 4
Note 3, 4
Note 4
25 (2.5)
15 (1.5)
10 (1.0)
8 (0.8)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
22 (2.2)
10 (1.0)
39 (4.0)
20 (2.0)
27 (2.8)
22 (2.2)
24 (2.4)
26 (2.6)
10 (1.0)
39 (4.0)
12 (1.2)
108 (11.0)
12 (1.2)
24 (2.4)
88 (9.0)
12 (1.2)
12
36
14
30
7
8
6
10
6
8
6
10
7
14
12
7
8
6
10
6
16
6
10
18
6
ENGINE
21-15
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Crankcase boIt
AIternator:
Stator boIt
FIywheeI boIt
CIamp socket boIt
Others:
Drive sprocket boIt
NeutraI switch
NeutraI switch nut
11
1
8
3
1
6
2
1
2
1
1
Note 1
Note 1
Note 4
Note 1
Note 1
Note 1
12 (1.2)
12 (1.2)
12 (1.2)
10 (1.0)
103 (10.5)
16 (1.6)
5 (0.5)
5 (0.5)
10 (1.0)
12 (1.2)
1.5 (0.15)
6
6
6
6
12
6
5
5
6
10
4
ENGINE (continued)
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
(Rear)
Maintenance:
Lubrication system:
OiI strainer nut
FueI system:
FueI strainer cup
FueI cock Iock nut
Engine mount:
Engine hanger nut
Steering stem nut
Steering top thread
Spoke nippIe
Front axIe
(Iower)
Fork center boIt
Fork boIt
1
2
4
2
2
1
1
1
1
1
1
1
4
6
1
1
36
4
1
4
4
4
2
2
Note 8
Note 7
Note 1
26 (2.6)
42 (4.3)
10 (1.0)
12 (1.2)
20 (2.0)
32 (3.3)
32 (3.3)
39 (4.0)
37 (3.8)
54 (5.5)
26 (2.7)
26 (2.7)
64 (6.5)
26 (2.7)
98 (10.0)
4.4 (0.45)
2.45 4.9 (0.25 0.5)
20 (2.0)
74 (7.5)
12 (1.2)
32 (3.3)
26 (2.7)
54 (5.5)
29 (3.0)
8
8
6
6
8
8
8
10
12
27
18
18
10
8
24
26
BC3.2
6
14
6
8
8
22
38
FRAME
21-16
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Driven sprocket nut
Rear axIe nut
(Lower)
(on the frame)
Swingarm pivot nut
Chain cover boIt
Brake System:
Brake hose boIt
nut
Push rod Iock nut
Others:
Right step boIt
nut
HandIe Iock screw
HeadIight guard nut
Speed sensor nut
6
4
1
1
1
1
1
1
1
2
4
2
2
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
Note 7
Note 8
Note 7
Note 7
Note 7
Note 7
Note 6, 7
Note 7
Note 7
Note 1
Note 1
Note 1
Note 1
Note 1
Note 1
Note 7
32 (3.3)
42 (4.3)
93 (9.5)
44 (4.5)
44 (4.5)
44 (4.5)
49 (5.0)
69 (7.0)
88 (9.0)
12 (1.2)
34 (3.5)
4.2 (0.43)
1.5 (0.15)
12 (1.2)
1.2 (0.12)
6 (0.6)
6 (0.6)
14 (1.4)
18 (1.8)
29 (3.0)
18 (1.8)
2.5 (0.25)
6 (0.6)
22 (2.2)
12 (1.2)
18 (1.8)
2.5 (0.25)
6 (0.6)
27 (2.8)
12 (1.2)
42 (4.3)
10 (1.0)
39 (4.0)
23 (2.3)
5 (0.5)
12 (1.2)
8
8
16
10
10
10
10
12
14
6
10
5
4
6
4
6
6
6
8
8
10
10
8
8
8
10
10
8
12
8
10
10
10
8
6
18
FRAME (continued)
21-17
R. TURN SIGNAL WIRE
HEADLIGHT 3P COUPLER
SPEEDOMETER CABLE
BRAKE HOSE
THROTTLE CABLE
L. TURN SIGNAL WIRE
CLUTCH CABLE
MAIN WIRE HARNESS
R. HANDLE SWITCH 6P COUPLER
MAIN SWITCH 2P (BLACK) COUPLER
STARTER SWITCH
(YELLOW]RED) COUPLER
R. TURN SIGNAL 2P (BLACK) COUPLER
DIGITAL METER 3P (BLACK) COUPLER
PILOT BOX 6P (BLUE) COUPLER
DIGITAL METER 3P
(BLUE) COUPLER
L. HANDLE SWITCH 4P
(BLACK) COUPLER
DIGITAL METER 4P
(BROWN) COUPLER
L. TURN SIGNAL 2P
(BLACK) COUPLER
L. HANDLE SWITCH 6P
(BLACK) COUPLER
CABLE & HARNESS ROUTING
XR250:
21-18
CARBURETOR INSULATOR
REMOVAL
Remove the three insuIator boIts.
Remove the insuIator.
INSTALLATION
New insuIator O-ring
InsuIator
InsuIator boIts
Band screw
NOTE:
When instaIIing the insuIator, aIign a groove of the insuIa-
tor with a projection of the carburetor.
When instaIIing the insuIator band, aIign a protruding por-
tion of the insuIator with a hoIe of the insuIator.
INSULATOR BAND SCREW
INSULATOR BOLT INSULATOR
CARBURETOR ASSY.
INSULATOR
ALIGN
INSULATOR
INSULATOR BAND
PROTRUDING
PORTION
PROJECTION
21-19
IDLING DROP METHOD:
NOTE:
The piIot screw is pre-set at the factory and adjustment is
not required unIess the piIot screw or the carburetor body
is repIaced. Just tighten the piIot screw untiI it IightIy con-
tacts the seat and then Ioosen it back the number of turns
you have recorded when removing the screw during the
carburetor disassembIy.
Secure the motorcycIe in an upright position at IeveI ground
whiIe working on the motorcycIe.
Warm up the engine before proceeding to piIot screw ad-
justment.
1. Connect a tachometer abIe to read 50 rpm or Iess in accor-
dance with the tachometer manufacturers instructions.
2. Tighten the piIot screw untiI it IightIy contacts the seat and
then back it out by the specified number of turns.
PILOT SCREW OPENING: 2 1]4 turns out
PiIot screw wrench 07908-4730001
CAUTION:
3. After warming up the engine, turn the throttIe stop screw
in or out to obtain the specified idIing speed.
4. Turn the carburetor piIot screw in or out about one haIf of
a turn to obtain the highest idIing speed.
5. Open and cIose the throttIe a coupIe of times and adjust
the idIing speed to the specified rpm.
6. SIowIy tighten the carburetor piIot screw to reduce the
idIing speed by 50 rpm beIow the specified rpm.
7. From the piIot screw setting obtained in Step 6 above, turn
the piIot screw out the number of turns for the specified
piIot screw opening.
PILOT SCREW OPENING AFTER IDLE SPEED REDUC-
TION: 3]4 of a turn out
8. Turn the throttIe stop screw to obtain the specified idIing
speed.
If the specified idIe speed can not be obtained, repeat the aII
adjustment steps from Step 1.
THROTTLE STOP SCREW
PILOT SCREW WRENCH
21-20
OIL PUMP
REMOVAL
Remove the R. crankcase cover (page 9-3).
Remove the O-ring.
Remove the oiI driven gear.
Remove the oiI pump boIts.
Remove the stopper pIate and oiI pump.
Remove the gasket and knock pin.
DRIVEN GEAR
O-RING
BOLT
GASKET
KNOCK PIN
21-21
INSTALLATION
InstaII the gasket and the knock pin.
InstaII the stopper pIate and oiI pump.
InstaII and tighten the oiI pump boIts secureIy.
AppIy engine oiI to the new O-ring and instaII it.
InstaII the oiI pump driven gear.
NOTE:
AIign notch of the oiI pump driven gear shaft with notch of
the pump shaft.
InstaII the R. crankcase cover (page 9-14).
NOTE:
Ensure not to faII out the O-ring when instaIIing the R. crank-
case cover.
GASKET
KNOCK PIN
BOLT
ALIGN
DRIVEN GEAR O-RING
21-22
ENGINE OIL INSPECTION
1. Start and warm up the engine.
2. Secure the motorcycIe in an upright position at IeveI ground.
3. AIIow the engine to idIe for one minute.
4. Stop the engine. Check the oiI IeveI quickIy using the oiI
IeveI gage.
NOTE:
Do not check the oiI when the body is incIined by using the
side stand, etc.
The throttIe must be cIosed during the idIe.
If the oiI IeveI is beIow the LOWER mark on the dipstick, fiII
to the UPPER mark with the recommended engine oiI.
Change the engine oiI if contaminated excessiveIy.
OIL FILTER CAP]DIPSTICK
UPPER MARK
LOWER MARK
21-23
108 Nm (11.0 kgfm)
12 Nm (1.2 kgfm)
12 Nm (1.2 kgfm)
12 Nm (1.2 kgfm)
88 Nm (9.0 kgfm)
21-24
PRIMARY DRIVE GEAR
REMOVAL
Remove the oiI pump (page 4-3).
InstaII the cIutch outer to the mainshaft.
WhiIe hoIding the primary drive gear with the gear hoIder,
remove the primary drive gear Iock nut.
Remove the Iock washer.
Remove the primary drive gear.
OIL PUMP
CLUTCH OUTER
GEAR HOLDER
LOCK NUT
LOCK WASHER PRIMARY DRIVE GEAR
21-25
INSTALLATION
InstaII the primary drive gear.
NOTE:
AIign the primary drive gear cutout with the crankshaft cut-
InstaII the Iock washer with the OUT SIDE mark facing out.
InstaII the cIutch outer guide and the cIutch outer.
PIace the gear hoIder between the primary drive gear and
driven gear to hoId the primary drive gear stiII.
AppIy oiI to the primary drive gear Iock nut threads and seat-
ing surface.
InstaII the primary drive gear Iock nut and tighten it to the
specified torque.
TOROUE: 88 Nm (9.0 kg fm, 65 Ibfft)
InstaII the oiI pump (page 4-7).
ALIGN
PRIMARY DRIVE GEAR
OUT SIDE MARK
WASHER
CLUTCH OUTER
GEAR HOLDER LOCK NUT
OIL PUMP
CLUTCH OUTER
21-26
HEADLIGHT (XR 250)
REMOVAL
Remove the boIts.
the Iower side of headIight from the steering stem.
Disconnect the headIight connector.
Remove the headIight adjust screws from the headIight unit.
Remove two screws, then remove the headIight unit.
INSTALLATION
Connect the 3P connector to the headIight.
Iower side of headIight with the steering stem.
BoIt
3P CONNECTOR
PROJECTION
BOLT
HEADLIGHT
SCREW
HEADLIGHT ADJUST SCREW
HEADLIGHT UNIT
21-27
BULB REPLACEMENT (XR 250)
Remove two boIts and remove the headIight unit Assy.
Disconnect the headIight 3P connector.
Remove the retainer spring and repIace the headIight buIb.
CAUTION:
Turn the TOP mark facing up and instaII the dust cover to
the headIight secureIy.
HEADLIGHT 3P CONNECTOR
DUST COVER
RETAINER SPRING
BULB BULB
TOP MARK
DUST COVER
HEADLIGHT 3P CONNECTOR
BULB (60]55W)
B u ] O
G
G
B u
L g ] R
B I ] B r
Y ] B I
B I ] B r
B r ] R B r ] R
R ] G
B I ] B r
B I
Y ] R
B u ] G
Y ] B u
B I ] B u
W ] B u
B u ] B I
G
R ] G
B I ] B r
B I
Y ] R
G ] B I
R ] Y
B I ] B r B u
B I
B I ] B u
W ] B u
B u ] B I
B r ] R
B I ] B r
B u ] G
Y ] R
Y ] B u
B u ] O
O ] W
L b
G r
B r ] B I
L b ] W
O
G
B r
G B I ] B r B I ] B r
B I
L g
B I
L b ] W
O ] W
B u ] W
G r
B u
W
B I ] B r
B u
L g
W
L b ] W
O ] W
B u ] W
G r
G ] W
L g
G ] R
L b ] W
O ] W
B u ] W
G r
B u
W
B r ] B I
B I ] B r
B I ] B u
B I ] R
R ] G
R
R ] B I
G ] W
L g ] R
G ] R
B r ] B I
B I ] B r
B I ] B u
B I ] R
R ] G
R
R ] B I
B I ] W
G ] W
B u ] Y
G ] B I
B I ] Y
B I
R
Y ] R
G ] R
R ] W
B I
B I
B I
B I
R ] B I
R
R ] B I
R
L g ] R
L g ] B I
B u ] B I
W ] B u
B I ] B u
G ] B I
G
L g ] R
B u ] Y
G
L g ] R
B u ] Y
G
Y
Y
Y
Y
Y
Y
G ] W
G
Y ] B I
G ] W
G
Y ] B I
Y
Y
Y
R ] W
G G
R
B I ] R
B I ] W
B I ] B u
B u ] W
Y ] R
B I ] B r
G ] Y
B I ] R
B I ] W
B I ] B u
B u ] W
Y ] R
22-1
22. XR 250]XR BAJA (Y) SUPPLEMENT
SPECIFICATIONS (XR250) 22-3
SERVICE DATA 22-7
TOROUE VALUES 22-14
SPECIAL TOOLS 22-17
CABLE & HARNESS ROUTING 22-19
EMISSION CONTROL SYSTEM 22-21
22
EXHAUST PIPE]MUFFLER 22-22
MAINTENANCE SCHEDULE 22-23
PERIODIC REPLACEMENT PARTS 22-25
IDLE EMISSION INSPECTION 22-26
CRANKCASE EMISSION CONTROL
SYSTEM 22-27
SECONDARY AIR SUPPLY SYSTEM 22-27
REAR CUSHION 22-30
CUSHION LINKAGE 22-31
22-2
XR 250]XR BAJA (Y) SUPPLEMENT
CARBURETOR SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION
COLOR LABEL LOCATION
FRAME SERIAL NUMBER
COLOR LABEL
22-3
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda BA-MD30
2,140 mm
820 mm
1,195 mm
1,420 mm
MD17E
0.249 Iitter
GasoIine
61 kg
69 kg
130 kg
2 persons
91 kg
149 kg
240 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
270 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
9.7 Iitter
VE88
32 mm
22-4
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
8 BTDC]1,300 rpm
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Gearshift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.076 (13]40)
WHEELS Caster
TraiI
Tire pressure Front
Rear
25 40
94 mm
2
)
2
)
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1500001 ~
MD17E 1700001 ~
22-5
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda BA-MD30
2,140 mm
820 mm
1,221 mm
1,420 mm
MD17E
0.249 Iitter
GasoIine
66 kg
71 kg
137 kg
2 persons
93 kg
154 kg
247 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
270 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
14 Iitter
VE88
32 mm
22-6
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
CDI
8 BTDC]1,300 rpm
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Shift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
Wet muIti-pIate
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
Left shift pedaI
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.076 (13]40)
WHEELS Caster
TraiI
Tire pressure Front
Rear
26 24
100 mm
2
)
2
)
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1500001 ~
MD17E 1700001 ~
22-7
at draining
at disassembIy
1.7 Iitter
1.4 Iitter
grade engine oiI
0.15
0.15 0.22
0.02 0.09
Tip cIearance
Body cIearance
Side cIearance
OiI pump rotor
0.20
0.25
0.12
LUBRICATION SYSTEM
SERVICE DATA
Unit: mm
Type
Setting mark
Venturi diameter
PiIot screw opening
FIoat IeveI
IdIe speed
Main jet
SIow jet
Carburetor VE 88D
VE 88D A
1-3]8 turns out
18.5 mm
1,300 100 rpm
#135
#45
2 6 mm
Unit: mm
FUEL SYSTEM
22-8
Warpage
VaIve seat width
Cam Iobe height
Runout
VaIve stem O.D.
VaIve guide I.D.
VaIve seat width
Free Iength
Rocker arm I.D.
Sub-rocker arm I.D.
ITEM
Unit: mm
CyIinder compression 667 kPa (6.8 kgfm)
0.10 0.02
0.12 0.02
1.1 1.2
30.672 30.872
30.719 30.919
4.975 4.990
4.955 4.970
5.000 5.012
5.000 5.012
0.010 0.037
0.030 0.057
1.1 1.2
1.1 1.2
43.44
44.03
11.500 11.518
7.000 7.015
7.000 7.015
11.466 11.484
6.972 6.987
6.972 6.987
0.016 0.052
0.013 0.043
VaIve spring
0.10
2.0
30.583
30.629
0.04
4.96
4.94
5.03
5.03
0.06
0.09
2.0
2.0
42.51
42.83
11.53
7.05
7.05
11.41
6.92
6.92
0.10
0.10
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
Inner
Outer
IN
EX
IN
EX
CyIinder head
Camshaft
VaIve and
vaIve guide
Rocker arm
Sub-rocker
arm
22-9
ITEM
Unit: mm
ITEM
Unit: mm
STANDARD
CIutch
CIutch outer I.D.
CIutch Outer guide
10 20
37.2
2.92 3.08
25.000 25.021
24.959 24.980
19.990 20.010
19.959 19.980
CyIinder
Piston, piston
pin and
piston ring
73.00 73.01

72.950 72.970
17.002 17.008
0.03 0.06
16.994 17.000
0.002 0014
0.016 0.040
0.15 0.30
0.30 0.45
0.20 0.70
0.015 0.05
0.015 0.05
mark facing up
mark facing up
73.11
0.05
0.05
0.10
72.87
17.05
0.1
16.97
0.05
0.09
0.30
0.45
0.86
0.12
0.12
17.06
CYLINDER]PISTON
I.D.
Taper
Out of round
Warpage
Piston O.D.
Piston pin O.D.
cIearance
Piston ring end gap
Piston ring-to-ring
groove cIearance
Piston ring mark
SERVICE LIMIT
33.5
2.7
25.04
24.12
20.03
0.3
19.91
Top
Second
OiI (side raiI)
Top
Second
Top
Second
O.D.
I.D.
22-10
ITEM
Unit: mm
Crankshaft
Transmission
0.050 0.065
0 0.008
20.000 20.021
23.000 23.021
23.000 23.021
25.020 25.041
25.000 25.021
22.000 22.021
18.000 18.018
22.000 22.021
22.959 22.980
24.979 25.000
24.959 24.980
22.959 22.980
19.959 19.980
17.966 17.984
21.959 21.980
21.959 21.980
0.02 0.062
0.02 0.062
0.020 0.062
0.020 0.062
0.02 0.062
0.02 0.062
0.016 0.052
0.02 0.062
13.000 13.021
12.966 12.984
4.930 5.000
4.900 5.000
19.959 19.980
0.80
0.05
0.05
20.08
23.07
23.07
25.09
25.07
22.07
18.08
22.1
22.90
24.90
24.90
22.92
19.91
17.91
21.91
21.91
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
13.05
12.91
4.50
4.50
19.90
Connecting
rod big end
Run out
Gear I.D.
Bushing I.D.
Bushing O.D.
M5
M6
C1
C2
C3
C4
C1
C2
C1
C2
C3
M6
side cIearance
radiaI cIearance
Mainshaft O.D. (M5)
Countershaft
O.D.
Gear-to-shaft
cIearance
Gear-to-
bushing
cIearance
Bush-to-shaft
cIearance
C1
C2
C4
M5
C4
M6
C1
C2
C3
C1
C2
Shift fork I.D.
bearing portion
R., L.
Center.
22-11
ITEM
Unit: mm
Front wheeI

2
)
2
)
2
)
44.1
391.8
460 4 cm
3
108
1 2 N (0.1 0.2 kgf)

0.2
2.0
2.0
3.0
43.7]45.1
387.9]386.4
0.2
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
A
i
r

p
r
e
s
s
u
r
e
One
passenger
Two
passengers
Street
Highway
Street
Fork Spring free
Iength
OiI capacity XR 250]XR BAJA
OiI IeveI XR 250]XR BAJA
OiI type
Tube runout
A XR 250]XR BAJA
B XR 250]XR BAJA
ITEM
Unit: mm
Rear wheeI

2
)
2
)
2
)
30 40
520MOZ9]104LE
520VC5]104LE
187.5
back untiI 10 13 cIicks are heard where
the punch mark meets the matching
notch.
0.2
2.0
2.0
3.0
10
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
A
i
r

p
r
e
s
s
u
r
e
One
passenger
Two
passengers
Street
Highway
Street
RepIacement
chain]Iink
Rear cushion spring Ioading Iength XR250]XR BAJA
RK
DID
Rear
(XR 250) Rear compression adjuster instaIIation
position
position
45.6
390.3
461 4 cm
3
107
186.5
Rear
(XR BAJA)
position
position
22-12
Brake fIuid
Brake pad wear
Brake disc runout
Mater cyIinder I.D.
Master piston O.D.
CaIiper piston O.D.
DOT 4
10 20
10 20
3.5
4.5
12.700 12.743
14.000 14.043
12.657 12.684
13.957 13.984
27.000 27.050
27.000 27.050
26.935 26.968
26.935 26.968
FR
RR
FR
RR
FR
RR
FR
RR
FR
RR
To the service
Iimit groove
0.15
3.0
4.0
12.76
14.06
12.64
13.95
27.10
27.10
26.89
26.89
Unit: mm
BRAKE SYSTEM
ITEM STANDARD
AIternator
ReguIator]rectifier
Battery
TripIe phase AC
204 kW]5,000 rpm
0.1 1.0
14.0 14.8 V
12 V 4 Ah
0.5 A]5 10 h
5.0 A]0.5 h
2.0 mA maximum
12.8 V minimum
12.3 V maximum
Type
Output
20 C
Type
VoItage range
Capacity
Charging current
Leakage current
Standard
Fast
VoItage at
20 C
FuII charging
Lack of charging
22-13
PuIse generator
ITEM SPECIFICATIONS
Ignition type
Spark pIug
CDI
Standard
IGNITION SYSTEM
NGK
CR8 EH-9
CR7 EH-9
CR9 EH-9
DENSO
U24FER9
U22FER9
U27FER9
Spark pIug gap
Ignition timing
0.8 0.9 mm
8 BTDC]1,300 rpm
1,900 200 rpm
4,300 rpm
MP13
0.1 0.3
7.2 11.0 k
3.5 4.7 k
100 V minimum
460 580
0.7 V minimum
F mark
advance
Type Ignition coiI
Resistance
at 20 C
Primary coiI
Secondary coiI with
a pIug cap
Secondary coiI
without a pIug cap
Peak voItage
Resistance at 20 C
Peak voItage
ITEM STANDARD
Unit: mm
SERVICE LIMIT
8.5
ITEM SPECIFICATIONS
Fuse
Light]buIb
20 A
5 A x 2, 15 A x 3
XR BAJA: 12 V 35]36.5 W XR250: 12 V 60]55 W
12 V 5]21 W
12 V 5 W x 2
12 V 15 W
12 V 15 W
12 V 2 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
12 V 1.7 W
Primary
Secondary
TaiI]brake Iights
License Iight
NeutraI indicator
22-14
above.
5 . AppIy cIean engine oiI to the O-ring.
7 . U-nut.
9 . CastIe nut
TOROUE VALUES
FASTENERS TYPE
TIGHTENING TOROUE
Nm (kgfm)
TIGHTENING TOROUE
Nm (kgfm)
5 (0.5)
10 (1.0)
22 (2.2)
34 (3.5)
54 (5.5)
5 mm screw
FASTENERS TYPE
4 (0.4)
9 (0.9)
12 (1.2)
26 (2.7)
39 (4.0)
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Maintenance:
VaIve hoIe cap
Timing hoIe cap
Crankshaft hoIe cap
Lubrication System:
(8 mm)
Spark pIug
(8 mm)
(10 mm)
Cam sprocket boIt
Rocker arm shaft
(EX)
CyIinder]Piston:
CyIinder boIt
1
4
1
1
2
1
2
1
13
1
2
4
2
2
4
2
2
2
4
11
1
1
1
1
1
Note 6
Note 6
Note 4
Note 1
Note 1
Note 1
Note 4
Note 3, 4
Note 4
25 (2.5)
15 (1.5)
10 (1.0)
8 (0.8)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
22 (2.2)
10 (1.0)
39 (4.0)
20 (2.0)
27 (2.8)
22 (2.2)
24 (2.4)
26 (2.6)
10 (1.0)
39 (4.0)
12 (1.2)
108 (11.0)
12 (1.2)
24 (2.4)
88 (9.0)
12 (1.2)
12
36
14
30
7
8
6
10
6
8
6
10
7
14
12
7
8
6
10
6
16
6
10
18
6
ENGINE
22-15
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Crankcase boIt
AIternator:
Stator boIt
FIywheeI boIt
CIamp socket boIt
Others:
Drive sprocket boIt
NeutraI switch
NeutraI switch nut
11
1
8
3
1
6
2
1
2
1
1
Note 1
Note 1
Note 4
Note 1
Note 1
Note 1
12 (1.2)
12 (1.2)
12 (1.2)
10 (1.0)
103 (10.5)
16 (1.6)
5 (0.5)
5 (0.5)
10 (1.0)
12 (1.2)
1.5 (0.15)
6
6
6
6
12
6
5
5
6
10
4
ENGINE (continued)
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
(Rear)
MuffIer taiI cap boIt
Maintenance:
Lubrication system:
OiI strainer nut
FueI system:
FueI strainer cup
FueI cock Iock nut
Engine mount:
Engine hanger nut
Steering stem nut
Steering top thread
Spoke nippIe
Front axIe
(Iower)
Fork center boIt
Fork boIt
1
2
4
2
2
1
1
3
1
1
1
1
1
4
6
1
1
31
4
1
4
4
4
2
2
Note 8
Note 7
Note 1
26 (2.6)
42 (4.3)
10 (1.0)
12 (1.3)
20 (2.0)
32 (3.3)
32 (3.3)
9 (0.9)
39 (4.0)
37 (3.8)
54 (5.5)
26 (2.7)
26 (2.7)
64 (6.5)
26 (2.7)
98 (10.0)
4.4 (0.45)
2.45 4.9 (0.25 0.5)
20 (2.0)
74 (7.5)
12 (1.2)
32 (3.3)
26 (2.7)
54 (5.5)
29 (3.0)
8
8
6
6
8
8
8
6
10
12
27
18
18
10
8
24
26
BC3.2
6
12
6
8
8
19
36
FRAME
22-16
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Driven sprocket nut
Rear axIe nut
(Lower)
(on the frame)
Swingarm pivot nut
Chain cover boIt
Brake System:
Brake hose boIt
nut
Push rod Iock nut
Others:
Right step boIt
nut
HandIe Iock screw
HeadIight guard nut
Speed sensor nut
6
4
1
1
1
1
1
1
1
2
4
2
2
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
Note 7
Note 8
Note 7
Note 7
Note 7
Note 7
Note 6, 7
Note 7
Note 7
Note 1
Note 1
Note 1
Note 1
Note 1
Note 1
Note 7
32 (3.3)
42 (4.3)
93 (9.5)
44 (4.5)
44 (4.5)
44 (4.5)
49 (5.0)
69 (7.0)
88 (9.0)
12 (1.2)
34 (3.5)
4.2 (0.43)
1.5 (0.15)
12 (1.2)
1.2 (0.12)
6 (0.6)
6 (0.6)
14 (1.4)
18 (1.8)
29 (3.0)
18 (1.8)
2.5 (0.25)
6 (0.6)
22 (2.2)
12 (1.2)
18 (1.8)
2.5 (0.25)
6 (0.6)
27 (2.8)
12 (1.2)
42 (4.3)
10 (1.0)
39 (4.0)
23 (2.3)
5 (0.5)
12 (1.2)
8
8
16
10
10
10
10
12
14
6
10
5
4
6
4
6
6
6
8
8
10
10
8
8
8
10
10
8
12
8
10
10
10
8
6
18
FRAME (continued)
22-17
SPECIAL TOOLS
DESCRIPTION
Maintenance:
Wrench B
NippIe wrench
Link pIate hoIder
FueI system:
FIoat IeveI gauge
PiIot screw wrench
VaIve guide driver
Cutter hoIder, 5 mm
VaIve seat cutter
Gear hoIder
Remover head, 15 mm
SIiding weight
Shaft compressor
Remover head, 13 mm
SIiding weight
CoIIar
Shaft
Adaptor
Driver handIe A
PiIot, 15 mm
PiIot, 20 mm
PiIot, 17 mm
PiIot, 22 mm
PiIot, 28 mm
TOOL NUMBER
07RMJ-MY50100
07708-0030400
07701-0020300
07HMH-MR10103
07HMH-MR10130
07401-0010000
07KMA-MS60101
07757-0010000
07942-MA60000
07984-MA60001
07781-0010400
07780-0010800
07780-0010200
07780-0012200
07780-0012000
07780-0014000
07923-KE10000
07724-0010100
07936-KC10000
07936-KC10100
07936-KC10200
07741-0010201
07936-1660120
07LMC-KZ10100
07741-0010201
07965-VM00000
07965-VM00100
07965-VM00200
07965-VM00300
07631-0010000
07749-0010000
07746-0010100
07746-0040300
07746-0010200
07746-0010300
07746-0040500
07746-0010300
07746-0040400
07746-0010400
07746-0041000
07746-0010600
07746-0041100
surement
Spoke tightening
PiIot screw adjustment
InIet
Exhaust
InIet
Exhaust
InIet]Exhaust
tion
tion
tion
22-18
07916-KA50100
07946-4300101
07948-4630100
07PMB-KZ40101
07947-KA50100
07947-KF00100
07746-0050100
07746-0050400
07749-0010000
07746-0010100
07746-0040300
07746-0010300
07931-MA70000
07946-KA50000
07GMD-KT80100
07946-MJ00100
07710-0010200
07710-0010401
07746-0050100
07746-0050500
07749-0010000
07746-0010700
07746-0040400
07746-0010200
07746-0040400
07746-0010300
07746-0040400
07914-3230001
07725-0040000
07733-0020001
DESCRIPTION
OiI seaI remover
Fork damper hoIder
Fork seaI driver
Fork seaI driver attachment
Driver handIe A
PiIot, 15 mm
Bush driver pin
Driver shaft
Retainer wrench B
Retainer wrench body
Driver handIe A
PiIot, 17 mm
PiIot, 17 mm
PiIot, 17 mm
Brake System:
Snap ring pIiers
FIywheeI hoIder
FIywheeI puIIer
TOOL NUMBER
instaIIation
and instaIIation
tion
Cushion arm needIe bearing (swingarm
side) removaI and instaIIation
removaI
Rear cushion needIe bearing removaI
and instaIIation cushion arm needIe
bearing (rear cushion side) removaI
Bearing retainer removaI and
instaIIation
Cushion arm needIe bearing (rear
cushion side) instaIIation
22-19
CABLE & HARNESS ROUTING
CLUTCH CABLE
SPARK PLUG CODE
MAIN WIRE HARNESS
SECONDARY AIR SUPPLY HOSE
(REED VALVE-TO-CYLINDER HEAD)
TURN SIGNAL RELAY
CDI UNIT
SECONDARY AIR SUPPLY
SYSTEM VACUUM TUBE
PULSE GENERATOR]
NEUTRAL SWITCH 3P
(NATURAL) COUPLER
SECONDARY AIR SUPPLY HOSE (AIR
CLEANER CASE-TO-SECONDARY
AIR SUPPLY CONTROL VALVE)
SIDE STAND SWITCH 3P
(BLACK) COUPLER
FUEL TUBE
THROTTLE STOP SCREW
22-20
CLUTCH CABLE
SECONDARY AIR SUPPLY SYSTEM VACUUM TUBE
BREATHER TUBE
THROTTLE CABLE
SPARK PLUG CODE
HORN WIRE
22-21
AIR CLEANER CASE
EMISSION CONTROL SYSTEM
Engines produce hydrocarbons and carbon monoxide during the combustion process.
Since hydrocarbons react in sunIight to form photochemicaI smog, it is very important to minimize these emissions.
Carbon monoxide does not react in a simiIar way, but is aIso harmfuI to man.
This motorcycIe adopts a Iean mixture (based on the carburetor setting), crankcase emission controI system, and second-
ary air suppIy system to reduce harmfuI hydrocarbons and carbon monoxide emissions to the minimum.
CRANKCASE EMISSION CONTROL SYSTEM
This motorcycIe features the device that prevents bIow-by gas produced in the crankcase from escaping into the atmo-
sphere by recycIing the gas back into the combustion chamber through the air cIeaner case and the carburetor.
SECONDARY AIR SUPPLY SYSTEM
This motorcycIe features a secondary air suppIy system to reduce hydrocarbons and carbon monoxide to a minimum.
The secondary air suppIy system functions to convert most of the hydrocarbons and carbon monoxide into harmIess
carbon dioxide and water by suppIying air from the air cIeaner to the exhaust port to react with such gases in the exhaust
system.
The secondary air suppIy system in this motorcycIe consists of a secondary suppIy controI vaIve (with a buiIt-in reed
vaIve).
The reed vaIve is a mechanism that prevents exhaust gases at the exhaust port from fIowing back into this system.
The secondary air controI vaIve is a mechanism to prevent after-burn in the exhaust system by stopping the secondary air
suppIy to the exhaust port during engine deceIeration.
This system needs no adjustment, however, it is important to inspect the components reguIarIy (at 12-month intervaIs).
CARBURETOR INTAKE PORT
REED VALVE
CONTROL VALVE
EXHAUST PORT
AIR
VACUUM PRESSURE
BLOW-BY-GAS
22-22
EXHAUST PIPE]MUFFLER
DISASSEMBLY
TAIL CAP
MUFFLER
GASKET
EXHAUST PIPE
GASKET
9 Nm (0.9 kgfm)
32 Nm (3.3 kgfm)
20 Nm (2.0 kgfm)
13 Nm (1.3 kgfm)
10 Nm (1.0 kgfm)
32 Nm (3.3 kgfm)
22-23
S
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MAINTENANCE SCHEDULE
: statute item, : maker specified item, : not appIicabIe item
MAINTENANCE ITEM
SPECIFICATION
Inspection part Inspection item
HandIe
Front fork
Brake pedaI and
brake Iever
Rod and cabIes
Hose and pipe
Reservoir tank
Master cyIinder
and brake caIiper
Brake drum and
brake shoe
Brake disk and pad
WheeI
Suspension arm
Shock absorber
CIutch
Transmission
Proper operation
Damage
InstaIIation condition of steering stem
Steering stem bearing Iooseness
Free pIay
Brake efficiency
Looseness, wear, and damage
Leak, damage, and proper mounting
FIuid IeveI
Function, wear, and damage
Correct cIearance between drum
and Iining
Wear of Shoe sIiding surface and
Iining
Wear or damage of drum
Correct cIearance between the disk
and the pad
Wear of pads
Wear or damage of disk
Tire pressure
Crack or damage of tire surface
Depth of tire groove or abnormaI wear
Looseness of wheeI nut and wheeI
boIt
Looseness of front wheeI bearing
Looseness of rear wheeI bearing
Looseness of Iinkage and damage
of arm
OiI Ieakage and damage
Free pIay of cIutch Iever
Smooth operation
OiI Ieakage and oiI IeveI
B
r
a
k
e

s
y
s
t
e
m
More than minimum
ShouId remain more than wear Iimit
Front wheeI: standard thickness
3.5 mm, Iimit 3.0 mm
Rear wheeI: standard thickness
4.5 mm, Iimit 4.0 mm
Front wheeI: 150 kPa (1.50 kgf]cm
2
)
Rear wheeI: 150 kPa (1.50 kgf]cm
2
)
R
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s
t
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m
S
u
s
p
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n
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s
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s
t
e
m
10 to 20 mm at Iever end
22-24
T
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2

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MAINTENANCE ITEM
SPECIFICATION
PropeIIer shaft
and drive shaft
Chain and
sprocket
Ignition system
Battery
Routing
Main unit
Lubrication
system
FueI system
CooIing system
Crankcase
emission controI
system
Carbon monox-
ide reIease
prevention
system
Looseness of Iinkage
Looseness of spIine
Looseness of universaI joint
Looseness of chain
Proper mounting and wear of
sprocket
CIeaning up the beIt case air
cIeaner
Spark pIug conditions
Ignition timing
FIuid IeveI
Specific gravity
Connecting conditions of terminaIs
Looseness and damage of connection
Starting condition and abnormaI
noise
Conditions of Iow speed and
acceIeration
Cam chain adjustment
IdIing speed
Exhaust gas conditions
Air cIeaner eIement conditions
OiI Ieakage
Contamination and oiI IeveI
FueI Ieakage
Conditions of carburetor Iinkage
Conditions of throttIe vaIve and
choke vaIve
Synchronization of carburetor and
starter vaIve
Water IeveI
Water Ieakage
Pipe damage
CIeaning up the breather drain
Function of secondary air suppIy
system
Damage and mounting condition of
pipe
30 to 40 mm at sprocket center
(when the side stand is used)
PIug gap: 0.8 to 0.9 mm
1.300 100 rpm
Dip stick: IeveI shouId be between
upper and Iower Iimit
ThrottIe grip pIay: 2 to 6 mm (fIange)
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22-25
D
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MAINTENANCE ITEM
SPECIFICATION
Lights and turn signaI
system
Horn and Iock system
Instrument
Exhaust pipe and
muffIer
Frame
Others
AbnormaI parts noticed
during the operation
Proper operation
Proper operation
Proper operation
Mounting Iooseness, damage
Function of muffIer
Lubrication condition of each parts
of chassis
Check if there is no abnormaIity in
such parts.
PERIODIC REPLACEMENT PARTS
Perform repIacement on an age or miIeage basis, whichever comes first.
IntervaI Periodic repIacement item Remarks
HydrauIic brake reIated rubber parts
Brake fIuid
Air cIeaner eIement
Engine oiI
OiI cIeaner
Every four years
Every two years
Every 20,000 km
InitiaI 1,000 km or one month then,
every 3,000 km
InitiaI 13,000 km then, every 12,000 km
Rubber parts of master cyIinder cup and
disk caIiper
Viscous type
22-26
IDLE EMISSION INSPECTION
NOTE:
Before the measurement, inspect and adjust the foIIowing:
Air cIeaner eIement condition (page 3-16)
Spark pIug condition (page 3-14)
Start and warm up the engine, then return the choke Iever
fuIIy.
Put the transmission in neutraI and secure the motorcycIe in
a verticaI and IeveI position.
Use a contact thermometer to measure the temperature of
the drain boIt.
NOTE:
Readings on Iiquid temperature thermometers may be af-
fected by the ambient temperature.
If the temperature of the drain boIt does not reach the speci-
fied vaIue, aIIow the engine to idIe for a few minutes, or
snap the engine continuousIy at approximateIy 1]4 open-
ing of the throttIe.
DRAIN BOLT TEMPERATURE: 53 63 C (reference vaIue:
oiI temperature 65 5 C)
Check for idIing speed and adjust it using the throttIe stop
screw, if necessary.
IDLING SPEED: 1,300 100 rpm
To ensure the statutory insertion depth (60 cm), prepare and
connect the adapter to the muffIer, as shown on the right.
Measure carbon monoxide (CO %) during idIing.
CO CONCENTRATION DURING IDLING: 1.0 3.5 %
If a measured vaIue exceed the Iimit, foIIow the foIIowing steps
to stop the operation of the secondary air suppIy system and
adjust the CO concentration IeveI.
Disconnect the secondary air suppIy controI vaIve vacuum
tube from the secondary air suppIy controI vaIve.
InstaII the tube cIamp to the secondary air suppIy controI vaIve
vacuum tube.
Connect the vacuum pump to the secondary air suppIy con-
troI vaIve vacuum tube and appIy the vacuum pressure of
450 mmHg minimum (the secondary air suppIy controI vaIve
does not operate at this condition).
THROTTLE STOP SCREW
PROBE ADAPTER
MUFFLER
TO CO TESTER
CO TESTER PROBE
ADAPTER
MUFFLER
VACUUM TUBE TUBE CLAMP
VACUUM PUMP
22-27
Start the engine and make sure that idIing speed is 1,300
100 rpm.
NOTE:
When the operation of the secondary air suppIy system is
stopped, the idIing speed changes. If the idIing speed devi-
ates from the specified vaIue, adjust speed when the second-
ary air suppIy system is stopped.
Turn the piIot screw on the carburetor to adjust the idIe CO
concentration.
TOOL:
PiIot screw wrench 07KMA-MS60101
CO concentration (when the operation of the secondary air
suppIy system is stopped): 5.0 0.5 %
Reconnect the secondary air suppIy controI vaIve vacuum
tube.
Start the engine.
Check the idIing speed and adjust it by turning the throttIe
stop screw, if necessary.
IDLING SPEED: 1,300 100 rpm
Measure the idIe CO concentration after the idIe speed ad-
justment.
IDLE CO CONCENTRATION: 1.0 3.5 %
If the CO concentration deviates from the specified vaIue,
check the secondary air suppIy system.
CRANKCASE EMISSION CONTROL
SYSTEM
DAMAGE OF TUBE
Check the crankcase breather tube and drain tube for discon-
nection, deterioration, or damage and repIace them with new
ones if there is abnormaIity.
SYSTEM
Check the secondary air suppIy hoses and pipes between the
secondary air suppIy controI vaIve and the cyIinder head for
disconnection, deterioration, or damage and repIace them
with new ones if there is abnormaIity.
Check the secondary air suppIy controI vaIve vacuum tube
for disconnection, deterioration, or damage and repIace it with
new one if there is abnormaIity.
PILOT SCREW
PILOT SCREW WRENCH
THROTTLE STOP SCREW
BREATHER TUBE
DRAIN TUBE
22-28
Check the secondary air suppIy hose between the air cIeaner
case and the secondary air suppIy controI vaIve for discon-
nection, deterioration, or damage and repIace it with new one
if there is abnormaIity.
FUNCTIONAL INSPECTION
Start and warm up the engine.
Remove the air cIeaner eIement (page 3-10).
Check near the secondary air suppIy port of the air cIeaner
for carbon contamination or deposit.
If there is carbon contamination or deposit, repIace the sec-
ondary air suppIy controI vaIve.
Disconnect the secondary air suppIy hose between the air
cIeaner case and the secondary air suppIy controI vaIve.
tube.
InstaII the tube cIamp to the secondary air suppIy controI vaIve
vacuum tube.
Connect the vacuum pump to the secondary air suppIy con-
troI vaIve.
Start the engine and open the throttIe grip sIightIy.
At this condition, make sure that the secondary air is suctioned
from the secondary air suppIy hose between the air cIeaner
and the secondary air controI vaIve.
If no secondary air is suctioned, check the secondary air sup-
pIy hose between the air cIeaner and the secondary air con-
troI vaIve for cIog.
AppIy vacuum pressure of 450 mmHg minimum to the sec-
ondary air suppIy controI vaIve vacuum pressure tube.
At this condition, make sure that the secondary air suction
from the secondary air suppIy hose between the air cIeaner
and the secondary air controI vaIve stops.
If the secondary air suction does not stop, or if the vacuum
pressure of 450 mmHg cannot be kept, repIace the secondary
air controI vaIve with new one.
If the secondary air suppIy system is normaI and after-burn
occurs on deceIeration, check the air cutoff vaIve (page 5-8).
VACUUM TUBE
SECONDARY AIR SUPPLY PORT
SECONDARY AIR
SUPPLY HOSE
VACUUM TUBE
TUBE CLAMP
SECONDARY AIR
SUPPLY CONTROL
VALVE
VACUUM PUMP
22-29
Remove the secondary air suppIy vaIve mounting boIts and
remove the secondary air controI vaIve cover.
Remove the secondary air hoses between the secondary air
controI vaIve, cyIinder head and air cIeaner case.
tube and remove the secondary air controI vaIve.
Remove the boIts and remove the secondary air suppIy pipe
from the cyIinder.
COVER
BOLT
VACUUM TUBE
SECONDARY AIR CONTROL VALVE
SECONDARY AIR SUPPLY PIPE
BOLT
22-30
Remove the gasket.
NOTE:
When instaIIing the gasket, repIace it with new one.
FoIIow the wiring diagram (page 22-27) to correctIy route
the tube and hoses.
REAR CUSHION
Remove the rear cushion (page 12-9).
Remove the coIIar and dust seaI.
Use the foIIowing tooI and hydrauIic press to remove the
needIe bearing.
DRIVER SHAFT 07946-MJ00100
AppIy grease to the new needIe bearing.
Use the foIIowing tooI and hydrauIic press to press the needIe
bearing into the rear cushion.
NOTE:
Press the needIe bearing into the specified depth.
GASKET
COLLAR DUST SEAL
DRIVER SHAFT
BEARING
DRIVER SHAFT
BEARING
3.5 0.2 mm
22-31
AppIy grease to the new dust seaI and instaII it.
NOTE:
The dust seaI shouId be instaIIed with the groove surface fac-
ing out.
InstaII the coIIar.
InstaII the rear cushion (page 12-12).
CUSHION LINKAGE
CUSHION ARM NEEDLE BEARING RE-
PLACEMENT
Remove and disassembIy the cushion arm (page 12-13).
Use the foIIowing tooI and hydrauIic press to remove the
needIe bearing.
AppIy grease to the new needIe bearing.
Use the foIIowing tooIs and hydrauIic press to press the needIe
bearing into the rear cushion.
Outer driver, 24 x 26 mm 07746-0010700
PiIot, 17 mm 07746-0040400
NOTE:
Press the needIe bearing into the specified depth.
AssembIy the cushion arm and instaII it (page 12-16).
COLLAR DUST SEAL
DRIVER SHAFT
BEARING
DRIVER HANDLE A
OUTER DRIVER]PILOT BEARING
5.0 0.2 mm
23-1
23
23. XR250]XR BAJA (3) SUPPLEMENT
PLASTIC PARTS 23-2
SPECIFICATIONS 23-6
SERVICE DATA 23-10
TOROUE VALUES 23-17
SPECIAL TOOLS 23-20
LUBRICATION AND SEAL POINTS 23-22
CABLE AND HARNESS ROUTING 23-24
FRONT FENDER (XR250) 23-31
FUEL TANK (XR250) 23-31
REAR FENDER (XR250) 23-32
INSULATOR REMOVAL]INSTALLATION
(XR250) 23-36
PiIot SCREW ADJUSTMENT 23-37
FRONT WHEEL (XR250) 23-41
FORK (XR250) 23-46
STEERING STEM (XR250) 23-58
IGNITION SYSTEM
PULSE GENERATOR PEAK VOLTAGE 23-69
PULSE GENERATOR INSPECTION 23-70
THROTTLE SENSOR 23-70
HEADLIGHT (XR250) 23-73
TAILLIGHT]STOP LIGHT (XR250) 23-74
TURN SIGNAL BULB (XR250) 23-74
INDICATOR]METER LIGHT
BULB (XR250) 23-75
SPEEDOMETER (XR250) 23-75
MAIN SWITCH (XR250) 23-77
WIRING DIAGRAM 23-79
23-2
XR250]XR BAJA (3) SUPPLEMENT
PLASTIC PARTS
Each of the pIastic parts of the machine weighing 100 grams or more is given an indication of the type of the materiaI used.
Method of indication
The above indication consists of a resin materiaI symboI and, where there is any suppIementary matter, a suppIementary
expIanation cIassification and a suppIementary expIanation symboI, as shown beIow.
There are two different suppIementary expIanation symboIs. Where the resin materiaI symboI is foIIowed by ~ the
suppIementary expIanation symboI represents the type of the resin materiaI reinforcement, and where the resin mate-
riaI symboI is foIIowed by the suppIementary expIanation symboI represents the characteristics of the resin mate-
riaI.
For the meanings of the resin materiaI symboIs and suppIementary expIanation symboIs, see the tabIe on the foIIowing
page.
For each part that is made of two or more different materiaIs, the abbreviated part name and the materiaI names are
shown.
SuppIementary expIanation symboI
SuppIementary expIanation cIassification
Resin materiaI symboI
LENS > PMMA <
HSG > ABS <
Abbreviated part name
The above exampIe shows that the Iens is made
of PMMA and the housing is made of ABS.
23-3
Resin names and characteristics
NOTE:
When heating the machine, pay due attention to the pIastic parts.
MateriaI
symboI
EP
PA
PBT
PC
PE
PET
PF
PMMA
POM
PP
PPE
PPS
PUR
PVC
UP
ABS
AES
ASA
E]VAC
Heat
resistance
( C)
120
80
120
130
80
120
120
80
100
80
100
200
80
80
110
80
80
80
60
Resin name
Epoxy
PoIyamide (nyIon)
PoIybutyIene
terephthaIate
PoIycarbonate
PoIyethyIene
PoIyethyIene
terephthaIate
PhenoI formaIde-
hyde (phenoI)
PoIymethyI meth-
acryIate (acryI)
PoIyoxymethyIene
PoIypropyIene
PoIyphenyIene ether
(PPO)
PoIyphenyIene
suIfide
PoIyurethane
PoIyvinyIchIoride
Unsaturated
poIyester
AcryIonitriIe-
butadiene-styrene
AcryIonitriIe-
ethyIenepro
pyIenediene-styrene
AcryIonitriIe-styrene-
acryIate (AAS)
EthyIene-
vinyIacetate (EVA)
SoIvent resistance
Resistant to aIcohoI and gasoIine
Resistant to smaII amount of aIcohoI
for short time
for very short time (e.g., aIcohoI used
for degreasing in short time)
for short time (e.g., aIcohoI used for
degreasing in short time)
for very short time (e.g., aIcohoI used
for degreasing in short time)
Resistant to smaII amount of aIcohoI]
gasoIine for short time (e.g., aIcohoI
used for degreasing in short time)
Remarks
Most soIvents are appIicabIe.
Battery Iiquid (suIfuric acid) is harmfuI.
Brake fIuid, wax, wax remover,
gasoIine and other organic soIvents
are harmfuI.
Surface-active agent (detergent)
causes stress cracking.
Immersion in and sticking of aIcohoI
or some other organic soIvent is
harmfuI.
Immersion in and sticking of gasoIine,
aIcohoI or some other organic soIvent
is harmfuI. ThoroughIy wash off wax
remover if it is used.
Battery Iiquid (suIfuric acid) is harmfuI.
aIcohoI or some other organic soIvent
is harmfuI.
aIcohoI or other organic soIvent is
harmfuI.
aIcohoI or other organic soIvent is
harmfuI.
AIkaIis are harmfuI.
GasoIine and other organic soIvents
are harmfuI.
are harmfuI.
are harmfuI.
are harmfuI.
The term heat resistance used here refers to the temperature at which there is a risk of thermaI deformation of
the resin during the work.
23-4
Main pIastic parts and their materiaIs
LICENSE PLATE
BRACKET >PP<
REAR FENDER >PP< R]L TANK SHROUDS >PP<
FRONT FENDER >PP<
FRONT VISOR >PP<
SEAT
SURFACE: PVC
CUSHION: URETHANE FORM
BOTTOM PLATE: >PP<
CHAIN CASE >PP<
R]L FORK PROTECTORS
>PP<
AIR CLEANER CASE >PP<
CHAIN GUIDE >PP<
23-5
XR250
FRAME SERIAL NUMBER : MD30-1700001 ~
FRAME SERIAL NUMBER : MD17E-4200001 ~
XR BAJA
FRAME SERIAL NUMBER : MD30-1700001 ~
FRAME SERIAL NUMBER : MD17E-4200001 ~
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
COLOR LABEL
COLOR LABEL
23-6
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda BA-MD30
2,175 mm
805 mm
1,190 mm
1,425 mm
MD17E
0.249 Iitter
GasoIine
63 kg
70 kg
133 kg
2 persons
89 kg
154 kg
243 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
285 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
9.7 Iitter
VE88E
32 mm
23-7
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
8 BTDC]1,300 rpm
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Gearshift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.076 (13]40)
WHEELS Caster
TraiI
Tire pressure Front
Rear
26 30
94 mm
2
)
2
)
Right
45
45
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1700001 ~
MD17E 4200001 ~
23-8
ITEM SPECIFICATION
Make]ModeI
OveraII Iength
OveraII width
OveraII height
WheeIbase
Engine modeI
DispIacement
FueI type
Rear axIe
TotaI
Seating capacity
Rear axIe
TotaI
Rear tire
Rim size Front rim
Rear rim
Ground cIearance
Stopping distance
Turning radius
Honda BA-MD30
2,140 mm
820 mm
1,221 mm
1,420 mm
MD17E
0.249 Iitter
GasoIine
66 kg
71 kg
137 kg
2 persons
93 kg
154 kg
247 kg
3.00 21 51P
4.60 18 63P
21 x 1.60
18 x 2.15
260 mm
14.5 m (50 km]h)
2.1 m
Engine type
VaIve train
Bore x Stroke
Compression ratio
Maximum output
Maximum torque
Exhaust
IdIing engine speed
Lubrication system
OiI pump type
OiI fiItration
OiI capacity
CooIing system
Starter motor
GasoIine, 4-stroke
OHC, chain driven
73.0 x 59.5 mm
9.3:1
28 PS]8,000 rpm
2.6 kgm]7,000 rpm
5 BTDC
35 ABDC
35 BBDC
5 ATDC
0.10 0.02 mm
0.12 0.02 mm
1,300 100 rpm
Trochoid
paper fiIter
1.7 Iitter
Air cooIed
Carburetor ModeI
Venturi diameter
Paper fiIter
14.5 Iitter
VE88E
32 mm
23-9
ITEM SPECIFICATION
ELECTRICAL
SYSTEM
Ignition system
Ignition timing
Spark pIug Standard
OptionaI for Iow
speed driving
OptionaI for high
speed driving
Spark pIug gap
CDI
8 BTDC]1,300 rpm
0.8 0.9 mm
CIutch operating
system
Ratio
Transmission Type
Shift operation
Gear ratio 1st
2nd
3rd
4th
5th
6th
Ratio
Wet muIti-pIate
MechanicaI
Gear reduction
3.100 (20]62)
Constant mesh
Left shift pedaI
2.769 (13]36)
1.882 (17]32)
1.380 (21]29)
1.083 (24]26)
0.923 (26]24)
0.814 (27]22)
Chain reduction
3.076 (13]40)
WHEELS Caster
TraiI
Tire pressure Front
Rear
26 24
100 mm
2
)
2
)
Right
48
48
BRAKE
SYSTEM
Type Front
Rear
SHOCK
ABSORBER
Rear
TeIescopic fork
Swingarm
Frame type
Frame seriaI number
Semi-doubIe cradIe
MD30 1700001 ~
MD17E 4200001 ~
23-10
at draining
at disassembIy
1.7 Iitter
1.4 Iitter
Stroke MotorcycIe (SAE10W-30) or
Honda UItra Super 8 Engine OiI for
4-stroke MotorcycIe (SAE10W-40)
When some other engine oiI is used,
it must meet aII the foIIowing require-
ments.
API cIassification: EquivaIent of
CIass SG, SH or SJ
JASO specification: MA
SAE specification: One of the four
grades shown at Ieft. SeIect the
most suitabIe grade according to
the ambient air temperature
0.15
0.15 0.22
0.02 0.09
Tip cIearance
Body cIearance
Side cIearance
OiI pump rotor
0.20
0.25
0.12
LUBRICATION SYSTEM
SERVICE DATA
Unit: mm
Type
Setting mark
Venturi diameter
PiIot screw opening
FIoat IeveI
IdIe speed
Main jet
SIow jet
Carburetor VE 88E
VE 88E A
1-3]8 turns out
18.5 mm
1,300 100 rpm
#135
#45
2 6 mm
FUEL SYSTEM
23-11
Warpage
VaIve seat width
Cam Iobe height
Runout
VaIve stem O.D.
VaIve guide I.D.
VaIve seat width
Free Iength
Rocker arm I.D.
Sub-rocker arm I.D.
ITEM
Unit: mm
2
)
0.10 0.02
0.12 0.02
1.1 1.2
30.672 30.872
30.719 30.919
4.975 4.990
4.955 4.970
5.000 5.012
5.000 5.012
0.010 0.037
0.030 0.057
1.1 1.2
1.1 1.2
43.44
44.03
11.500 11.518
7.000 7.015
7.000 7.015
11.466 11.484
6.972 6.987
6.972 6.987
0.016 0.052
0.013 0.043
VaIve spring
0.10
2.0
30.583
30.629
0.04
4.96
4.94
5.03
5.03
0.06
0.09
2.0
2.0
42.51
42.83
11.53
7.05
7.05
11.41
6.92
6.92
0.10
0.10
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
Inner
Outer
IN
EX
IN
EX
CyIinder head
Camshaft
VaIve and
vaIve guide
Rocker arm
Sub-rocker
arm
23-12
ITEM
Unit: mm
ITEM
Unit: mm
STANDARD
CIutch
CIutch outer I.D.
CIutch Outer guide
10 20
37.2
2.92 3.08
25.000 25.021
24.959 24.980
19.990 20.010
19.959 19.980
CyIinder
Piston, piston
pin and
piston ring
73.00 73.01

72.950 72.970
17.002 17.008
0.03 0.06
16.994 17.000
0.002 0014
0.016 0.040
0.15 0.30
0.30 0.45
0.20 0.70
0.015 0.05
0.015 0.05
mark facing up
mark facing up
73.11
0.05
0.05
0.10
72.87
17.05
0.1
16.97
0.05
0.09
0.30
0.45
0.86
0.12
0.12
17.06
CYLINDER]PISTON
I.D.
Taper
Out of round
Warpage
Piston O.D.
Piston pin O.D.
cIearance
Piston ring end gap
Piston ring-to-ring
groove cIearance
Piston ring mark
SERVICE LIMIT
33.5
2.7
25.04
24.12
20.03
0.3
19.91
Top
Second
OiI (side raiI)
Top
Second
Top
Second
O.D.
I.D.
23-13
ITEM
Unit: mm
Crankshaft
Transmission
0.050 0.065
0 0.008
20.000 20.021
23.000 23.021
23.000 23.021
25.020 25.041
25.000 25.021
22.000 22.021
18.000 18.018
22.000 22.021
22.959 22.980
24.979 25.000
24.959 24.980
22.959 22.980
19.959 19.980
17.966 17.984
21.959 21.980
21.959 21.980
0.02 0.062
0.02 0.062
0.020 0.062
0.020 0.062
0.02 0.062
0.02 0.062
0.016 0.052
0.02 0.062
13.000 13.021
12.966 12.984
4.930 5.000
4.900 5.000
19.959 19.980
0.80
0.05
0.05
20.08
23.07
23.07
25.09
25.07
22.07
18.08
22.1
22.90
24.90
24.90
22.92
19.91
17.91
21.91
21.91
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
13.05
12.91
4.50
4.50
19.90
Connecting
rod big end
Run out
Gear I.D.
Bushing I.D.
Bushing O.D.
M5
M6
C1
C2
C3
C4
C1
C2
C1
C2
C3
M6
side cIearance
radiaI cIearance
Mainshaft O.D. (M5)
Countershaft
O.D.
Gear-to-shaft
cIearance
Gear-to-
bushing
cIearance
Bush-to-shaft
cIearance
C1
C2
C4
M5
C4
M6
C1
C2
C3
C1
C2
Shift fork I.D.
bearing portion
R., L.
Center.
23-14
ITEM
Unit: mm
Front wheeI

2
)
2
)
2
)
440
A: 45.6 B: 390.3
576 4 cm
3
77
1 2 N (0.1 0.2 kgf)

back untiI 10 cIicks are heard.
0.2
2.0
2.0
3.0
431
45.1]386.4
0.2
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
A
i
r

p
r
e
s
s
u
r
e
One
passenger
Two
passengers
Street
Highway
Street
Fork Spring free
Iength
OiI capacity XR250]XR BAJA
OiI IeveI XR250]XR BAJA
OiI type
SIide pipe runout
XR250
XR BAJA
ITEM
Unit: mm
Rear wheeI

2
)
2
)
2
)
30 40
520MOZ9]104LE
520VC5]104LE
183.5
0.2
2.0
2.0
3.0
10
AxIe runout
Rim runout
Tire
RadiaI
AxiaI
A
i
r

p
r
e
s
s
u
r
e
One
passenger
Two
passengers
Street
Highway
Street
RepIacement
chain]Iink
RK
DID
461 4 cm
3
107
Fork Compression adjuster
instaIIation position
Rear cushion spring Ioading Iength XR250]XR BAJA
Rear
(XR250)
Compression adjuster instaIIation position
Rebound adjuster instaIIation position
Rear
(XR BAJA)
Compression adjuster instaIIation position
Rebound adjuster instaIIation position
186.5
23-15
Brake fIuid
Brake pad wear
Brake disc runout
Mater cyIinder I.D.
Master piston O.D.
CaIiper piston O.D.
DOT 4
10 20
10 20
3.5
4.5
12.700 12.743
14.000 14.043
12.657 12.684
13.957 13.984
27.000 27.050
27.000 27.050
26.935 26.968
26.935 26.968
FR
RR
FR
RR
FR
RR
FR
RR
FR
RR
To the service
Iimit groove
0.15
3.0
4.0
12.76
14.06
12.64
13.95
27.10
27.10
26.89
26.89
Unit: mm
BRAKE SYSTEM
ITEM STANDARD
AIternator
ReguIator]rectifier
Battery
TripIe phase AC
0.204 kW]5,000 rpm
0.1 1.0
14.0 14.8 V
12 V 4 Ah
0.5 A]5 10 h
5.0 A]0.5 h
2.0 mA maximum
12.8 V minimum
12.3 V maximum
Type
Output
20 C
Type
VoItage range
Capacity
Charging current
Leakage current
Standard
Fast
VoItage at
20 C
FuII charging
Lack of charging
23-16
PuIse generator
ITEM SPECIFICATIONS
Ignition type
Spark pIug
CDI
Standard
IGNITION SYSTEM
NGK
CR8 EH-9
CR7 EH-9
CR9 EH-9
DENSO
U24FER9
U22FER9
U27FER9
Spark pIug gap
Ignition timing
0.8 0.9 mm
8 BTDC]1,300 rpm
1,900 200 rpm
4,300 rpm
MP13
0.1 0.3
7.2 11.0 k
3.5 4.7 k
100 V minimum
460 580
0.7 V minimum
F mark
advance
Type Ignition coiI
Resistance
at 20 C
Primary coiI
Secondary coiI with
a pIug cap
Secondary coiI
without a pIug cap
Peak voItage
Resistance at 20 C
Peak voItage
ITEM STANDARD
Unit: mm
SERVICE LIMIT
8.5
ITEM SPECIFICATIONS
Fuse
Light]buIb
20 A
XR BAJA: 5 A x 2, 15 A x 3 XR250: 5 A x 1, 15 A x 3
XR BAJA: 12 V 35]36.5 W x 2 XR250: 12 V 60]55 W
12 V 5]21 W
12 V 5 W x 2
12 V 15 W
12 V 15 W
XR BAJA: 12 V 2 W XR250: 12 V 3.4 W
XR BAJA: 12 V 1.7 W XR250: 12 V 3.4 W
XR BAJA: 12 V 1.7 W XR250: 12 V 3.4 W
12 V 1.7 W
12 V 1.7 W
Primary
Secondary
TaiI]brake Iights
License Iight (XR BAJA)
NeutraI indicator
Side stand indicator (XR BAJA)
23-17
TOROUE VALUES
above.
5 . AppIy cIean engi ne oiI to the O-ring.
7 . U-nut.
9 . CastIe nut
FASTENERS TYPE
TIGHTENING TOROUE
Nm(kgfm)
TIGHTENING TOROUE
Nm(kgfm)
5 (0.5)
10 (1.0)
22 (2.2)
34 (3.5)
54 (5.5)
5 mm screw
FASTENERS TYPE
4 (0.4)
9 (0.9)
12 (1.2)
26 (2.7)
39 (4.0)
ITEM REMARKS
TIGHTENING TOROUE
Nm(kgfm)
THREAD DIA.
(mm)
OTY
Maintenance:
VaIve hoIe cap
Timing hoIe cap
Crankshaft hoIe cap
Lubrication System:
(8 mm)
Spark pIug
(8 mm)
(10 mm)
Cam sprocket boIt
Rocker arm shaft
(EX)
CyIinder]Piston:
CyIinder boIt
1
4
1
1
2
1
2
1
13
1
2
4
2
2
4
2
2
2
4
11
1
1
1
1
1
Note 6
Note 6
Note 4
Note 1
Note 1
Note 1
Note 1
Note 4
Note 3, 4
Note 4
24 (2.5)
15 (1.5)
10 (1.0)
8 (0.82)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
12 (1.2)
23 (2.2)
10 (1.0)
39 (4.0)
20 (2.0)
27 (2.8)
22 (2.2)
24 (2.4)
26 (2.6)
12 (1.2)
39 (4.0)
12 (1.2)
108 (11.0)
12 (1.2)
24 (2.4)
88 (9.0)
12 (1.2)
12
36
14
30
7
8
6
10
6
8
6
10
7
14
12
7
8
6
10
6
16
6
10
18
6
ENGINE
23-18
ITEM REMARKS
TIGHTENING TOROUE
Nm(kgfm)
THREAD DIA.
(mm)
OTY
Crankcase boIt
Bearing set pIate
AIternator:
Stator boIt
FIywheeI nut
CIamp socket boIt
Others:
Drive sprocket boIt
NeutraI switch
NeutraI switch nut
11
1
8
3
1
6
2
1
2
1
1
Note 1
Note 1
Note 4
Note 1
Note 1
Note 1
12 (1.2)
12 (1.2)
12 (1.2)
10 (1.0)
103 (10.5)
16 (1.6)
5.2 (0.53)
5.2 (0.53)
10 (1.0)
12 (1.2)
1.5 (0.15)
6
6
6
6
12
6
5
5
6
10
4
ENGINE (continued)
ITEM REMARKS
TIGHTENING TOROUE
Nm(kgfm)
THREAD DIA.
(mm)
OTY
(Rear)
MuffIer taiI cap boIt
Frame Body PaneIs]Rear fender
Rear fender A boIt
Maintenance:
Lubrication system:
OiI strainer nut
FueI system:
FueI strainer cup
FueI cock Iock nut
Engine mount:
Engine hanger nut
Steering stem nut XR250R
XR BAJA
Steering top thread XR250R
XR BAJA
Spoke nippIe
Front axIe XR250R
XR BAJA
Front axIe hoIder XR250R
XR BAJA
Fork cIamp boIt (upper) XR250R
XR BAJA
(Iower)
Fork center boIt XR250R
XR BAJA
Fork boIt XR250R
XR BAJA
Lock nut (fork boIt) (XR250)
Protector socket boIt (XR250)
1
2
4
2
2
1
1
3
2
1
1
1
1
1
4
6
1
1
1
1
36
4
1
1
2
4
4
4
4
2
2
2
2
2
6
26 (2.7)
42 (4.3)
10 (1.0)
12 (1.2)
20 (2.0)
32 (3.3)
32 (3.3)
9 (0.92)
13 (1.3)
39 (4.0)
36 (3.7)
54 (5.5)
26 (2.7)
26 (2.7)
64 (6.5)
26 (2.7)
103 (10.5)
98 (10.0)
6.4 (0.65)
4.4 (0.45)
2.45 4.9 (0.25 0.5)
20 (2.0)
88 (9.0)
74 (7.5)
20 (2.0)
12 (1.2)
31 (3.2)
32 (3.3)
20 (2.0)
55 (5.6)
54 (5.5)
30 (3.0)
30 (3.0)
15 (1.5)
6.4 (0.65)
8
8
6
6
8
8
8
6
6
10
12
27
18
18
10
8
24
24
26
26
BC3.2
6
16
14
8
6
8
8
8
22
22
46
38
10
6
FRAME
Refer to 23-61
Refer to 23-61
23-19
ITEM REMARKS
TIGHTENING TOROUE
Nm (kgfm)
THREAD DIA.
(mm)
OTY
Driven sprocket nut
Rear axIe nut
(Lower)
(on the frame)
Swingarm pivot nut
Chain cover boIt
Brake System:
Brake hose boIt
nut
Push rod Iock nut
Others:
Right step boIt
nut
HandIe Iock screw
HeadIight guard nut (XR BAJA)
Speed sensor nut (XR BAJA)
6
4
1
1
1
1
1
1
1
2
4
2
2
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
Note 7
Note 8
Note 7
Note 7
Note 7
Note 7
Note 6, 7
Note 7
Note 7
Note 8
Note 8
Note 1
Note 1
Note 1
Note 1
Note 7
32 (3.3)
42 (4.3)
93 (9.5)
44 (4.5)
44 (4.5)
44 (4.5)
49 (5.0)
69 (7.0)
88 (9.0)
12 (1.2)
34 (3.5)
4.2 (0.43)
1.5 (0.15)
12 (1.2)
1.2 (0.12)
5.9 (0.6)
5.9 (0.6)
14 (1.4)
17.2 (1.75)
30 (3.1)
17.2 (1.8)
2.5 (0.25)
5.4 (0.55)
22 (2.2)
12.3 (1.25)
17.2 (1.75)
2.5 (0.25)
5.4 (0.55)
27 (2.8)
12 (1.2)
42 (4.3)
10 (1.0)
39 (4.0)
23 (2.3)
5 (0.51)
12 (1.2)
8
8
16
10
10
10
10
12
14
6
10
5
4
6
4
6
6
6
8
8
10
10
8
8
8
10
10
8
12
8
10
10
10
8
6
18
FRAME (continued)
23-20
SPECIAL TOOLS
DESCRIPTION
Maintenance:
Wrench B
NippIe wrench
Link pIate hoIder
FueI system:
FIoat IeveI gauge
PiIot screw wrench
VaIve guide driver
Cutter hoIder, 5 mm
VaIve seat cutter
Gear hoIder
Remover head, 15 mm
SIiding weight
Shaft compressor
Remover head, 13 mm
SIiding weight
CoIIar
Shaft
Adaptor
Driver handIe A
PiIot, 15 mm
PiIot, 20 mm
PiIot, 17 mm
PiIot, 22 mm
PiIot, 28 mm
TOOL NUMBER
07RMJ-MY50100
07708-0030400
07701-0020300
07HMH-MR10103
07HMH-MR10130
07401-0010000
07KMA-MS60101
07757-0010000
07942-MA60000
07984-MA60001
07781-0010400
07780-0010800
07780-0010200
07780-0012200
07780-0012000
07780-0014000
07923-4280000
07724-0010100
07936-KC10000
07936-KC10100
07936-KC10200
07741-0010201
07936-1660120
07LMC-KZ10100
07741-0010201
07965-VM00100
07965-VM00200
07965-VM00300
07631-0010000
07749-0010000
07746-0010100
07746-0040300
07746-0010200
07746-0010300
07746-0040500
07746-0010300
07746-0040400
07746-0010400
07746-0041000
07746-0010600
07746-0041100
surement
Spoke tightening
PiIot screw adjustment
InIet
Exhaust
InIet
Exhaust
InIet]Exhaust
tion
tion
tion
23-21
07916-KA50100
07946-4300101
07948-4630100
07PMB-KZ40101
07YMD-MCF0100
07746-0050100
07746-0050500
07749-0010000
07746-0010100
07746-0040400
07746-0010300
07931-MA70000
07946-KA50000
07GMD-KT80100
07946-MJ00100
07746-0050100
07746-0050500
07749-0010000
07746-0010700
07746-0040400
07746-0010200
07746-0040400
07746-0010300
07746-0040400
07914-SA50001
07725-0040000
07733-0020001
07HGJ-0020100
07GMJ-ML80100
DESCRIPTION
OiI seaI remover
Fork damper hoIder
Fork seaI driver
Driver handIe A
PiIot, 17 mm
Bush driver pin
Driver shaft
Driver handIe A
PiIot, 17 mm
PiIot, 17 mm
PiIot, 17 mm
Brake System:
Snap ring pIiers
FIywheeI hoIder
FIywheeI puIIer
Ignition system:
Peak voItage adapter
Inspection adapter
TOOL NUMBER
instaIIation
and instaIIation
tion
Cushion arm needIe bearing removaI
and instaIIation
removaI
Rear cushion needIe bearing removaI
cushion side) removaI
cushion side) instaIIation
PuIse generator and throttIe sensor
inspection
23-22
LUBRICATION AND SEAL POINTS
CyIinder inner surface
Piston outer surface
Piston pin hoIe inner waII
Piston ring surface
Cam chain surface
Rocker arm shaft (rocker arm sIiding surface)
Sub-rocker arm shaft (sub rocker arm sIiding surface)
CIutch disc Iining
CIutch arm pivot
Shift fork shaft outer surface
VaIve adjust screw thread
Each transmission gear
FIywheeI boIt thread and seating surface
CyIinder head boIt (10 mm) thread and seating surface
CyIinder boIt (10 mm) thread and seating surface
CIutch center Iock nut thread and seating surface
Primary drive gear Iock nut thread and seating surface
Each bearings
Each O-rings
Each oiI seaI Iips
Each oiI seaI surface
Piston pin outer surface
Connecting rod smaII end
Camshaft Iobe
Camshaft center journaI
Rocker arm sIiding surface
Sub-rocker arm adjusting screw contact area
VaIve sIiding surface
CIutch outer guide outer surface
Outer surface of each transmission gear
M3]4, C5, and C6 gearshift fork groove
CIutch Iifter arm pivot
Each oiI seaI Iips
Rocker arm shaft threads
Sub-rocker arm shaft threads
Bearing set pIate boIt threads
Cam sprocket boIt threads
Shift drum stopper arm boIt threads
Stator boIt threads
One-way cIutch outer boIt threads
PuIse generator cIamp socket boIt threads
Honda UItra U Engine OiI
for 4-Stroke MotorcycIe
(SAE10W-30) or Honda
UItra Super 8 Engine OiI
for 4-stroke MotorcycIe
(SAE10W-40)
When some other engine
oiI is used, it must meet aII
the foIIowing require-
ments.
API cIassification:
EquivaIent of CIass SG,
SH or SJ
JASO specification: MA
Use moIybdenum oiI
soIution (mixture of the
engine oiI and moIybde-
num grease in a ratio of
1:1).
Three Bond #13238 or
#2415
Coating width:
3 mm at the middIe
of boIt thread
Coating width:
6.5 1 mm from tip
Coating width:
5 1 mm from tip
Coating width:
6.5 1 mm from tip
ENGINE
23-23
Front wheeI dust seaI Iip
Rear wheeI dust seaI Iip
ThrottIe grip sIiding surface
CIutch Iever pivot sIiding part
Speedometer pinion gear
Speedometer gearbox interior
Steering head bearing roIIing part
Steering head dust seaI Iip
Swingarm pivot bearing roIIing part
Swingarm pivot dust seaI Iip
Rear cushion needIe bearing
Rear cushion dust seaI Iip
Cushion arm]Iink needIe bearing
Cushion arm]Iink dust seaI Iip
HandIe grip inner surface
Front brake Iever piston contact surface
Front brake Iever pivot sIiding part
Rear master cyIinder piston, pushrod contact part
Brake caIiper boot interior
Brake caIiper pin boot interior
Brake caIiper pin sIiding part
Brake master piston, cup
Brake caIiper piston, piston seaI
Fork cap O-ring
Fork dust seaI, oiI seaI Iip
SIider bush, guide bush
Fork center boIt threads
AIternator one-way cIutch boIt threads
Stator boIt threads
PuIse generator socket boIt threads
MuItipurpose grease
Urea-based waterproof
grease containing extreme-
pressure additive (ExceIite
EP2 of Kyodo Yushi, SheII
Stamina EP2 of Showa
SheII Sekiyu or equivaIent)
MuItipurpose grease (SheII
AIbania EP2 or equivaIent)
Honda Bond A or
Cemedine #540
SiIicone grease
DOT 4 brake fIuid
Honda UItra Cushion OiI
No. 5
Thread Iocking agent
FRAME
3 to 5 grams for upper
part and Iower part,
respectiveIy
23-24
CABLE AND HARNESS ROUTING
XR BAJA:
BRAKE HOSE
SPEED SENSOR WIRE
THROTTLE CABLES
CLUTCH CABLE
RIGHT HANDLE SWI TCH WIRE
LEFT HANDLE SWI TCH WIRE
SPEEDOMETER CABLE
MAIN WIRE HARNESS
LEFT HANDLE SWI TCH
WIRE 9P (BLACK) COUPLER
LEFT HANDLE SWI TCH CONNECTOR
DIGITAL METER 3P
(BLACK) COUPLER
DIGITAL METER 4P
(BLACK) COUPLER
DIGITAL METER 3P
(BLUE) COUPLER
LEFT TURN SIGNAL
2P (BLACK) COUPLER
RIGHT TURN SIGNAL
2P (BLACK) COUPLER
RIGHT HEADLIGHT 3P
(NATURAL) COUPLER
RIGHT HANDLE SWI TCH
9P (RED) COUPLER
LEFT HEADLIGHT 3P
(NATURAL) COUPLER
PILOT BOX 6P (BLUE)
COUPLER
23-25
BRAKE HOSE
XR 250:
CLUTCH WIRE
RIGHT TURN SIGNAL WIRE
LEFT TURN SIGNAL WIRE
SPEEDOMETER CABLE
MAIN WIRE HARNESS
RIGHT HANDLE SWI TCH 6P (RED) COUPLER
LEFT HANDLE SWI TCH 6P
(GREEN) COUPLER
METER 6P (NATURAL) COUPLER
LEFT HANDLE SWI TCH
4P (BROWN) COUPLER
23-26
THROTTLE CABLE
CLUTCH CABLE
MAIN WIRE HARNESS
BRAKE HOSE THROTTLE CABLE
BREATHER TUBE
CLUTCH CABLE
SPEEDOMETER CABLE
23-27
SECONDARY AIR SUPPLY NEGATIVE PRESSURE TUBE
CLUTCH CABLE
THROTTLE CABLES
BREATHER TUBE
HIGH TENSION CORD
HORN WIRE
23-28
TURN SIGNAL RELAY
CLUTCH CABLE
CDI UNIT
SECONDARY AIR
SUPPLY NEGATIVE
PRESSURE TUBE
PULSE GENERATOR]
NEUTRAL SWITCH 3P
(NATURAL) COUPLER
HIGH TENSION
CORD
SIDE STAND SWITCH
3P (BLACK) COUPLER
MAIN WIRE HARNESS
(BETWEEN REED VALVE AND
CYLINDER HEAD)
THROTTLE STOP SCREW
(BETWEEN AIR CLEANER CASE AND
secondary AIR SUPPLY CONTROL VALVE)
FUEL TUBE
23-29
CARBURETOR SUB-AI R
CLEANER CASE TUBE
CARBURETOR AIR VENT TUBE BREATHER CHAMBER
AIR CLEANER CASE TUBE
CARBURETOR
SUB-AIR CLEANER
CASE
SIDE STAND
SWITCH 3P
(BLACK)
COUPLER
ENGINE
BREATHER
CHAMBER
STARTER MOTOR CABLE
ENGINE EARTH CABLE
ENGINE BREATHER
CHAMBER DRAIN TUBE
23-30
BATTERY (+) CABLE
SUB-WIRE HARNESS
RIGHT TURN SIGNAL WIRE
BATTERY () CABLE
STARTER MOTOR CABLE
LEFT TURN SIGNAL WIRE
ENGINE EARTH CABLE
MAIN WIRE HARNESS
FUSE BOX
BATTERY
23-31
FRONT FENDER (XR250)
REMOVAL
Remove the boIts, front fender, washer (Ieft front), front visor
stay and coIIars.
INSTALLATION
FUEL TANK (XR250)
REMOVAL
NOTE:
Keep the fueI cock in the OFF position during the work.
Remove the side covers and seat (page 2-2).
Remove the two boIts and four machine screws to remove
the shrouds.
NOTE:
By removing onIy the two boIts, it is possibIe to remove the
fueI tank and shrouds as a unit.
Disconnect the fueI tube from the fueI cock.
Remove the tank mounting boIt and remove the fueI tank.
INSTALLATION
NOTE:
After instaIIing the fueI tank, turn the fueI cock to ON and
check that the fueI does not Ieak from the fueI tube.
COLLARS
STAY
WASHER
FRONT FENDER
BOLTS
MACHINE SCREW
SHROUD
SHROUD
BOLT
FUEL TANK
TANK MOUNTING
BOLT
FUEL TUBE
23-32
REAR FENDERS (XR250)
REMOVAL
Rear fender A
Disconnect the taiIIight]brake Iight 6P (bIack) coupIer.
Use the main switch key to disconnect the taiI bag cabIes.
Remove the taiI bag strap.
Take the furnished tooIs out of the taiI bag.
Remove the rubber pIate.
Remove the taiI bag socket boIts, coIIars and bottom pIate.
Remove the taiI bag.
Remove the boIts and rear fender A.
Rear fender B
Remove the boIts and remove rear fender B from the frame.
6P (BLACK) COUPLER
STRAP
BOTTOM PLATE
TAIL BAG
BOLTS]COLLARS
REAR FENDER A
BOLTS
BOLTS
REAR FENDER B
23-33
Remove the boIts and remove the stay from rear fender B.
Remove the boIt and refIector.
Remove the screws and remove the mud guard from rear
fender B.
BOLT
STAY
REFLECTOR
BOLT
SCREWS
MUD GUARD
23-34
Rear fender B
InstaII the mud guard to rear fender B and tighten the screws.
INSTALLATION
RUBBER PLATE
REAR FENDER A
STAY
MUD GUARD
REAR FENDER B
REFLECTOR
13 Nm (1.3 kgfm)
SCREWS
MUD GUARD
23-35
InstaII the refIector.
InstaII the stay to rear fender B and tighten the boIts.
InstaII rear fender B to the frame and tighten the boIts.
Rear fender A
Tighten the boIts to the specified torque.
Torque: 13 Nm (1.3 kgfm)
REFLECTOR
BOLT
BOLT
STAY
BOLT
REAR FENDER B
BOLTS
23-36
Bottom pIate
CoIIars
TaiI bag socket boIts
Rubber pIate
Put the furnished tooIs back in the taiI bag and fasten them
together with the taiI bag strap.
Connect the taiI bag cabIes and Iock them with the heImet
hoIder.
Connect the taiIIight]brake Iight 6P (bIack) coupIer.
InstaII the seat and side covers (page 2-2).
INSULATOR REMOVAL]INSTALLA-
TION (XR250)
REMOVAL
Disconnect the throttIe cabIes from the throttIe drum (page
5-4).
Remove the carburetor heat guard from the insuIator boIts.
WhiIe turning the throttIe drum by hand, remove the insuIa-
tor boIt (top right).
STRAP
BOTTOM PLATE
TAIL BAG
BOLTS]COLLARS
6P (BLACK) COUPLER
CARBURETOR HEAT GUARD
BAND SCREW
BOLT
23-37
Remove the remaining insuIator boIts (top Ieft and bottom).
INSTALLATION
AppIy engine oiI to a new insuIator O-ring and instaII it to the
insuIator.
NOTE:
When instaIIing the insuIator, aIign the groove in the insuIa-
tor with the carburetor projection.
NOTE:
The piIot screw has been controIIed and adjusted properIy
at the factory. Use due care when readjusting the piIot
screw. Improper adjustment of the piIot screw causes the
concentrations of CO and HC emissions to increase sig-
nificantIy.
During adjustment work, keep the machine upright in a
IeveI pIace and the transmission gear in neutraI in order to
ensure the safety of service personneI.
Before making the necessary measurements, inspect and
adjust the foIIowing items:
Air cIeaner eIement (page 3-10)
Spark pIug (page 3-11)
Ignition timing (page 15-9)
BIow-by gas reducing device (page 22-27)
Secondary air suppIy (page 22-27)
Adjustment based on measurement of CO]
HC concentrations
1. Connect a suitabIe pipe or hose (adaptor having resistance
to heat and oiIs) to the muffIer so that the measuring probe
can be inserted 60 cm or more into the adaptor.
2. ProperIy instaII a tachometer which permits reading speed
differentiaIs of 50 rpm with reference to the instruction
manuaI.
BOLTS O-RING
O-RING
PROBE ADAPTOR MUFFLER
TO CO METER
23-38
3. Tighten the piIot screw untiI it IightIy contacts the stopper
and then return it by the standard number of turns.
CAUTION:
Standard number of turns: 1-3]8
4. Start the engine.
Use a contact thermometer to measure the temperature of
the drain boIt.
NOTE:
When a thermometer for measuring Iiquid temperatures
is used, the reading may be infIuenced by the ambient air
temperature.
If the drain boIt temperature is Iower than the specified
temperature, Ieave the engine idIing for 2 to 3 minutes or
snap the acceIerator continuousIy with the throttIe vaIve
opening set at around 1]4.
Drain boIt temperature : 53 C to 63 C (reference vaIue:
oiI temperature 65 C 5 C)
5. Check the engine idIing speed. If necessary, adjust the idIing
speed by turning the throttIe stop screw.
IdIing speed: 1,300 100 rpm
6. Measure the carbon monoxide concentration (CO, %) and
hydrocarbon concentration (HC, ppm) whiIe the engine is
idIing.
CO concentration during engine idIing: 2.1% or Iess.
HC concentration during engine idIing: 100ppm or Iess.
PILOT SCREW PILOT SCREW WRENCH
DRAIN BOLT
THROTTLE STOP SCREW
CO]HC METER PROBE MUFFLER
ADAPTOR
23-39
If either of the concentrations is higher than the aIIowabIe
Iimit, use the foIIowing procedure to stop and adjust the sup-
pIy of secondary air.
Disconnect the secondary air suppIy controI vaIve negative
pressure tube from the secondary air suppIy controI vaIve.
InstaII a tube cIamp to the secondary air suppIy controI vaIve
negative pressure tube.
Connect a vacuum pump to the secondary air suppIy controI
vaIve negative pressure tube and appIy a negative pressure
of 450 mmHg or more. (Now the suppIy of secondary air
stops.)
7. Start the engine, turn the piIot screw to adjust the CO con-
centration during engine idIing and check that the HC con-
centration is within the service Iimit.
CO concentration (with secondary air suppIy stopped):
5% 1%.
HC concentration (with secondary air suppIy stopped):
130ppm or Iess.
8. Remove the tube cIamp from the secondary air suppIy hose.
Start the engine.
Check the idIing speed. If necessary, turn the throttIe stop
screw to adjust the idIing speed.
IdIing speed: 1,300 100 rpm
After adjusting the idIing speed, measure the CO and HC
concentrations whiIe the engine is idIing.
CO concentration after adjustment: 2.1% or Iess.
HC concentration after adjustment: 100ppm or Iess.
If the CO and HC concentrations are higher than the speci-
fied vaIues, inspect the secondary air suppIy (page 22-27).
NEGATIVE PRESSURE TUBE
TUBE CLAMP
VACUUM PUMP
PILOT SCREW PILOT SCREW WRENCH
THROTTLE STOP SCREW
23-40
XR250:
23-41
FRONT WHEEL (XR250)
REMOVAL
Remove the screw and disconnect the speedometer cabIe.
Loosen the front axIe hoIder boIts.
NOTE:
Just Ioosen the front axIe hoIder boIts.
Raise the front wheeI off the ground by secureIy Iifting the
engine.
Remove the front axIe and front wheeI.
NOTE:
moved.
DISASSEMBLY
Remove the foIIowing parts:
Speedometer gearbox
Left wheeI coIIar
METER CABLE SCREW
BOLT
FRONT WHEEL
FRONT AXLE
SPEEDOMETER GEAR BOX
LEFT WHEEL COLLAR
23-42
Front brake disc
Hub cover
Left dust seaI
Right dust seaI
Speedometer gear retainer
speciaI tooIs.
BRAKE DISC
BOLT HUB COVER
DUST SEAL
DUST SEAL
GEAR RETAINER
REMOVER HEAD, 17 mm
REMOVER SHAFT
23-43
AppIy grease to a new right wheeI bearing.
ing speciaI tooIs.
Outer driver, 32 x 35 mm 07746-0010100
PiIot, 17 mm 07746-0040400
NOTE:
RIGHT DUST SEAL
ASSEMBLY
SPEEDOMETER
GEAR RETAINER
RIGHT WHEEL
BEARING (6003)
DISTANCE COLLAR
LEFT WHEEL BEARING (6003)
HUB COVER
BRAKE DISK
SPEEDOMETER GEAR RETAINER
DISTANCE COLLAR
BRAKE DISK
BRAKE DISK BOLT
20 N-m (2.0 kg-m)
BRAKE DISK BOLT
20 N-m (2.0 kg-m)
LEFT DUST
SEAL
LEFT DUST SEAL
RIGHT DUST SEAL
RIGHT WHEEL BEARING ( 6003)
LEFT WHEEL BEARING (6003)
DRIVER HANDLE A
OUTER DRIVER]PILOT
RIGHT WHEEL BEARING
23-44
AppIy grease to a new Ieft wheeI bearing.
ing speciaI tooIs.
Outer driver, 32 x 35 mm 07746-0010100
PiIot, 17 mm 07746-0040400
AppIy grease to the speedometer gear retainer.
InstaII the speedometer gear retainer into the wheeI, aIigning
the retainer tabs with the wheeI hub sIots.
AppIy grease to the right dust seaI Iip and instaII it to the
wheeI.
AppIy grease to the Iip of a new Ieft dust seaI.
InstaII the Ieft dust seaI and hub cover.
DRIVER HANDLE A
OUTER DRIVER]PILOT
LEFT WHEEL BEARING
GEAR RETAINER
ALIGN
DUST SEAL
DUST SEAL
HUB COVER
23-45
InstaII the front brake disc.
NOTE:
torque.
TOROUE: 20 Nm (2.0 kgfm)
AppIy grease to the speedometer gearbox tangs and retainer
tangs.
InstaII the speedometer gearbox into the wheeI hub, aIigning
the gearbox tangs with the retainer tangs.
INSTALLATION
InstaII the front wheeI.
NOTE:
PIace the brake disc between the brake pads, and instaII the
front wheeI.
InstaII the front axIe.
Make sure that the speedometer gearbox boss is aIigned with
the right front fork stopper.
BRAKE DISK
DRIVE MARK BOLTS
WHEEL COLLAR
TANG
GEARBOX
ALIGN
ALIGN
FRONT AXLE
23-46
Tighten the front axIe to the specified torque.
TOROUE: 88Nm (9.0 kgfm)
Remove the support under the engine. With the front brake
appIied, pump the front forks up and down severaI times and
make sure that the front axIe is secureIy seated on the axIe
hoIder.
Tighten the axIe hoIder boIt.
TOROUE: 20 Nm (2.0 kgfm)
Connect the speedometer cabIe and secureIy tighten the
screw.
FORK (XR250)
RemovaI
Front wheeI (page 23-41).
Hose cIamp boIts and cabIe cIamp boIt
Remove the socket boIts to remove the fork protectors.
NOTE:
Do not hang the caIipers by the brake hose.
If the brake hose is disconnected, air must be compIeteIy
bIed from the brake system after the fork instaIIation (page
13-4).
Loosen the upper bridge pinch boIts.
To disassembIe the fork, remove the handIebar (page 11-3)
and Ioosen the fork boIt.
NOTE:
Do not remove the fork boIt. SimpIy Ioosen it.
FRONT AXLE
SPEEDOMETER CABLE
SCREW
BOLT
FORK PROTECTOR
CLAMP BOLTS
SOCKET BOLT
CALIPER
BOLTS
FORK BOLT
23-47
Loosen the Iower bridge pinch boIts and remove the fork.
DISASSEMBLY
Before disassembIing the fork, cIean it thoroughIy (especiaIIy
the sIide pipe sIiding surface and the part around the center
boIt).
CAUTION:
Remove the fork boIt from the outer tube.

Push down the outer tube untiI the dust seaI IightIy contacts
the axIe hoIder.
Remove the fork boIt from the piston rod whiIe hoIding the
Iock nut.
Remove the spring seat and fork spring.
CAUTION:
FORK
BOLTS
COMPRESSION ADJUSTER
FORK BOLT
OUTER
TUBE
FORK BOLT
SPRING SEAT
FORK SPRING LOCK NUT
23-48
Remove the Iock nut, coIIar and spring guide.
Compress the fork 8 to 10 times to drain the oiI.
Cover the sIide pipe axIe hoIder with a shop toweI and hoId it
in a vise.
CAUTION:
Loosen and remove the fork center boIt.
Remove the seaIing washer.
Remove the fork damper from the sIide pipe.
CAUTION:
COLLAR
LOCK NUT
SPRING GUIDE
FORK DAMPER
HOLDER
FORK DAMPER
WASHER
CENTER BOLT
23-49
Compress the piston rod 8 to 10 times to drain the oiI.
Remove the dust seaI from the outer tube and remove the
stopper ring.
CAUTION:
With the dust seaI and stopper ring removed, check that the
sIide pipe smoothIy sIides through the outer tube interior.
If the sIide pipe does not move easiIy, check whether the sIide
pipe is bent and the bush for wear or damage (page 23-51).
If the sIide pipe movement is difficuIt despite the sIide pipe
and bush being in good condition, the outer tube is IikeIy
to be defective.
PuII the sIide pipe out of the outer tube.
CAUTION:
To repIace the sIide bushing with a new one, remove the oId
bushing by prying the sIot of the bushing with a fIat-head
screwdriver.
CAUTION:
Remove the foIIowing parts from the sIide pipe.

Guide bushing
Back-up ring
OiI seaI
Stopper ring
Dust seaI
FORK DAMPER
STOPPER RING
DUST SEAL
DUST SEAL OIL SEAL GUIDE BUSHING
STOPPER RING BACK-UP RING SLIDE BUSHING
23-50
Wear ring inspection
Check the outer tube wear ring for wear.
If the wear ring has worn to such a degree that it is IeveI with
the outer tube surface, repIace it with a new one.
Front fork inspection
Damaged center boIt RepIace
Bent or damaged center boIt needIe RepIace
CAUTION:
RepIace the seaIing washer and O-ring with new ones.
Scratched outer tube sIiding surface of the sIide pipe Re-
pIace
Distorted outer tube inner surface due to the deformation of
outer tube outer surface RepIace
Worn or damaged fork damper RepIace
Bent, worn or damaged fork damper piston rod RepIace
Worn or damaged fork damper oiI Iock vaIve RepIace
WEAR RING
CENTER BOLT
O-RING
SEALING WASHER
OUTER TUBE
SLIDE PIPE FORK DAMPER
PISTON ROD
OIL LOCK VALVE
23-51
Measure the free Iength of the fork spring.
Service Iimit : 431 mm RepIace if 431 mm or Iess.
VisuaIIy inspect the sIiding surfaces of the sIide bushing and
guide bushing. If the TefIon coating is worn out and any cop-
per (goId) part appears on the sIiding surfaces, or excessive
scratches are observed, repIace the bushing.
Deformed inspection points of the back-up ring RepIace
Remove any metaI particIes from the sIide bushing and guide
bushing using a nyIon brush and fork oiI.
Check the sIide pipe for bend.
Service Iimit : 0.2mm RepIace if 0.2 mm or more.
The actuaI amount of bend is 1]2 of the indicator reading (de-
fIection).
BUSHING
SLIDING SURFACES
BACK-UP RING
INSPECTION POINTS
SLIDE PIPE
23-52
ASSEMBLY
OIL SEAL INSTALLATION
CAUTION:
AppIy cushion oiI to the Iips of a new dust seaI and oiI seaI.
InstaII the foIIowing parts to the sIide pipe.
Dust seaI
Stopper ring
OiI seaI
NOTE:
InstaII the oiI seaI with its marked side facing the dust seaI.
Remove the tape.
InstaII the back-up ring and guide bushing.
If the sIide bushing has been removed, reinstaII the bushing.
NOTE:
Make sure that the sIot of the sIide bushing has no remain-
ing burr before instaIIation.
Remove any remaining burr from the bushing using a knife
whiIe being carefuI not to damage the TefIon coating.
Do not open the sIot of the bushing more than necessary.
OUTER TUBE
SLIDE PIPE Comp.
WEAR RING
WASHER
O-RINGS
CENTER BOLT Comp.
OIL SEAL
SLIDER BUSHING
GUIDE BUSHING
BACK-UP RING
STOPPER RING
DUST SEAL
DAMPER Comp.
O-RING
FORK BOLT
COLLAR
LOCK NUT
SPRING SEAT
SPRING GUIDE
FORK SPRING
TAPE
OIL SEAL
BACK-UP RING
SLIDE BUSHING
GUIDE BUSHING
23-53
AppIy cushion oiI to the sIide bushing and guide bushing and
instaII the sIide pipe to the outer tube.
Drive in the oiI seaI to just under the edge of the stopper ring
groove using the foIIowing tooIs.
Fork seaI driver 07YMD-MCF0100
SecureIy instaII the stopper ring in the outer tube groove.
InstaII the dust seaI.
Cover the sIide pipe axIe hoIder with a shop toweI and hoId it
in a vise.
CAUTION:
OUTER TUBE
SLIDE PIPE
OIL SEAL DRIVER
DUST SEAL
STOPPER RING
OIL SEAL
BACK-UP RING
GUIDE BUSHING
STOPPER RING
DUST SEAL
23-54
Use the foIIowing speciaI tooI to instaII the fork damper.
CIean and degrease the center boIt threads and appIy Iocking
Tighten the center boIt together with a new seaIing washer to
NOTE:
Tighten the center boIt with the compression adjuster set to
the LOWEST posi tion.
InstaII the spring guide, coIIar and Iock nut to the piston rod.
Pour the specified amount of the recommended cushion oiI
into the fork taking care not to Iet the oiI bubbIe.
Recommended cushion oiI: Honda UItra Cushion OiI No. 5
Amount of oiI: 576 4 cm
3
With the front fork extended and the outer tube fork boIt hoIe
bIocked by the paIm of one hand, gentIy compress the outer
tube.
ReIease the hand from the fork boIt hoIe and extend the front
fork.
Repeat the above action 2 to 3 times. (This is to force the oiI
into the fork damper by compressing the air inside the fork
and thereby appIying pressure to the oiI.)
FORK DAMPER HOLDER
FORK DAMPER
SEALING WASHER
CENTER BOLT
COLLAR LOCK NUT
SPRING GUIDE
OUTER TUBE
23-55
Pump the outer tube and piston rod sIowIy 8 to 10 times to
bIeed air from the fork.
Pump the outer tube and piston rod sIowIy 8 to 10 times again
and Ieave them for five minutes.
After the oiI between the outer tube and sIide pipe has dropped
and settIed, measure the oiI IeveI.
Standard oiI IeveI: 77 mm
NOTE:
Compress the fork aII the way when measuring the fork oiI
IeveI.
Compress the piston rod aII the way, position the fork ver-
ticaIIy, and check the fork oiI IeveI.
Attach a wire more than 30 cm Iong under the Iock nut to puII
up the piston rod.
SIowIy puII the piston rod up by puIIing the attached wire
upward.
InstaII the fork spring and spring seat.
Remove the wire.
77 mm
WIRE
SPRING SEAT
FORK SPRING
23-56
InstaII a new O-ring to the fork boIt.
HoId the Iock nut and instaII the fork boIt to the piston rod.
HoId the Iock nut and tighten the fork boIt to the specified
torque.
Torque: 15Nm (1.5 kgfm)
InstaII the fork boIt to the outer tube.
NOTE:
With the fork boIt instaIIed on the machine, tighten it to
the specified torque (see beIow).
Turn the compression adjuster back by the number of turns
noted down before disassembIy and reinstaII its rubber cap.
INSTALLATION
AIign the outer tube stopper ring groove with the upper sur-
face of the top bridge and instaII the fork with the air vent boIt
facing forward.
Tighten the Iower bridge pinch boIts to the specified torque.
O-RING
FORK BOLT
LOCK NUT
FORK BOLT
COMPRESSION ADJUSTER
ALIGN FACING
FORWARD
BOLTS
23-57
If the fork has been disassembIed and reassembIed, tighten
the fork boIt to the specified torque.
InstaII the handIebar (page 11-6).
Tighten the Iower bridge pinch boIts to the specified torque.
InstaII the fork protectors and tighten the socket boIts to the
specified torque.
Torque: 6.4Nm (0.65 kgfm)
InstaII the foIIowing parts:
Hose cIamp boIt and cabIe cIamp boIt
NOTE:
Tighten the hose cIamp boIt with the white mark on the brake
hose aIigned with the top end of the cIamp.
FORK BOLTS
BOLTS
ALIGN WITH
THE WHITE
MARK
CLAMP
BOLTS
FORK
PROTEC-
TORS
SOCKET BOLTS CALIPER
23-58
STEERING STEM
REMOVAL
HeadIight (XR250) (page 23-73)
Speedometer (XR250) (page 23-75)
BoIts (XR BAJA)
Speedometer cabIe (XR BAJA)
Speed sensor (XR BAJA)
Upper and Iower brake hose guide
Turn signaI stay
HeadIight stay
Front fork
Steering stem nut
Washer
Top bridge
Loosen the cabIe guide boIt of the steering stem and detach
the meter cabIe from the cabIe guide.
XR BAJA: BOLTS
SPEED
SENSOR
SPEEDOMETER CABLE
HEADLIGHT STAY HOSE GUIDE
TURN SIGNAL STAY
BOLTS
STEM NUT WASHER
TOP BRIDGE
METER CABLE BOLT
CABLE GUIDE
23-59
Use the foIIowing tooI to remove the steering top thread.
Upper dust seaI
Upper bearing
Damaged upper bearing RepIace
Damaged upper outer race of the steering head pipe RepIace
Remove the steering stem.
Damaged Iower bearing RepIace
Damaged Iower outer race of the steering head pipe RepIace
STEERING HEAD BEARING REPLACEMENT
NOTE:
AIways repIace the bearings and bearing outer races as a set.
Remove the upper and Iower races of the steering head us-
ing the foIIowing tooI.
TOP THREAD
DUST SEAL BEARING
OUTER RACE
OUTER RACE
BEARING STEERING STEM
OIL SEAL REMOVER
23-60
Use the foIIowing tooIs to drive in the upper and Iower outer
races of the steering head.
Outer driver, 42 x 47 mm 07746-0010300
Remove the Iower bearing and dust seaI using a tooI such as
a chiseI.
CAUTION:
Press a new dust seaI and Iower bearing into the steering
stem.
DRIVER HANDLE
OUTER DRIVER
DUST SEAL LOWER BEARING
STEM NUT
STEM DRIVER
23-61
AppIy grease to the upper and Iower bearings.
Steering stem
Upper bearing
Dust seaI
Use the foIIowing tooI to tighten the steering top thread to
INSTALLATION
UPPER OUTER RACE
STEERING STEM
STEERING TOP THREAD
DUST SEAL
UPPER BEARING
LOWER OUTER RACE
LOWER BEARING
DUST SEAL
DUST SEAL
STEERING STEM UPPER BEARING
STEM SOCKET
TOP THREAD
23-62
Move the stem right and Ieft 5 times or more to break in the
bearings. CompIeteIy Ioosen the steering top thread once.
Then tighten it with the prescribed torque.
Turn the stem Iock-to-Iock at Ieast five times to seat the bear-
ings. CompIeteIy Ioosen the steering top thread once and
tighten the steering top thread again to the specified torque.
Torque : XR250: 6.4 Nm (0.65 kgfm)
XR BAJA: 4.4 Nm (0.45 kgfm)
Connect the meter cabIe to the cabIe guide and tighten the
boIt.
InstaII the top bridge secureIy and instaII the washer and steer-
ing stem nut temporariIy.
InstaII the front fork (page 23-56).
InstaII the Iower brake hose guide and tighten the bridge pinch
boIts to the specified torque.
Tighten the steering stem nut to the specified torque.
Torque : XR250: 103 Nm (10.5 kgfm)
XR BAJA: 98 Nm (10.0 kgfm)
Inspect the steering head bearing (page 3-25).
InstaII the headIight stays, turn signaI stays and upper brake
hose guide and tighten the bridge pinch boIts to the specified
torque.
Torque : XR250: 31 Nm (3.2 kgfm)
XR BAJA: 32 Nm (3.3 kgfm)
METER CABLE
BOLT
CABLE GUIDE
STEM NUT]WASHER
GUIDE
BOLT
FORK
BOLTS HEADLIGHT STAYS GUIDE
TURN SIGNAL STAYS
23-63
Speed sensor (XR BAJA)
Speedometer cabIe (XR BAJA)
BoIts (XR BAJA)
Speedometer (XR250) (page 23-75)
HeadIight (XR250) (page 23-73)
XR BAJA:
BOLTS
SPEED SENSOR
SPEEDOMETER CABLE
23-64
XR250:
MAIN SWITCH
CDI UNIT
IGNITION COIL
BATTERY
SPARK PLUG
PULSE GENERATOR
SIDE STAND
SWITCH
THROTTLE SENSOR
FUSE 20A
MAIN SWITCH
ENGINE STOP
SWITCH
CDI UNIT
BATTERY
Lg]R
DIODE
TO
NEUTRAL
INDICATOR
L
g
]
R
B
u
]
Y
L
g
]
R
G]W
G]W
DIODE
G
]
R
NEUTRAL
SWITCH
PULSE
GENERATOR
BI BI
CLUTCH
SWITCH
Y
]
R
Y
]
B
u
G
]
W
B
I
]
W
B
u
]
Y
G
]
B
I
B
I
]
Y
IGNITION COIL
G
SPARK PLUG
G
]
W
G
THROTTLE
SENSOR
SIDE STAND
SWITCH
BI ....... BLACK
Y ....... YELLOW
Bu....... BLUE
G ....... GREEN
R ....... RED
W ....... WHITE
Lg ....... LIGHT GREEN
R R]BI
23-65
XR BAJA:
FUSE 20A
MAIN SWITCH
ENGINE STOP
SWITCH
CDI UNIT
BATTERY
Lg]R
DIODE
TO
NEUTRAL
INDICATOR
L
g
]
R
B
u
]
Y
L
g
]
R
G]W
G]W
DIODE
G
]
R
NEUTRAL
SWITCH
PULSE
GENERATOR
BI BI
CLUTCH
SWITCH
Y
]
R
Y
]
B
u
G
]
W
B
I
]
W
B
u
]
Y
G
]
B
I
B
I
]
Y
IGNITION COIL
G
SPARK PLUG
G
]
W
G
THROTTLE
SENSOR
SIDE STAND
SWITCH
BI ....... BLACK
Y ....... YELLOW
Bu....... BLUE
G ....... GREEN
R ....... RED
W ....... WHITE
Lg ....... LIGHT GREEN
TO SIDE STAND
INDICATOR
R R]BI
23-66
IGNITION SYSTEM TROUBLESHOOTING
Inspect the foIIowing before diagnosing the system.
FauIty connection of spark pIug cap or spark pIug wire.
Water got into the spark pIug cap
FauIty connection of the ignition system coupIers or connectors.
No spark at pIug
Inspect the operation of starter motor (page 16-2).
Measure the ignition coiI primary voItage
(page 15-6).
STANDARD: 100 V MINIMUM
Disconnect the CDI unit coupIer.
Measure the puIse generator peak voItage at the
harness side of the CDI unit (page 23-69).
AbnormaI
NormaI
FauIty or dead battery
FauIty starting unit
NormaI
CDI unit fauIty
NormaI
AbnormaI
AbnormaI
FauIty spark pIug or ignition coiI secondary cur-
rent Ieaking
Ignition coiI fauIty
23-67
Disconnect the puIse generator coupIer and
connect the inspection adapter.
Measure the puIse generator peak voItage (page
23-69).
Turn the main switch ON and inspect the opera-
tion of side stand warning Iight (XR BAJA).
CONNECTION: White cIip (+) body ground ()
Check for the continuity of the side stand switch
(page 17-22).
SIDE STAND RETRACTED STATE: Green]White -
Green CONTINUITY
SIDE STAND PARKING STATE: YeIIow]BIack -
Green CONTINUITY
AbnormaI
NormaI
PuIse generator fauIty
AbnormaI
Side stand switch fauIty
NormaI
AbnormaI
Open or short circuit in yeIIow]bIack terminaI cord
BIown side stand warning Iight buIb
Disconnected or poorIy connected side stand
switch coupIer
Side stand switch fauIty
NormaI
Open or short circuit in bIue]yeIIow terminaI cord
IGNITION CUTOFF SYSTEM INSPECTION
23-68
Inspect the continuity at CDI unit coupIer harness
side.
CONNECTION: Green]White terminaI (+) Body
ground
Transmission in neutraI position: Continuity
Transmission not in neutraI position: No conti-
nuity
AbnormaI
Open circuit in fresh green]red cord.
Diode fauIty.
Open circuit in green]white terminaI cord.
CDI unit fauIty.
NormaI
23-69
PULSE GENERATOR PEAK VOLTAGE
NOTE:
obtained.
Connect the peak voItage adapter to the digitaI voItmeter.
Peak voItage adapter 07HGJ-0020100
Remove the CDI unit 8P (naturaI) coupIer.
harness side of the foIIowing terminaI.
CONNECT TERMINAL: BIue]YeIIow (+) Body ground ()
Crank the engine with starter motor and measure the peak
voItage.
PEAK VOLTAGE: 0.7 V minimum
Measure the peak voItage at puIse generator]neutraI switch
3P (naturaI) coupIer again if the peak voItage measured at
CDI unit 8P (naturaI) coupIer terminaI is abnormaI.
coupIer and connect the inspection adapter.
Inspection adapter 07GHJ-ML80100
white cIip.
CONNECTION: White cIip (+) Body ground ()
peak voItage.
PEAK VOLTAGE: 0.7 V MINIMUM
If the voItage measured at the CDI unit coupIer terminaI is
abnormaI and the voItage measured at the puIse genera-
tor coupIer is normaI, check for open circuit in wire har-
ness or contact faiIure in coupIer.
If both voItages are abnormaI, repIace the puIse generator
(page 14-9).
PEAK VOLTAGE
ADAPTER
INSPECTION ADAPTER
23-70
PULSE GENERATOR INSPECTION
INSPECTION
NOTE:
The puIse generator can be inspected whiIe it is mounted on
the engine.
Disconnect the CDI unit 8P (naturaI) coupIer.
Measure the resistance of the puIse generator between the
CDI unit 8P (naturaI) coupIer bIue]yeIIow terminaI and body
ground.
STANDARD: 460 580 (20 C)
If the measured vaIue is abnormaI, inspect the puIse genera-
tor separateIy.
coupIer.
Measure the resistance between the puIse generator side bIue]
yeIIow terminaI and body ground.
STANDARD: 460 580 (20 C)
If the measured vaIue is abnormaI, repIace the puIse genera-
tor (page 14-9).
THROTTLE SENSOR
INSPECTION
XR BAJA:
INPUT VOLTAGE
Turn the main switch ON and measure the voItage at the main
harness side of the throttIe sensor 3P (naturaI) coupIer.
CONNECTION: YeIIow]Red (+) BIue]Green ()
STANDARD : 4.5 5.5 V
If there is any abnormaIity in the above inspection, check for
open circuit in wire harness or contact faiIure in coupIer.
23-71
OUTPUT VOLTAGE
Turn the main switch OFF and connect the inspection adapter
to the throttIe sensor 3P (naturaI) coupIer.
Inspection adapter 07GMJ-ML80100
Connect the tester to the anaIog voItmeter.
Turn the main switch ON and check that the voItage indicator
needIe fIuctuates smoothIy as the throttIe is graduaIIy opened.
CONNECTION: White cIip (+) green cIip ()
If any abnormaIity is reveaIed through the above inspections,
check for continuity.
Turn the main switch OFF and disconnect the inspection
adapter.
Connect the throttIe sensor 3P (naturaI) coupIer.
Disconnect the CDI unit 8P (naturaI) coupIer and measure the
resistance at the coupIer harness side.
CONNECTION: YeIIow]Red Green]BIack
STANDARD: 4-6 k (20 C)
CONNECTION: YeIIow]BIue Green]BIack
STANDARD:
CLOSED): 0.4 0.6 k (20 C)
If any abnormaIity is reveaIed by the above inspections, per-
form the same inspection on the 3P coupIer of the throttIe
sensor.
Measure the resistance at the throttIe sensor side of the 3P
(naturaI) coupIer.
CONNECTION: YeIIow]Red Green]BIack
STANDARD: 4-6 k (20 C)
CONNECTION: YeIIow]BIue Green]BIack
STANDARD:
the throttIe sensor.
If there is no abnormaIity in the above inspections, repIace
the wire harness.
INSPECTION ADAPTER
23-72
HEADLIGHT BULB
MAIN SWITCH
REAR BRAKE
LIGHT SWITCH
FRONT TURN
SIGNAL BULB
BATTERY
REAR TURN SIGNAL BULBS
NETURAL SWITCH
TAILLIGHT]BRAKE LIGHT
BULB
XR BAJA:
DIGITAL METER
BI ....... BLACK
Y ....... YELLOW
Bu....... BLUE
G ....... GREEN
R ....... RED
W ....... WHITE
Br ....... BROWN
SPEED SENSOR
B
I
]
B
r
R
]
G
B
I
Y
]
R
G
B
u
]
G
Y
]
B
u
B
I
]
B
u
W
]
B
u
B
u
]
B
I
B
I
]
B
r
R
]
G
B
u
]
B
I
W
]
B
u
B
I
]
B
u
Bu]BI
G
FUSE 5A
FUSE 15A
R]BI
MAIN
SWITCH R
R
MAIN FUSE
20A
BATTERY
23-73
HEADLIGHT (XR250)
REMOVAL
Remove the boIts.
the Iower side of headIight from the front visor stay.
Disconnect the 3P connector from the headIight.
Remove the headIight adjust screw from the headIight unit.
Remove the two screws to remove the headIight unit.
INSTALLATION
Connect the 3P connector to the headIight.
Iower side of headIight with the front visor stay.
HEADLIGHT
3P CONNECTOR
BOLTS
PROTRUDING PORTION
SCREWS
HEADLIGHT UNIT
HEADLIGHT ADJUST SCREW
23-74
TAILLIGHT]STOP LIGHT (XR250)
Loosen the screw and remove the taiIIight]stop Iight Iens.
Turn the taiIIight]stopIight buIb countercIockwise to remove
it.
TURN SIGNAL BULB (XR250)
Loosen the screw and remove the turn signaI Iens.
Turn the turn signaI buIb countercIockwise and remove it.
SCREWS
BULB
SCREW
BULB
23-75
INDICATOR]METER LIGHT BULB
(XR250)
Remove the speedometer assembIy (see beIow).
Remove the socket from the under-case assembIy and repIace
the buIb.
SPEEDOMETER (XR250)
REMOVAL
Left handIe switch 4P (brown) and 6P (green) coupIers
Right handIe switch 6P (red) coupIer
Meter 6P (naturaI) coupIer
Main switch 2P (bIack) coupIer
Speedometer cabIe
Remove the nuts and remove the speedometer stay.
Remove the speedometer assembIy.
SOCKET
STAY
NUTS
SPEEDOMETER ASSEMBLY
23-76
Remove the socket component.
Remove the screws and remove the meter unit from the un-
der-case assembIy.
INSTALLATION
SOCKET
SCREWS
UPPER CASE Comp.
KNOB
UNDER-CASE ASSEMBLY
SPEEDOMETER Comp.
INNER-CASE ASSEMBLY
BULBS
SOCKET Comp.
23-77
InstaII the meter unit to the under-case assembIy and tighten
the screws.
InstaII the socket component.
NOTE:
Harness the wires correctIy according to the Wiring Diagrams
(page 23-24).
MAIN SWITCH (XR250)
INSPECTION
Check for continuity at the main switch side of the 2P (bIack).
the contact base component.
ON
OFF
LOCK
COLOR
BAT 1
R
BAT 2
R]BI
SCREWS
SOCKET
2P (BLACK) COUPLER
23-78
Remove the speedometer (page 23-75).
Remove the bridge pinch boIt (upper right) and remove the
turn signaI stay and headIight stay.
Remove the socket boIts.
Use Torx Bit T10 to remove the screw.
Check for continuity at the main switch (contact base compo-
nent) (page 23-77).
Tighten the socket boIt.
InstaII the headIight stay and turn signaI stays and tighten
the bridge pinch boIt (upper right) to the specified torque.
InstaII the speedometer (page 23-75).
InstaII the headIight (page 23-73).
SOCKET BOLTS
SCREWS
LOCK Comp.
CONTACT BASE Comp.
SOCKET BOLTS
O
G
G
G
B u
L g ] R
B I ] B r
B I ] B r
L b
O
L b ] W
L b
B r ] B I
B u ] O
O ] W
Y ] R
B I ] R
B I ] W
B u ] W
B I ] B u
Y ] R
B I ] R
B I ] W
B u ] W
B I ] B u
B I ] B r
G ] Y
R ] B I
R
R ] B I
R
B I
B I
G r
O
G
L g
B I ] B r B I ] B r B I ] B r
L b ] W
O ] W
B u ] W
B I B u
L g
G r
B I
B I
W
L g
B I
G ] W
G ] R
L b ] W
O ] W
B u ] W
L g
G r
B u
W
L b ] W
O ] W
B u ] W
G r
B u
W
B I ] Y
G ] B I
G
G
B r ] B I
R ] B I
B I ] B r
B I ] B u
B I ] R
B r ] B I
R ] B I
B I ] B r
B I ] B u
B I ] R
G ] W
G ] R
L g ] R
G ] B I
Y ] R
Y ] B u
L g ] B I
L g ] R
G ] W
B I ] W
Y ] B u
B u ] Y
G ] B I
Y ] R
B I ] Y
R
B r
R
B r
B I ] B r
G ] Y
R
G
L g ] R
B u ] Y
G
Y
Y
Y
G ] W
R ] W
G
G
G ] W
Y ] B I
G
Y
Y
Y
R
G
Y
Y
Y
L g ] R
B u ] Y
G
R
Y ] R
G ] R
R ] W
B I
B I
L b O
L b ] W
L b
B r ] B I
B u ] O
O ] W
G r
O
Y ] R
B I ] R
B I ] W
B u ] W
B I ] B u
Y ] R
B I ] R
B I ] W
B u ] W
B I ] B u
B I ] B r
G ] Y
R ] B I
R
R ] B I
R
B I
B I
G ] B I
Y ] R
Y ] B u
L g ] B I
L g ] R
R
B r
R
B r
B I ] B r
G ] Y
R
G
B u ] O
L g ] R
B I ] B r
Y ] B I
B I ] B r
B I ] B u
W ] B u
B u ] B I
R ] G
B I ] B r
B I
Y ] R
G
B I ] B u
W ] B u
B u ] B I
R ] G
B I ] B r
G
B u ] G
Y ] B u
G
B I ] B r
G
G
B u
B u ] O
L g ] R
B I ] B r
Y ] B I
G
B u
B I
B I ] B u
W ] B u
B u ] B I
G
L g
L g
B u
W
B I ] B r
L g
B u
B I
B I
W
B I ] B r
L b ] W
O ] W
B u ] W
G r
G ] R
G ] W
L b ] W
O ] W
B u ] W
G r
L b ] W
B I ] B r
W
O ] W
B u ] W
G r
B u
L g
B I
B I
B I ] Y
G
B r ] B I
R ] G
R
R ] G
G ] B I
G
R
R ] B I
B I ] B r
B I ] B u
B I ] R
B r ] B I
R ] B I
B I ] B r
B I ] B u
B I ] R
G ] W
G ] R
L g ] R
G ] W
B I ] W
Y ] B u
B u ] Y
G ] B I
Y ] R
B I ] Y
L g ] R
B u ] Y
G
Y
Y
Y
G ] W
R ] W
G
G
G ] W
Y ] B I Y ] B I
G
Y
Y
Y
R
G
Y
Y
Y
L g ] R
B u ] Y
G
R
Y ] R
G ] R
R ] W
B I
B I
L b ] W
B I
R
B I
INDEX (aIphabeticaI order)
Air CIeaner ................................................................ 3-10
Air CIeaner Case ....................................................... 5-19
AIternator .................................................................. 14-9
Battery ....................................................................... 14-5
Brake FIuid ................................................................ 3-20
Brake FIuid RepIacement]Air BIeeding ................... 13-4
Brake Pad RepIacement ........................................... 13-6
Brake Pad Wear ........................................................ 3-21
Brake PedaI ............................................................... 13-29
Brake System............................................................ 3-21
BuIb RepIacement .................................................... 17-4
(XR250 (V)) ..................................................... 21-27
CabIe And Harness Routing .................................... 1-19
(XR250 (V)) ..................................................... 21-17
(XR250]XR BAJA (Y)) .................................... 22-19
(XR250 BAJA (3)) .......................................... 23-42
Camshaft InstaIIation ............................................... 7-17
Camshaft RemovaI ................................................... 7-7
Carburetor ................................................................. 5-4
Carburetor InsuIator ................................................. 21-18
Charging System Inspection ................................... 14-7
Choke Operation....................................................... 3-10
CIutch ........................................................................ 3-22
CIutch InstaIIation..................................................... 9-11
CIutch RemovaI ........................................................ 9-5
CIutch Switch ............................................................ 17-21
Crankcase AssembIy ................................................ 10-20
Crankcase Breather .................................................. 5-3
Crankcase Emission ControI System...................... 22-27
Crankcase Separation .............................................. 10-4
Crankcase bearing RepIacement............................. 10-15
Crankshaft]BaIancer Shaft ....................................... 10-12
Cushion Linkage ....................................................... 12-13
(XR250]XR BAJA (Y)) .................................... 22-31
CyIinder Compression ............................................. 3-16
CyIinder Head AssembIy ......................................... 7-15
CyIinder Head Cover AssembIy .............................. 7-20
CyIinder Head Cover DisassembIy.......................... 7-5
CyIinder Head Cover InstaIIation ............................ 7-22
CyIinder Head Cover RemovaI ................................ 7-4
CyIinder Head DisassembIy ..................................... 7-10
CyIinder Head InstaIIation ....................................... 7-16
CyIinder Head RemovaI ........................................... 7-9
CyIinder InstaIIation ................................................. 8-8
CyIinder RemovaI ..................................................... 8-3
DigitaI Meter ............................................................. 17-11
Drive Chain ............................................................... 3-17
Drive Chain SIider .................................................... 3-20
Drive Sprocket InstaIIation ...................................... 6-5
Drive Sprocket RemovaI .......................................... 6-2
Emission ControI System ........................................ 22-21
Engine Does Not Start Or Is Hard To Start ............. 19-1
Engine InstaIIation.................................................... 6-4
Engine Is FauIty At MiddIe And High Speed .......... 19-3
Engine OiI .................................................................. 3-13
Engine OiI FiIter ........................................................ 3-15
Engine OiI Inspection (XR250]XR BAJA (V)) .......... 21-22
Engine RemovaI ....................................................... 6-3
Exhaust Pipe]MuffIer ................................................ 2-7
(XR250]XR BAJA (Y)) .................................... 22-22
Fork .......................................................................... 11-14
(XR250 (3)) ..................................................... 23-46
Front Brake CaIiper ................................................... 13-8
Front Fender ............................................................. 2-2
(XR250]XR BAJA (V)) .................................... 21-24
(XR250 (3)) ..................................................... 23-31
Front Master CyIinder .............................................. 13-12
Front WheeI .............................................................. 11-8
(XR250 BAJA (3)) .......................................... 23-41
FueI Cock................................................................... 3-9
FueI Tank ................................................................... 5-22
(XR250 (3)) ..................................................... 23-31
FueI Tube ................................................................... 3-9
Gearshift Cam........................................................... 9-10
HandIebar.................................................................. 11-3
HandIebar Switch ..................................................... 17-19
HeadIight (XR BAJA) ................................................ 17-8
(XR250 (V)) ..................................................... 21-26
HeadIight (XR250) .................................................... 17-11
(XR250 (3)) ..................................................... 23-73
HeadIight Beam Adjustment ................................... 3-22
Horn ........................................................................ 17-23
IdIe Emission Inspection.......................................... 22-26
IdIe Speed Adjustment ............................................ 3-15
Ignition CoiI ............................................................... 15-8
Ignition System Inspection...................................... 15-6
Ignition System TroubIeshooting
(XR250 BAJA (3)) .......................................... 23-66
Ignition Timing ......................................................... 15-9
Indicator]Meter BuIb (XR250(3)) .............................. 23-75
InsuIator RemovaI]InstaIIation (XR250(3)) .............. 23-36
Lubrication And SeaI Points .................................... 1-18
(XR250 BAJA (3)) .......................................... 23-22
Main Switch .............................................................. 17-18
(XR250 (3)) ..................................................... 23-77
Maintenance ScheduIe ............................................ 3-2
(XR250]XR BAJA (Y)) .................................... 22-23
ModeI Identification ................................................. 1-1
(XR BAJA (T) ................................................. 20-1
(XR250]XR BAJA (V)) .................................... 21-2
(XR250]XR BAJA (Y)) .................................... 22-2
(XR250]XR BAJA (3)) .................................... 23-5
NeutraI Switch .......................................................... 17-21
OiI Pass Pipe ............................................................. 4-8
OiI Pipes .................................................................... 4-9
OiI Pump ................................................................... 4-3
(XR250]XR BAJA (V)) .................................... 21-20
OiI Strainer Nut CIeaning......................................... 4-2
OiI Strainer Screen CIeaning ................................... 4-2
Periodic RepIacement Parts..................................... 22-25
PiIot Screw Adjustment ........................................... 5-18
(XR250]XR BAJA (V)) .................................... 21-19
(XR250 BAJA (3)) .......................................... 23-37
Piston InstaIIation..................................................... 8-6
Piston RemovaI ......................................................... 8-4
PIastic Parts (XR BAJA (3)) ...................................... 23-2
Poor Performance At Low And IdIe Speed ............ 19-2
Poor Power And Lack Of Speed At High Speed .... 19-4
Primary Drive Gear ................................................... 9-8
PuIse Generator Inspection ..................................... 15-9
(XR250 BAJA (3)) .......................................... 23-70
PuIse Generator Peak VoItage (XR250 BAJA (3)) ... 23-69
Rear Brake CaIiper .................................................... 13-19
Rear Cushion ............................................................ 12-9
(XR250]XR BAJA (Y)) .................................... 22-30
Rear Fender ............................................................... 2-3
(XR250 (3)) ..................................................... 23-32
Rear Master CyIinder ............................................... 13-24
Rear WheeI ................................................................ 12-3
ReguIator]Rectifier .................................................... 14-8
Right Crankcase Cover InstaIIation ......................... 9-14
Right Crankcase Cover RemovaI ............................. 9-3
Secondary Air SuppIy System ................................ 22-27
Service Data .............................................................. 1-6
(XR BAJA (T)) ................................................ 20-4
(XR250]XR BAJA (V)) .................................... 21-7
(XR250]XR BAJA (Y)) .................................... 22-7
(XR250]XR BAJA (3)) .................................... 23-10
Service Information
(Brake System) .............................................. 13-2
(Charging System]AIternator) ...................... 14-1
(CIutch]Gearshift Linkage) ............................ 9-1
(Crankshaft]Transmission) ............................ 10-1
(CyIinder Head]VaIves) .................................. 7-1
(CyIinder]Piston) ............................................ 8-1
(Engine RemovaI]InstaIIation) ...................... 6-1
(Frame]Body PaneIs]Exhaust System) ........ 2-1
(Front WheeI]Suspension]Steering) ............ 11-1
(FueI System) ................................................ 5-1
(Ignition System) ........................................... 15-1
(Light]Meter]Switch) ..................................... 17-1
(Lubrication) .................................................. 4-1
(Rear WheeI]Suspension) ............................. 12-1
(Starting System) .......................................... 16-1
Side Cover]Seat ........................................................ 2-2
Side Stand................................................................. 3-23
Side Stand Switch .................................................... 17-22
Spark PIug................................................................. 3-11
SpeciaI TooIs............................................................. 1-16
(XR250]XR BAJA (Y)) .................................... 22-17
(XR250]XR BAJA (3)) .................................... 23-20
Specifications (XR250) ............................................. 1-2
(XR250 (V)) ..................................................... 21-3
Specifications (XR BAJA) ........................................ 1-4
(XR BAJA (T)) ................................................ 20-2
(XR BAJA (V)) ................................................ 21-5
(XR250 (Y)) ..................................................... 22-3
(XR BAJA (Y)) ................................................ 22-5
(XR250 BAJA (3)) .......................................... 23-6
Speed Sensor ........................................................... 17-14
Speedometer (XR250 (3)) ........................................ 23-75
Starter Motor ............................................................ 16-7
Starter Motor ReIay Switch ..................................... 16-14
Starter Reduction Gear ............................................ 16-6
Steering Head Bearing............................................. 3-25
Steering Stem........................................................... 11-26
(XR250 (3)) ..................................................... 23-58
StopIight Switch (Inspection]Adjustment) ............. 3-21
StopIight Switch (Light]Meter]Switch) ................... 17-20
Suspension ............................................................... 3-23
Swingarm.................................................................. 12-17
TaiIIight]StopIight (XR250 (3)) ................................. 23-74
ThrottIe Operation.................................................... 3-9
ThrottIe Sensor ......................................................... 17-16
(XR250 BAJA (3)) .......................................... 23-70
Torque VaIues ........................................................... 1-14
(XR BAJA (T)) ................................................ 20-11
(XR250]XR BAJA (V)) .................................... 21-14
(XR250]XR BAJA (Y)) .................................... 22-14
(XR250 BAJA (3)) .......................................... 23-17
Transmission ............................................................ 10-6
TroubIeshooting
(Brake System) .............................................. 13-3
(Charging System]AIternator) ...................... 14-3
(CIutch]Gearshift Linkage) ............................ 9-2
(Crankshaft]Transmission) ............................ 10-3
(CyIinder Head]VaIves) .................................. 7-3
(CyIinder]Piston) ............................................ 8-2
(Frame]Body PaneIs) ..................................... 2-1
(Front WheeI]Suspension]Steering) ............ 11-2
(FueI System) ................................................ 5-2
(Ignition System) ........................................... 15-3
(Light]Meter]Switch) ..................................... 17-2
(Lubrication) .................................................. 4-1
(Rear WheeI]Suspension) ............................. 12-2
(Starting System) .......................................... 16-2
Turn SignaI BuIb (XR250 (3)) ................................... 23-74
Under Guard ............................................................. 2-7
VaIve CIearance ........................................................ 3-11
VaIve Guide RepIacement ........................................ 7-12
VaIve Seat Inspection And Refacing ....................... 7-13
WheeI ........................................................................ 3-24
Wiring Diagram ........................................................ 18-1
(XR250 (V)) ..................................................... 21-29
(XR250 BAJA (3)) .......................................... 23-79
To print chapters, click on the printer icon and fill
in the page range.
1. General Information 3 - 27
2. Frame/Body panels/Exhaust system 28 - 36
3. Maintenance 37 - 61
4. Lubrication system 62 - 73
5. Fuel system 74 - 97
6. Engine removal/Installation 98 - 104
7. Cylinder head/Valves 105 - 127
8. Cylinder/Piston 128 - 141
9. Clutch/Gearshift linkage 138 - 153
10. Crankshaft/Transmission 154 - 175
11. Front wheel/Suspension/Steering 176 - 206
12. Rear wheel/ /Suspension 207 - 230
13. Brake system 231 - 261
14. Charging system/Alternator 262 - 281
15. Ignition system 282 - 292
16. Starting system 293 - 307
17. Lights/Meters/Switches 308 - 331
18. Wiring diagrams 332 - 333
19. Troubleshooting 334 - 338
20. Supplement XRBAJA (T) 339 - 351
21. Supplement XR250/XR BAJA (V) 352 - 379
22. Supplement XR250/XR BAJA (Y) 380 - 410
23. Supplement XR250/XR BAJA (3) 411 - 490

XR 250 L 01

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XR 250 L 01

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00-2

G-n Paste manu-

BR-2 pIus manufactured by

IN mark facing to the intake side

0.1 0.2 kg-m

181 7.5 kg when compressed to 10 mm

Loosen the drive chain.

ThrottIe grip free pIay

CIean the cyIinder head and the vaIve after Iapping.

IN mark facing to the intake side

Remove the crankshaft and baIancer from the Ieft crankcase

0.1 0.2 kg-m

181 7.5 kg when compressed to 10 mm

Remove the piston seaIs and dust seaIs.

Remove the piston seaIs and the dust seaIs.

LEAK CURRENT: 2.0 mA maximum

IN mark facing to the intake side

150 kPa (1.50 kgf]cm

0.1 0.2 kgfm

150 kPa (1.50 kgf]cm

IN mark facing to the intake side

150 kPa (1.50 kgf]cm

0.1 0.2 kg-m

150 kPa (1.50 kgf]cm

IN mark facing to the intake side

150 kPa (1.50 kgf]cm

1 2 N (0.1 0.2 kgf)

150 kPa (1.50 kgf]cm

IN mark facing to the intake side

150 kPa (1.50 kgf]cm

1 2 N (0.1 0.2 kgf)

150 kPa (1.50 kgf]cm

Remove the fork boIt from the outer tube.

Remove the foIIowing parts from the sIide pipe.

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