Honda VFR400R Motorcycle Service Manual

 Introduction Contents
This service manual describes the service procedures for .
and technical feature of the VFR400R. - General Information
This Model Specific Manual includes every service pro-
cedure that is of a specific nature to this particular
— medel. Basic service procedures that are common to
other Honda Motorcycles/Motor Scooters/ATVs are
Frame/Body Panels/Exhaust System
| Mn |
covered in the Common Service Manual, This Model Maintenance I
— Specific Service Manual should be used together with o
the Common Service Manual in order to provide com- Lubrication System
- - plete service information on all aspects of this. motor- —
cycle. Cooling System
Performing the first scheduled maintenance is very im-
__ portant. It compensates for the initial wear that occurs
during the break-in period.
Fuel System
Engine Removal/installation
Section 1 and 3 apply to the whole motorcycle, Section
2 illustrates procedures for removal/installation of com-
- __ponents that may _be required to perform service de-
scribed in the following sections.
While Section 4 through 19 describe parts of the motor-
- cycle, grouped according ‘to locations.
Cylinder Head/Valves
Clutch
Engine and Drive Train
Gearshift Linkage
EE
—— Find the section you want on this page, then turn to
the table of contents on the first page of the section. — Crankshaft/Piston/ Transmission
Most sections describe the service procedure through
___ System illustration. Refer to the next page for details on
how to use this manual.
Front Wheel/Suspension/Steering
Rear Wheel/Suspension
Chassis
If you are not familiar with this motorcycle, read Techni-
cal Feature in section 20. Brake System
-—— If. you don't know the source of the trouble, go to section
— 21 TROUBLESHOOTING. a LS
a Charging System/Alternator
EY ES RE I RE |
O ESE ENS E
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS = Ignition System
AND SPECIFICATIONS INCLUDED IN THIS PUBLI- © —
CATION ARE BASED ON THE LATEST PRODUCT 5 Flectric Starter/Starter Clutch
- | INFORMATION AVAILABLE AT THE TIME OF AP- © =
PROVAL FOR PRINTING. HONDA MOTOR CO., LTD. ” LU . .
RESERVES THE RIGHT TO MAKE CHANGES AT Lights/Meters/Switches 18 |
-— | ANY TIME WITHOUT NOTICE AND WITHOUT 7 . —
INCURRING ANY OBLIGATION WHATEVER. NO Wiring Diagram
PART OF THIS PUBLICATION MAY BE REPRO-” —
DUCED WITHCUT WRITTEN PERMISSION. THIS a Technical Feature 20
MANUAL !S WRITTEN FOR PERSONS WHO HAVE ВЕ
ACQUIRED BASIC KNOWLEDGE OF MAIN- Troubleshoot 21
TENANCE ON HONDA MOTORCYCLES, MOTOR FOUDIESNOOUNG
— I SCOOTERS OR ATVS. —
— = = ~ HONDA MOTOR CO., LTD.
SERVICE PUBLICATION OFFICE
Date of Issue: February, 1990
O HONDA MOTOR CO., LTD. а
|
- -Important Safety Notice
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION: Indicates a possibility of equipment damage if instructions are not followed.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is
important to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda,
might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.
Type Codes = =
Throughout this manual, the following abbreviations are used to identify individual model.
Code Area Type
E U.K.
AR Austrie
F (M Model only} France
G {M Model } Germany
| 4 dA
|
How to Use This Manual
Finding Information You Need
* This manual is divided into sections which cover each of
the major components of the motorcycie.
To quickly find the section you are interested in, the first |
page of each section is marked with a black tab that lines
up with one of the thumb index tabs before this page.
The first page of each section lists the table of contents. i
within the section.
Read the service information and troubleshooting related
to the section before you begin working.
* An index of the entire book is provided in the last chapter
to directly locate the information you need.
Note on the Explanation Method of This Manual
* The removal and installation of parts are for the most part illustrated by large and clear illustrations that should provide
the reader with visual! aid in understanding the major point for servicing.
* The system illustrations are augmented by callouts whose numbers or letters indicate the order in which the parts should
be removed or installed. ZZ
* The sequence of steps represented numerically are differentiated from the ones represented alphabetically to notify the
reader that they must perform these steps seperately.
For example, if the steps prior and up to camshaft removal are performed with the engine installed, but the subsequent
steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders.
+ The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be taken.
REfer to the next page for the meaning of each symbol mark.
* Also in the illustration is a chart that lists information such as the order in which the part is removed/installed, the name
of the part, and some extra notes that may be needed.
* Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is neces-
sary or illustrations alone would not suffice.
= Service procedures required before or after the procedure described on that particular page, or inspection/adjustment proce-
dures required following the installation of parts, are described under the title Requisite Service.
* Standard workshop procedures and knowledge covered in the Common Service Manuat are abbreviated in this manual.
Detailed description
Symbol mark E. System illustration ] _ of the procedure | ]
a ) CYLINDER HEAD/CYLINDERETON / = = == rm re se
NET / ons ou cinco mas YE
e 25130, 221 V MOTT
Ч Orar ghey Pia Quinn Fi? Yee
Fariddl 4 Mire diles emmvar draj Pearly bem, Theva
Ip WA Primi, pm maT,
E Male pl do ried pratt, 11 Fre
EE
" 1 В E
CH SF e. 2
Y oF
Step
sequence
or alphabets po чая
PROCIO Эт ERA a
IER, DER Nay ro ter e Peral -
DI] Corsa Fupral dcha! Met 12 rar ipuga 15)
VE) Creer Feel Prob do 2
Wir chi a Wo] Thal Copied Pop rc de
и ma ; DE rte Wk UP marks ing J d Tigre Shek оны! nl oral trang Aw 9 & уйма,
LES | Ei pes 1 rr fateh
oo pre wily Queer Comba Gut ъ
Cara reg abil Tomer,
pa Pie mann Shan Can ” y “нее Sita Ma ны ОО ант, 2 lp)
| Carrell ulin gia Sel 1 Wemutirng els 11 Wem НД ант, В Мб
MO] Connor | a mue чи,
À ho, man Ÿ ела laure nverd souris noi.
8-4 !
- =r 7 — — — rer
Part number Number of — notes or precaution
parts related to the service procedure
N
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertain-
ing to these symbols, it would be explained specifically in the text without the use of the symbols.
ола луны"
<?
= == == =
Replace the part{s) with new one(s) before assembly.
ST
Use special tool
Use optional tool. These tools are obtained as you order parts.
10 2)
Torque specification. 10 Nem {1.0 kg-m, 7.2 ft-Ib)
(1.0, 7
Use recommended engine oil, unless otherwise specified.
A
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1).
FE
Use multi-purpose grease {Lithium based multi-purpose grease NLG! # 2 or equivalent)
AG
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGt # 2 or
equivalent)
Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste {containing more than 40% molybdenum disulfide, NLG! #2 or
equivalent)
Example: Molykote® G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 45 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease
Apply a locking agent. Use the agent of the middle strength, unless otherwise specified.
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
Use Fork or Suspension Fluid.
> TT «< —ите= TO AE
"|
1. General Information
General Safety 1-1
Model Identification 1-3
Specifications 1-4
Torque Values 1-14
Tools 1-17
Lubrication & Seal Points 1-19
Cable & Harness Routing 1-21 |
General Safety
Carbon Monoxide
Н the engine must be running to do some work, make sure
Used Engine/Transmission Oil
the area is well ventilated. Never run the engine in an en- -—
closed area.
* The exhaust contains poisonous carbon monoxide gas
that can cause loss of consciousness and may lead to
death. *
Run the engine in an open area or with an exhaust evacua-
tion system in an enclosed area.
Gasoline _
Work in a well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is stored.
AWARNING
* Gasoline is extremely flammable and is explosive
under certain conditions. KEEP OUT OF REACH OF
CHILDREN.
Hot Components
* Engine and exhaust system parts become very hot and
remain hot for some time after the engine is run.
Wear insulated gloves or wait until the engine and
exhaust system have cooled before handling these
parts.
* Used engine oil {or transmission oil in two-strokes) may
cause skin cancer if repeatedly left in contact with the
-skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still
advisable to thoroughly wash your hands with soap
and water as soon as possible after handling used oil.
KEEP OUT OF REACH OF CHILDREN.
Brake Dust
never use an air hose or dry brush to clean brake
assemblies.
A WARNING
+. Inhaled asbestos fibers have been found to cause
respiratory disease and cancer.
Brake Fluid
— CAUTION
1
« Spilling fluid on painted, plastic or rubber parts will |
damage them. Place a clean shop towel over these
parts whenever the system is serviced. KEEP OUT OF
REACH OF CHILDREN.
1-1
General Information
Coolant
Under some conditions, the ethylene glycol in engine coolant
is combustible and its flame is not visible. H the ethylene
glycol does ignite, you will not see any flame, but you can
be burned.
Á WARNING o
* Avoid spilling engine coolant on the exhaust system
or engine parts. They may be hot enough to cause the
coolant to ignite and burn without a visible fiame.
+ Coolant (ethylene glycol) can cause some skin irrita-
REACH OF CHILDREN.
The coolant is under pressure and could scald you.
* Keep hands and clothing away from the cooling fan,
as it starts automatically.
tion and is poisonous if swallowed. KEEP OUT OF |
* Do not remove the radiator cap when the engine is hot. |
If it contacts your skin, wash the affected areas immedi-
ately with soap and water. If it contacts your eyes, flush
them thoroughly with fresh water and get immediate medi-
cal attention. If it is swallowed, the victim must be forced
to vomit then rinse mouth and throat with fresh water
before obtaining medical attention. Because of these
dangers, always store coolant in a safe place, away from
the reach of children. _ _
Nitrogen Pressure
For shock absorbers with a gas-filled reservoir:
AWARNING
* Use only nitrogen to pressurize the shock absorber.
The use of an unstable gas can cause a fire or explo-
= sion resulting in serious injury.
* The shock absorber contains nitrogen under high
pressure. Allowing fire or heat near the shock ab-
sorber could lead to an explosion that could result in
serious injury,
* Failure to release the pressure from a shock absorber
before disposing of it may lead to a possible explosion
¡ and serious injury if it is heated or pierced. |
To prevent the possibility of an explosion, release the
nitrogen by pressing the valve core. Then remove the valve
stem from the shock absorber reservoir.
Before disposal of the shock absorber, release the nitrogen
by pressing the valve core. Then remove the valve stem
from the shock absorber.
Battery Hydrogen Gas & Electrolyte
A WARNING
* The battery gives off explosive gases; keep sparks,
flames and cigarettes away. Provide adequate venti-
lation when charging.
* The battery contains sulfuric acid {electrolyte}. Con-
tact with skin or eyes may cause severe burns, Wear
protective clothing and a face shield.
— If electrolyte gets on your skin, flush with water.
— H electrolyte gets in your eyes, flush with water for
at least 15 minutes and call a physician.
* Electrolyte is poisonous.
— If swallowed, drink large quantities of water or milk
and follow with milk of magnesia or vegetable oil
and call a physician. KEEP OUT OF REACH OF
CHILDREN.
Ч
rr ей = —
General Information
JE
Model Identification —
(1) FRAME SERIAL NUMBER
The frame serial number is stamped on the right side of
the steering head.
(2) ENGINE SERIAL NUMBER (3) CARBURETOR IDENTIFICATION NUMBER
The engine seríal number is stamped on the top of the crank- The carburetor identification number is stamped on the
case right side. _ carburetor body intake side.
(4) COLOR CODE LABEL
The color code label is attached to the rear fender below
the rear seat. When ordering color-coded part, alway
specify its designated color.
1-3
= - °° TT TU EA A y E W TE ee
1
|!
General Informations
Specifications
Unit: mm (in)
— General
Item Specifications
Dimensions Overall length 1,285 (78.1)
Overall length {M Mode! only) 2,035 (80.1), G: 2,070 (81.5)
Overall width — __ —| 705 (27.8)
Overall height 1,075 (42.3)
Wheelbase 1,345 (53.0)
Ground ciearance - —| 125 (4.9)
Dry weight 175 kg (385.8 Ib)
Dry weight (M Mode! only) 176 kg (388.1 1b)
Curb weight 192 kg (423.3 Ib)
Maximum weight capacity
Maximum weight capacity
(M Model only)
347 kb (765.0 16}
342 kg (754.0 Ib)
Frame Frame type
Front suspension
Front wheel travel
Rear suspension
Rear wheel travel
y Rear damper
Front tire size
Rear tire size
Tire brand (Bridgestone) FR/RR
Tire brand (Dunlop) FR/IRR oo
Tire brand (Yokohama) FR/RR _
Tire brand (IRC) _ FR/RR
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity
Backbone
Telescopic fork
120 (4.7)
Swingarm
120 (4.7)
Gas-filled damper with reservoir
120/60 VR17
150/60 VR18
K510A RADIAL/K510 RADIAL
Hydraulic double disc
Hydraulic single disc
25920
96 (3.8)
15 liters (4.0 US gal, 3.5 Imp gal)
2.0 liters (0.5 US gal, 0.4 Imp gal)
Engine Bore and stroke _ —
Displacement
Compression ratio _ —
Valve train
Intake valve opens at 1 mm lift
Intake valve closes at 1 mm lift
Exhaust valve opens at 1 mm lift
Exhaust valve closes at 1 mm lift
Lubrication system _
Oil pump type
Cooling system
Air filtration
Crankshaft type
Firing order
Cylinder arrangement
Cylinder humber
55.0 x 42.0 (2.16 x1.65)
393 em? (24.3 cu in)
11,3:1 —
Gear driven DOHC, 4 valves per cylinder
15° BTDC
35° ABDC
35° BBDC
5% ATDC I
Forced pressure and wet sump
Trockoid
Liquid cooled
Paper filter
Unit-type, 4 main journals
1 — 90° — 4 — 270° — 3 — 80° — 2
4 cylinders 90° \/
General Information
Unit: mm (in)
_ General (Cont'd] -
ltem Specifications
Carburetor Carburetor type Constant velocity, 4 carburetors
Throttle bore 32 (1.3)
Drive Train Clutch system Multi-plate, wet
Clutch operation system Cable operated
Transmission —t 6 speeds
Primary reduction 2.117 (34/72)
Secondary reduction —
Third reduction om
Final reduction 2.666 (15/40)
Gear ratio ist 2.928 (14/41)
Gear ratio 2nd 2.166 (18/39)
Gear ratio 3rd 1.800 (20/36)
Gear ratio 4th 1.691 (22/35)
Gear ratio bth 1.435 (23/33)
Gear ratio 6th 1.318 (22/29)
Gear ratio reverse | —— _
Gearshift pattern -| Left foot operated return system 1—-N—2—3—4—5—6
Electrical Ignition system - | Digitalized full transistor ignition
Starting system — | Electric starter motor
Charging system —| Triple phase output alternator
Regulator/rectifier type SCR Shorted/triplé phase full-wave rectification
Lighting system Battery
_ _ AC regulator type —
|
1-5
General information
Unit: mm (in)
Г Lubrication
Item
Standard
Service Limit
—
Engine oil capacity at draining
at disassembly
at oil filter change
Recommended engine oil
OIL VISCOSITIES
Oil pressure at oil pressure switch
Oil pump rotor tip clearance (1)
body clearance @
end clearance @
2.4 liters (2.54 US qt, 2.11 Imp at)
3.0 liters (3.17 US qt, 2.64 Imp qt}
2.5 liters {2.64 US at, 2.20 Imp at)
Use Honda 4-stroke oil or equivalent
Viscosity: SAE 10W— 40
Other viscosity shown in the chart may be
used when the average temperature in your
riding area is within the indicated range.
490—588 kPa (5.0—6.0 kg/cm?, 71-85 psi)
at 5,000 rpm(80°C/176°F)
0.15 (0.006) -
0.15—0.22 (0.006—0.009)
0.04—0.09 (0.0016—0.0035)
|
NA
— Fuel System ===
Carburetor identification number
Carburetor identification number (M Model only)
Main jet
(High altitude)
(2, 3)
(1, 4)
{Front)
(Rear)
Slow jet
Jet needle clip position
Pilot screw initial opening
Pilot screw high altitude adjustment
Pilot screw final opening
Pilot screw final opening (M Model only)
Air screw initial opening
Air screw high altitude adjustment
Float level
Carburetor Vacuum difference
Base carburetor (For carburetor synchronization)
idle speed
Throttle grip free play
Accelerator pump clearance
VDE 3A (E), VDE 3C (AR)
VDE 3F (E, F)
VDE 3G (AR)
VDE 3H (G)
#35
2 turns out
1/4 turns out
1 turns out (E, F)
1/2 turns out (AR, G)
6.8 (0.28)
Within 40 mmHg (1.6 inHg)
No. 2 carburetor
1,300 + 100 min-* (rpm)
2—6 (0.08—0.24)
———
PELLE
И
1-6
General information
Unit: mm {in}
— Cylinder Head
{tem
Standard
Service Limit
Cylinder compression
Cylinder compression difference
Valve clearance IN
EX
Cylinder head warpage
Com lobe height (M) IN
EX
Camshaft runout
Camshaft oil clearance A
Camshaft journal Q.D. A
B
Camshaft holder LD. A
B
Valve stem O.D. IN
EX
Valve guide 1.D. IN
EX
Stem-to-guide clearance IN
EX
Valve guide projection above cylinder head IN (h)
EX (nh)
Before guide installation:
1. Chill the valve guide in the
freezer section of a refrigerator
for about an hour.
2. Heat the cylinder head to
100—150%C (212-—300*F)
Valve seat width IN
EX
Valve spring free length IN
EX
inner IN
inner EX
Quter IN
Quter EX
Rocker arm 1.D. IN
EX
Rocker arm shaft O.D. IN
EX
Rocker arm-to-rocker arm shaft clearance
Valve lifter Q.D.
Valve lifter bore LD.
Hydraulic tappet adjuster assist spring free length
Hydraulic tappet adjuster compression stroke with
kerosene
1,274 + 196 kPa (13.0 + 2.0 kg/em?,
185 + 28 psl)/400 min"! trpm)
40 mmHg (1.6 inHg)
0.12—0.18 (0.005—0.007)
0.21-0.27 (0.008—0.011)
32.717—32.957 (1.2882— 1.2975)
32.428-— 32.668 (1.2767— 1.2861]
—
0.040 —0.082 (0.0016—0.0032)
27.939 — 27.960 (1.1000—1.1008)
28.000— 28.021 {(1.1024— 1.1032}
4.475—4.490 (0.1762—0.1788)
4.455—4.480 (0.1758—0.7 764)
4.500—4.512 (0.1772—0.1770)
4.500—4.512 (0.1772—0.1776)
0.010—0.037 (0.0004— 0.001 5}
0.020—0.047 (0.0008 — 0.0019}
10 (0.4)
10 (0.4)
1.70—2.30 (0.067 —0.091)
1.70—2.30 (0.067—0.091)
— =
31.4 (1.24)
31.4 (1.24)
34.4 (1.35)
34.4 {1.35)
8.500—8.515 {0.3346—0.3352)
8.500—8.515 (0.3346 —0.3352)
8.466—8.484 (0.3333—0.3340)
8.466 — 8.484 (0.3333 —0.3340)
НО
0.10 (0.004)
32.67 (1.286)
32.38 (1.275)
0.03 (0.001)
0.092 {0.0036)
—_—,——] ]
27.93 (1.010)
—
28.03 (1.104)
4.47 10.176)
0.46 (0.1756)
4.56 (0.180)
4.56 (0.180)
0.09 (0.004)
0.12 (0.005)
30.2 (1.19)
30.2 (1.19)
33.2 (1.31)
33.2 (1.31)
8.53 (0.336)
8.53 (0.336)
8.46 (0.333)
8.46 (0.333)
И
1-7
—— тнт еее
General information
Unit: mm (in)
— Cylinder/Piston
| Item
Standard
Service Limit |
| Cylinder 1.D.
Cylinder out of round
| Cylinder taper
Cylinder warpage
Piston mark direction
Piston O.D. (D)
Piston O.D. measurement point (H)
Piston pin hoie |.D. {d)
Cylinder-to-piston clearance
Piston pin O.D.
Piston-to-piston pin clearance
Connecting rod-to-piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Second ring end gap
Oil ring (side rail) end gap
Top ring mark
Second ring mark
95.000— 55.015 (2.1654-— 2.1659)
os
————————
"—— =.
“IN” mark facing toward the intake side
54.9 70— 54.990 (2.1642 — 2.1650)
10 (0.4)
14.002 -- 14.008 (0.5513—0.5515)
зы
0.010—0.045 (0.0004—0.0018)
13.994 —14.000 {0.5509—0.5512)
0.002-0.014 (0.0001 —0.0006)
0.016—0.040 (0.0006 —0.0016)
0.015—0.050 (0.0006 -—0.0020)
0.015—0.045 (0.0006—0.0018)
0.18—0.33 (0.007 —0.013)
0.18—0.33 (0.007—0.013)
0.20—0.80 {0.008—0.031)
“R” mark facing up
“e” mark facing up
—
55.07 (2.168)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)
E—]ÑÑb o
54.92 (2.168)
14.02 (0.552)
0.10 (0.004)
13.98 (0.550)
0.04 (0.002)
0.06 (0.002)
0.10 (0.004)
0.10 (0.004)
0.65 (0.026)
0.65 (0.026)
0.95 (0.037)
ey.
bg
Crankshaft
Connecting rod small end LD.
Connecting rod big end side clearance
radial clearance
Crankshaft runout
Crankpin oil clearance
Crankpin bearing selection
Main journal oil clearance
Main journal bearing selection
14.016—14.034 (0.5518—0.5525)
0.10—0.30 (0.004—0.012)
——
——
0.028— 0.052 (0.0011—0.0020)
See page 11-10
0.025—0.049 (0.0010—0.0019)
See nage 11-10
14.05 (0.553) |
0.4 (0.02)
—
0.03 (0.001)
0.07 (0.003)
0.07 {0.003)
Г Kickstarter
Kickstarter pinion gear 1.D.
Kickstarter spindle Q.D.
Kickstarter idle gear 1.D.
Countershaft O.D. at kickstarter idle gear
Kickstarter idle gear bushing O.D.
LD.
TTT
И
1-8
General information
Unit: mm (in)
— Transmission — =
item Standard Service Limit
ar учун"
Transmission gear LD. M5, M6
C2, C3, C4
Transmission gear bushing O.D. M5, MG
C2, C3, C4
Transmission gear bushing 1.D. Mb
C2
Gear-to-bushing clearance at Mb, M6 gear
at C2, C3, C4 gear
Mainshaft O.D. at M5 gear bushing
M5
Countershaft O.D. at C2 gear bushing
C2
===" -
Gear-to-shaft clearance
Gear bushing-to-shaft clearance at M5 gear
at C2 gear
Shift fork clew thickness L
С
В
Shift fork 1.0. |
с
В
Shift fork shaft OD. L
C
R
28.000—28.021 {1.1024— 1.1032)
28.000— 28.021 (1.1024— 1.1032}
27.959— 27.980 (1.1007—1.1016)
27.959—27.980 (1.1007— 1.1016)
24.985— 25.006 (0.9837—0.9845)
24.985— 25.006 (0.9837—0.9845)
0.020—0.062 (0.0008—0.0024)
0.020—0.062 (0.0008 —0.0024)
24.967 — 24.978 (0.9830—0.9834)
24.967 — 24,978 (0.9830—0.9834)
0.007—0.039 (0.0003—0.,0015}
0.007—0.039 (0.0003—0.0015)
5.93—6.00 (0.233—0.236)
5.93—6.00 (0.233—0.236)
5.93—6.00 (0.233—0.236)
12.000— 12.021 (0.4724—0.4733)
12.000— 12.021 (0.4724—0.4733)
12.000— 12.021 (0.4724—0.4733)
11.969— 11.980 (0.4712—0.4 717)
11.969— 11.980 (0.4712—0.471 7)
11.969— 11.980 (0.4712—0.4717)
28.04 (1.104)
28.04 (1.104)
27.94 (1.100)
27.94 (1.100)
25.03 (0.985)
25.03 (0.985}
0.10 (0.004)
0.10 (0.004)
24.96 (0.983)
24,96 (0.983)
0.06 (0.002)
0.06 (0.002)
5.8 (0.23)
5.8 (0.23)
5.8 (0.23)
12.04 (0.474)
12.04 (0.474)
12.04 (0.474)
11.95 (0.470)
11.95 (0.470)
11.95 (0.470)
will
General information
7 Clutch System
item
Standard
TA
Unit: mm (in)
Service Limit
Ciutch lever free play
Recommended clutch fluid
Clutch master cylinder 1.D.
Ciutch master piston O.D.
Clutch outer 1.D.
Clutch outer guide O.D.
[.D.
Mainshaft O.D. at clutch outer guide
Oil pump drive sprocket 1D.
Clutch center B 1.D
One way ciutch inner C.D.
Clutch spring free height (As a set of 3pcs.)
Ciutch_spring free length
Clutch disc thickness
Clutch disc thickness A —
B
Clutch plate warpage
Centrifugal clutch drum LD.
bushing O.D.
Centrifugal ciutch center guide [.D.
O.D.
Centrifugal clutch center guide collar height
Centrifugal clutch spring free length
Clutch lining thickness
Crankshaft O.D. at clutch center
10— 20 (0.4—0.8)
29.000— 29.021 (1.1417— 1.1426)
28.967 — 28.980 (1.1404 — 1.1409)
21.995— 22.015 (0.8659—0.8667)
23.025— 29.075 (1.1427—1.1447)
63.964 — 63.990 (2.5183— 2.5193)
47.365—47.378 (1.8648 — 1.8653)
5.3 (0.21)
2.92—3.08 (0.115—0.121)
И
23.06 (1.144)
28.93 (1.139)
22.05 (0.868)
29.11 (1.146)
64.00 (2.520)
47.36 (1.8646)
4.8 (0.19)
|
2.8 (0.110)
0.30 (0.012)
THT
ИНН
Cooling System ===
Coolant capacity (Radiator and engine)
M Model
(Reserve tank)
Radiator cap relief pressure
Thermostat begins to open
Thermostat fully open
Thermostat valve lift
2.1 liters (2.22 US ft. 1.85 Imp qt)
2.0 liters {2.11 US ft, 1.76 Imp at)
0.2 liter (0.27 US qt, 0.18 Imp at)
108—137 kPa
(1.10—1.40 kg/cm?, 16-20 psi)
80-—-84°C (176—183°F)
95°C (203°F) )
8.0 (0.23) min.
I
|
И
— Drive Train
Recommended final drive oil
Final drive gear oil capacity at disassembly
at draining
Final drive gear backlash
Final drive gear backlash difference between
measurements
Ring gear-to-stop pin clearance (A)
Stop pin shim
Ring gear spacer
Pinion spacer
Final drive gear assembly preload
Output gear backlash
Output gear 1.D,
Output gear bushing O.D.
LD.
Output drive shaft Q.D.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim
НИ |
НЕ PELO
1-10
=== тает
— Wheels/Tires
General information
Unit: mm (in)
ltem
Standard
Service Limit
|=
|
|
|
Minimum tire tread depth (FR)
(RR)
Cold the pressure Driver only (FR)
Driver only {RR)
Driver and passenger (FR)
Driver and passenger (RR)
Front and rear axie runout
Front and rear wheel rim runout {Radial)
(Axial)
Front wheel hub-to-rim distance
Front wheel hub standard surface
Rear wheel hub-to-rim distance
Rear wheel hub standard surface
Wheel balance weight (Front)
(Rear)
Drive chain slack
Drive chain size link (DID)
NI
225 kPa (2.25 kg/em?, 33 psi)
225 kPa (2.25 kg/cm”, 33 psi)
225 kPa (2.25 kg/em?, 33 psi)
250 kPa (2.50 kg/cm”, 36 psi)
15—25 (5/8—1)
1.5 (0.06)
2.0 (0.08)
Sl—
—Ñ Ea
0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
—
—
"N
60 g {2.1 oz} max.
60 g {2.1 oz) max.
(RK) RK GB525SM4/104 —
+
— Front Suspension
Fork spring free length 277.3 (10.92) 271.8 (10.70)
Fork spring free length A — —
B ———— _ — _ —
Fork spring direction Tightly wound coil end facing down —
Fork tube runout 0.20 (0.008)
Recommended fork oil Fork fluid —
Fork oil level 122 mm {4.8 in) —
Fork oil level (R) — —
(L) — —
Fork oil capacity 390 cc (13.2 US oz, 13.7 Imp oz) —
Fork oil capacity (M Model only) 404 cc (13.7 US az, 14.2 Imp oz) —
Fork oil capacity (R) — —_—
(L) — — —
Fork alr pressure — —
Steering bearing preload 1.0—1.5 Ка (2.2 — 3.3 6} —
— Rear Suspension *
Shock absorber spring free length 1 158.7 (6.2 in) 155.5 (6.12)
Shock absorber spring free length (R)
(L)
Damper gas pressure
Damper compressed gas
Damper rod compressed force at 10 mm compressed
Damper drilling point
Shock absorber spring installed length
(Standard)
{Adjustable range)
Shock absorber spring adjuster standard position
Shock absorber spring direction
Recommended shock absorber oil
Shock absorber oil capacity
air pressure
—’чмт
98 kPa (10 kg/cm?, 142 psi)
Nitrogen
15—20 ка (33—44 |b)
See page 13—13
147.7 (5.81)
—2Ñ
—
ИИ
ИИ
1-11
General information
Unit: mm {in}
— Brakes
item Standard | Service Limit
Front brake fluid DOT 4 —
Brake lever free play — _—
Brake pad wear indicator — To the groave 1
Da |
à Г
brake disc thickness 4 (0.16) 3.5 (0,14)
brake disc runout — 0.30 (0.012)
master cylinder !.D. 14.000— 14.043 (0.5512—0.5529) 14.06 (0.554) |
master piston O.D. 13.957— 13.984 (0.5495—0.5506) 13.95 (0.549) |
caliper cylinder 1.D. — — |
caliper cylinder 1.D. (Upper) 30.230—-30.280 (1.1902— 1.1921) 30.29 (1.193) |
{Lower) 25.400 — 25.450 {1.0000— 1.0020) 25.46 (1.0024)
caliper piston O.D. —_— - —
daliper piston O.D. {Upper} 30.148—30.198 (1.1869 — 1.1889) 30.14 (1.1866)
, (Lower) 25.318—25.368 (0.9968—0.9987) 25.31 (0.9965)
brake drum 1.D. — -—
brake lining thickness — —
Rear brake fluid DOT 4 —
brake pedal height — —
brake pedal free play — ——
brake pad wear indicator — To the groove 2
brake disc thickness 6.0 (0.24) 5.0 (0.20)
brake disc runout — 0.30 (0.012)
master cylinder LD. 14.000 — 14.043 (0.5512—0.5529) 14.06 (0.554)
master piston O.D. 13.957— 13.984 (0.5495—0.5506) 13.95 (0.549)
caliper cylinder 1.D, 25.400—25.450 (1.0000— 1.0020] 25.46 (1.0024)
caliper piston O.D. 25.318— 25.368 (0.9968—-0.9987) 25.31 (0.996)
brake drum 1.D. — —
brake lining thickness — —
— Battery/Charging System
Alternator charging coil resistance (At 20°C/68°F} | 01—1.0 © —
Reguiator/rectifier regulated voltage/amperage 13.5—15.5 VIO—6 A at 5,000 min” (rpm) —
Battery capacity 12V — бАН —
(Maintenance Free battery: YTX7A—BS) —
Specified current leakage — 1 MA max
Battery specific gravity (Fully charged) — —
(Needs charging) — —
Battery charging rate (Normal) 0,7 A/5—10 hr. —
(Quick) 3.0 AM hr. —
Battery voltage (Fully charged at 20°C/68°F) 13.0—13.2 V —
(Needs charging at 20% C/68*F) 12.3 V ——
Alternator lighting coil resistance (At 20°C/68°F) — ——
AC regulator regulated voltage (With anatogue type)| —— —
(With digital type) — _ —
— ignition System
General information
Unit: mm {in}
Item
Standard
Service limit !
Spark plug (Standard NGK)
"(Standard ND)
(For cold climate/below 5°C/41°F NGK)
(For cold climate/below 5°C/41°F ND)
{For extended high speed riding NGK)
(For extended high speed riding ND)
Spark plug gap
ignition timing “F”” mark
Advance starts
stops —
Fully advance
Alternator exciter coil resistance {At 20°C/68°F)
ERSEH.
Y27FER
ERSEH
Y24FER
ER10EH
Y 31FER
0.6—0.7 (0.024-—0.028)
18° BTDC at 1,200 min”! (rom)
1,800 + 200 min** (rpm)
12,000 + 200 min”! trpm)
37+ 2° BTDC at 12,000 min! (rpm)
ИНО
ignition coil resistance (Primary: at 20°C/68°F) 2.5—3.5 9.
{Secondary with plug cap} 14—25 kQ
(Secondary without plug cap) | 11—14 kf
Pulse generator resistance (At 20°C/68°F) | 450— 5500
— Lights/Méters/Switches
Main fuse 30 A
Fuse 20A x 1, 10A x 3
— —— — —— "=" — --— ———
Headlight {high/low beam}
Tail/brake light
License light
Position light
Front turn signal/running light
Front turn signal light
Rear turn signal light
Instrument light
Oil pressure warning indicator
— Tail/brake light warning indicator
— Side stand warning indicator
— Starting System
Low fuel indicator
Coolant temperature indicator
Oil temperature indicator
High beam indicator
Turn signal indicator
Neutral indicator
Reverse indicator
Overdrive indicator
Oil temperature sensor resistance
Fuel unit resistance (At full level)
(At empty)
Fuel pump fiow capacity (min./minute)
Thermo sensor resistance (50°C/122°F)
(B0°C/176°F)
(120°C/248°F)
Fan motor switch Starts to close (ON)
Stops to open (OFF)
12 V 60/50 W x 2 (Há)
12 V 5/21 Wx 2
12V5W
12 V 5 W (E, AR), 12 V 4 W{F, G)
12 V 21 W
12 V 21 W
12 V1.7 Wxb
12 V 1.7 W
130—180 ©
45—60 9
10—20 @
98— 102°C (208—-216°F)
33—97°C (199— 207°)
UE
| Starter driven gear Q.D.
Starter reduction gear shaft O.D.
Starter reduction gear |.D.
Starter motor brush length
1
|
41.975—42.000 (1.6526— 1.6535)
9.994— 10.000 (0.3935— 0.3937)
10.070— 10.1170 (0.3965 — 0.3980)
12—13 {0.47 —051)
41.96 (1.652)
9.90 (0.390)
10.16 (0.400)
6.5 (0.26)
1-13
General information
Torque Values
—— Standard
Torque
Fasteners Type
N-m (kg-m, ft-1b)
Torque
—
Fasteners Type
N-m (kg-m, ft-lb) |
5 mm hex bolt and nut 5 (0.5, 3.5) 5 mm screw 4 (0.4, 3}
6 mm hex bolt and nut | 10 (1.0, 7.2) 6 mm screw 9 (0.9, 7)
8 mm hex bolt and nut | 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9, 7)
10 mm hex bolt and nut | 35 (3.5, 25) 6mm flange bolt {10 mm head) and nut 12 (1.2, 9)
12 mm hex bolt and nut 55 (5.5, 40) 8 mm flange bolt and nut 27 (2.7, 20)
| 10 mm flange boit and nut 40 (4.0, 29)
* Torque specifications listed below are for important fasteners.
* Others shouid be tightened to standard torqué values listed above.
Notes: 1. Apply looking agent to the threads.
2. Apply oil to the threads and flange surface.
3. Apply molybdenum disulfide oil to the threads and flange surface.
4. Apply sealant to the threads.
5. Stake.
6. Apply clean engine oil to the O-ring.
7. UBS bolt.
8. Self-locking nut.
5. Never apply molybdenum disulfide oil.
Engine Thread x
, rea orque
Item Q'ty dia. (mm) Nm (kg-m, ft-Ib) Remarks
Lubrication:
Qil pump driven sprocket bolt — 1 6 15 (1.5, 11) Note 1
Oil pump mounting bolt 3 6 12 (1.2, 9)
Oil pump cover bolt 3 6 12 (1.2, 9)
Oil filter 1 20 10 (1.0 ,7) Note 6
Oil drain bolt 1 12 38 {3.8, 27)
Oil pressure switch — 1 PT1/8 12 (1.2, 9} Note 4
Fuel system:
Carburetor insulator band screw . 8 4 1 (0.1, 0.7)
Cooling system:
Water pump mounting bolt 2 6 10 (1.0, 7)
Water pump cover bolt - 2 6 10 (1.0, 7) Note 4
Thermo sensor 1 PT1/8 10 (1.0, 7) Note 4
Cylinder head/cylinder/piston: a
Cam gear case mounting bolt 8 8 36 (3.6, 26) Note 2
Cam gear case set bolt 2 6 12 {1.2, 9) Note 2
Cylinder head cover bolt 8 6 10 {1.0, 7)
Camshaft holder bolt 32 6 12 (1.2, 9)
Rocker arm shaft plug 8 PT1/8 8 (0.8, 6) Note 4
Cylinder head special bolt, 8 mm 16 8 36 (3.6, 26) Note 2
Cylinder head boit, 6 mm 6 6 12 (1.2, 9)
Spark plug 4 8 9 (0.9, 7)
Clutch/gearshift linkage:
Right crankcase cover 12 6 10 (1.0, 7)
Ciutch lock nut — 1 20 85 (8.5, 61) Note 5
Gearshift return spring stud pin 1 8 23 (2.3, 17) Note 1
Shift drum center bolt 1 6 23 (2.3, 17) Note 1
Shift drum set plate bolt 2 6 12 (1.2, 9} Note 1
Shift fork shaft set bolt 1 6 12 (1.2, 9) Note 1
Timing hole cap 1 45 18 (1.8, 13) Note 3
1-14
L
General Information
— Engine (Cont'd)
Thread
Torque
item QY | día. (mm) N-m (kg-m, ft-1b) Remarks
e ——
Crankcase/crankshaft/transmission: _
Drive sprocket bolt 1 10 55 (5.5, 40)
Neutral switch 1 10 12 11.2, 9)
Connecting rod bearing cap nut 8 7 24 (2.4, 17) Note 2, 9
Crankcase bolt 6 mm 12 6 12 (1.2, 9)
8 mm 11 8 23 (2.3, 17)
10 mm 1 10 40 (4.0, 29)
Lower case oil bolt 1 10 23 (2.3, 17)
Alternator:
Fiywheel bolt 1 10 85 (8.5, 61) Note 7
Starter clutch:
Primary drive gear bolt (starter clutch bolt) 1 10 85 (8.5, 61) Note 7
Starter clutch cover bolt 3 8 28 (2.8, 20) Note 1 Ш
— Frame = =
Frame/body panels:
Main step holder bolt 4 8 27 (2.7, 20) Note 1
Main step bolt 2 10 45 (4.5, 33)
Pillion step bracket bolt 4 8 27 (2.7, 20)
Sub-frame mounting bolt 4 10 27 (2.7, 20)
Side stand pivot bolt 1 10 38 (3.8, 27)
Side stand bracket bolt 2 8 35 (3.5, 25) Note 1
Exhaust system:
Exhaust pipe joint nut 8 6 8 (0.6, 6)
Cooling system:
Fan motor switch 1 16 23 (2.3, 17) Note 4
Fuel system:
Fuel tank breather check valve 1 18 11 (1.1, 1.8)
Fuel valve 1 18 23 (2.3, 17)
Engine mount:
Engine mounting bolt 7 10 40 (4.0, 29)
Engine mounting adjust bolt 2 22 11 (1.1, 8)
Engine mounting lock nut 2 22 55 (5.5, 40)
Engine mounting nut 1 10 40 (4.0, 29)
Gearshift pedal bolt 1 6 12 (1.2, 9)
Front suspension:
Handlebar holder pinch bolt. 4 6 12 (1.2, 9)
Ignition switch mounting bolt 2 8 25 (2.5, 18) Note 1
Fork socket bolt 2 8 20 (2.0, 14) Note 1
Fork bolt 2 37 23 (2.3, 17)
Upper fork pinch bolt 2 7 11 (1.1, 8)
Lower fork pinch bolt 2 10 40 (4.0, 29)
Steering bearing adjustment nut 1 35 50 (5.0, 36) Note 2
Steering stem nut 1 33 140 (14.0, 101)
Front axle pinch bolt 4 8 22 (2.2, 16)
| Front axle bolt 1 14 60 (6.0, 43)
1-15
General Information
Г Frame (Cont'd)
Thread Torque
| item dia. (mm) N'm (kg-m, ft-Ib) Remarks
Rear suspension:
Rear wheel nut 1 18 120 (12.0, 87)
Rear axle holder lock nut 1 38 165 (16.5, 119) Note 5
Swingarm pivot nut 1 18 95 (9.5, 69)
Swingarm pivot adjust bolt 1 30 15 (1.5, 11)
Swingarm pivot lock nut 1 30 80 (8.0, 58)
Drive chain slider screw - 4 5 4 (0.4, 2.9)
Driven sprocket nut 6 8 35 (3.5, 25)
Torque link bolt/nut 2 10 35 (3.5, 25)
Rear shock absorber mounting bolt 2 10 45 (4.5, 33) Note 8
Rear shock absorber spring adjuster lock nut —1 — 90 (9.0, 65)
Rear shock absorber reservoir holder band 2 — 4 (0.4, 2.9)
Shock linkage bolt/nut 3 | 10 45 (4.5, 33) Note 8
Rear bearing holder pinch bolt 1 14 55 (5.5, 40)
| Drive pin bolt 4 12 15 (1.5, 11} Note 1
| Brake/clutch system:
Master cylinder mounting bolt 4 6 12 {1.2, 9)
Master cylinder oil bolt 2 10 35 (3.5, 25)
Front caliper bolt 8 8 33 {3.3, 24) Note 1
Front caliper oil boit 2 10 35 (3.5, 25)
Front brake disc bolt 12 6 20 (2.0, 14)
Caliper mounting bolt 6 8 27 (2.7, 20)
Caliper pad pin 3 10 17 (1.7, 12)
Caliper pad pin plug 3 10 2.5 (0.25, 1.8)
Caliper bieed valve 3 8 6 (0.6, 4.3)
Rear brake reservoir mounting bolt _ 1 6 3 (0.9, 7)
Rear brake reservoir hose joint screw 1 5 1.5 (0.15, 1.1) Note 1
Rear caliper pivot pin bolt (5 mm HEX side) 1 8 13 (1.3, 9) Note 1
Rear caliper pivot pin bolt 1 E 23 12.3, 17) Note 1
Rear brake hose joint nut {hose side) 1 10 14 (1.4, 10)
Rear brake hose joint (caliper side) 1 10 35 (3.5, 25)
Rear brake disc nut _4 8 Note 8
3% (3.5, 2b)
1-16
TE Mr
General Information
Attachment, 42 x 47 mm
Attachment, 62 x 68 mm
Pilot, 40 mm
Shock absorber compressor attachment
Shock absorber compressor
Bushing driver B
Pivot adjust wrench
Driver shaft
Attachment, 37 x 40 mm
Pilot, 20 mm
Bearing remover set
— Remover handle
— Bearing remover
— Sliding weight
Needle bearing remover
Driver shaft
Pilot, 28 mm
07746— 0010300 —
07746- 0010500 —
07746 — 0040900 —
07959 — MB 10000
replacement
07GME - 0010000 —
07HMEF — MM90200
07908 — 4690001
07946 —MJ00100
Shock absorber disassembly/assembly
т Bearing holder needle bearing
I
Shock absorber upper mounting
bushing replacement
Swingarm pivot bolt removal/installation
07746 — 0010200 —
07746 — 0040500 —
07936 — 3710001
Right swingarm pivot bearing
installation
07936- 3710100 —
07336 — 3710600 —
07741 —- 0010201 —
07HMC—MR70100
Right swingarm pivot bearing removal
07946 — MJOO 100 —
07746 — 0041100 —
Left swingarm pivot bearing
replacement
Tools
. The newly designed tools are indicated with * mark in the list.
=
Description Tool Number Application Section
но —
Compression gauge attachment, 8 mm *Q7KME - MR80100 Cylinder compression measurement 3
Oi! pressure gauge attachment 07510— 4220 TOO Engine oil pressure measurement
Oil filter wrench O7HAA — PJ70100 Oil filter replacement
Spark plug wrench, 8 mm *O7KMA—MRS80200 Spark plug removal/installation
Lock nut wrench 07HMA — MR70200 Engine removal/installation 7
Valve spring compressor attachment 07959 — KM30TO1 Cylinder head disassembly/assembly 8
Valve guide driver 07HMD — MLOO100 Valve guide replacement
Valve guide reamer, 4.5 mm 07HMH- MLOO101 Valve guide reaming
Valve seat cutter, 24 mm {45° IN) 07780- 0010600 —-- Valve seat refacing
Valve seat cutter, 22 mm (45° EX) 07780- 0010701 —
Valve flat cutter, 24 mm (329 IN) 07780 - 0012500 —
Valve flat cutter,21.5 mm (329 EX) 07780 - 0012800 —
Valve interior cutter, 22 mm (60% IN/EX) | 07780-0014202 —
Cutter holder, 4.5 mm 07781 - 0010600 —
Lock nut wrench, 26 x 30 mm 07716 — 0020203 TT Clutch disassembly/assembly 9
Extension bar 07716-— 0020500 —
Gear holder 07724- 0010100 Primary drive gear removal/installation
Fork seal driver 07947 - KA50100 TT Fork oil seal installation 12
Fork seal driver attachment 07947 — KFO0100 —
Lock nut wrench, 38x41 mm 07GMA — KS40100 Steering stem nut removal/installation
Steering stem socket 07HMA —MR70100 Steering bearing adjustment nut
tightening
Steering stem driver attachment 07HMD —MR70100 Steering bearing lower inner race
inner driver C 07746 — 0030700 + instaliation
Driver attachment B (2 pcs. required) 07946 - KM90200 —— Steering bearing outer race removal/
Driver assembly shaft 07946 - KM90300 —— installation
Bearing remover B 07946 — KM90500 —
Assembly base 07946 — KM30600 —
Driver 07749— 001 0000 Bearing installation 13
1-17
General Information
ee
Rotor puller
Description Tool Number Application Section
Pin driver assembly 07GMD -KT80100 Shock arm needle bearing removal 13
Bearing remover 07936 — 3710300 —— Shock link needie bearing removal
Remover handle 079236 - 0710100 |
Sliding weight 07741-0010201 —
Driver 07749 - 0010000 — Shock arm and link needle bearing
Attachment, 24 x 26 mm 07746 -0010700 + installation
Pilot, 17 mm 07746 —- 0040400 —
Snap ring pliers 07914-3230001 Brake master cylinder disassembiy/ 14
assembiy
Peak voltage adaptor 07HGJ- 0020100 IT Peak voltage measurement 16
Digital multitester 07411-0020000 —
Universal holder 07725 -— 0030000 TT Flywheel removal/instaliation 17
07733-— 0020001 —
|
Lubrication & Seal Points
General Information
— Engine
Location
Material
Remarks
Valve stem {valve guide sliding surface)
Connecting rod small end baring
Transmission gearshift fork groove
Timing hole cap threads
Connecting rod bearing
Crankshaft main bearing
Molybdenum disulfide oil
Crankcase mating surface
Liquid sealant
Do not apply sealant near the |
main bearings.
Sealant
Cylinder head bolt threads
Connecting rod bearing cap nut
Rocker arm sliding surface _
Camshaft journal, cam lobe
Other sliding surface
Rocker arm shaft plug |
Qil pressure switch threads Do not apply sealant to the
- switch thread head as shown.
|
| 3-4 mm
Thermo sensor threads (0.12-0.16 in)
Qil filter O-ring Engine oil
Piston |
CAUTION
Never apply molybdenum
disulfide oil.
Clutch lifter rod {lifter cam contacting area)
Multipurpose grease
— —_— ml
Cylinder head sealing bolt threads
Shift drum center bolt threads
Gearshift return spring stud pin
Shift drum set plate bolt threads
Shift fork shaft set bolt threads
Oil pump driven sprocket bolt threads
JE
5.5-7.5 mm
(0.22-0.30 in)
Locking agent
1-19
General Information
— Frame
Location
Material
Remarks
Drive chain
Gear oil # 80-90
Axle holder bearing
Side stand pivot
Shock linkage bearing collar
| Shock linkage bearing
Seat lock hook
Gearshift pedal pivot
Shock absorber upper mounting collar
Swingarm pivot bearing
Steering head bearing
Step pivot
Speedometer gearbox
Throttle pipe flange
Rear brake pedal pivot
Dust seal lip
Pad pin threads
Pad pin plug threads
Multipurpose grease
Caliper piston
Caliper piston seal
Caliper dust seal
Master cylinder piston
Master cylinder piston cup
DOT 4 brake fluid
Steering bearing adjustment nut threads
Engine oil
Fan motor switch threads
Sealant
Handlebar grip rubber
Honda Bond A or equivalent
Caliper pivot pin
Caliper pivot pin boot
Silicone grease
Side stand bracket bolt threads
Drive chain slider screw threads
Drive pin bolt threads
Fork socket bolt threads
Ignition switch mounting bolt threads
Main step holder bolt threads
Rear caliper pivot bolt threads
Hear brake reservoir hose screw threads
Locking agent
Genera! Information
Cable & Harness Routing
(2) CLUTCH CABLE
>
A
=
(1) THROTTLE CABLES
(3) OIL PIPE
\ NaN
Ne в < ча (4) SPEEDOMETER CABLE
TAS
| x I ; pr =
WD NI=
N CAR <<<
q
ZN
A >
E URETA
Te
(5) CLUTCH CABLE
(7) LEFT FRONT TURN SIGNAL
WIRE CONNECTORS
(9) RIGHT FRONT
TURN SIGNAL
WIRE CONNECTORS
(11) OIL PIPE
(10) RIGHT FRONT BRAKE HOSE
1-21
General Information
(1} HEADLIGHT RELAY
(5) RIGHT FRONT TURN SIGNAL
WIRE CONNECTORS
{6} FUSE BOX
(13) TURN SIGNAL RELAY
Le
(2) HEADLIGHTS
(3) LEFT FRONT TURN
SIGNAL WIRE CONNECTORS
{4) POSITION LIGHTS
(7) SEAT LOCK CABLE (8) SPARK UNIT
VS
(9) REAR TURN SIGNAL WIRE
(10) BRAKE/TAILLIGHT
WIRE CONNECTOR
(12) REGULATOR/RECTIFIER
- - - - ——— ZT el de — —
General Information
{3} SUB AIR
CLEANER TUBES
(1) THROTTLE CABLES
{4} CRANKCASE
BREATHER HOSE
(2) FUEL LINES
=”
(5) REAR IGNITION
{8} REAR SHOCK ABSORBER
(9) AUTO FUEL VALVE
VACUUM TUBE
(10) THROTTLE STOP
CONTROL CABLE
DRAIN TUBE
(12) CLUTCH CABLE
(11) SPEEDOMETER CABLE
{13) FRONT IGNITION COIL
(14} CHOKE CABLE
N
(15) THROTTLE STOP
CONTROL KNOB
(16) FUEL TANK DRAIN TUBE
(17) FAN MOTOR SWITCH
1-23
General Information
{2) STARTER RELAY SWITCH (5) FUEL TANK
(MAIN FUSE) (4) AUTO FUEL VALVE BREATHER TUBE
(1) RESERVE TANK VACUUM TUBE
OVERFLOW TUBE
(3) FUEL LINE
(6) RADIATOR
OVERFLOW TUBE
(9) NEUTRAL SWITCH
(8) HI BEAM RELAY (7) STARTER MOTOR
CABLE
oo = (13)
(10) RIGHT CONNECTOR BRACKET
A: IGNITION SWITCH WIRE CONNECTOR
(3P-BLACK)
B: PULSE GENERATOR WIRE CONNECTOR
{4P-BLACK)
OIL PRESSURE SWITCH/NEUTRAL SWITCH
WIRE CONNECTOR (2P-BLACK)
RIGHT HANDLEBAR SWITCH WIRE
CONNECTOR (6P-RED)
ALTERNATOR WIRE CONNECTOR
(3P-WHITE)
9 о
m
Ce]
Chr
a
(14) VIEW
2. Frame/Body Panels/Exhaust System
—
| Service Information 2-1 Fuel Tank Removal/Installation 2-5
Seat Cowling Removal/Installation 2-2 Windshield Removal/Installation 2-6
Upper Fairing Removal/installation 2-2 Muffler Removal/Installation 2-8
Side Fairing Removal/instaliation . 2-3 Exhaust Pipe Removal/lnstallation 2-10
Lower Fairing Removal/Installation 2-4 _ Sub-Frame Removal/Installation 2-12
Service Information
A WARNING
LX т В - = +
* Gasoline is extremely flammable and explosive under certain conditions.
* Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
« Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can
cause a fire or explosion.
* This section cover removal and installation of the frame_body panels, fuel tank and exhaust system.
+ Frame body panel installation is in the reverse order of removal, unless noted otherwise.
* When removing the cover, be careful not to damage any tab or groove of the cover.
* Be careful not to bind the wire harnesses when installing the sub-frame.
Frame/Body panels/Exhaust System
Seat Cowling Removal/Installation
Unlock the rear seat by turning the ignition key clockwise.
Remove the rear seat.
Remove the six attaching screws,
Raise the rear of the seat cowling and release the two boss-
es from the grommets.
Disconnect the brake/taillight wire connector and remove the
seat cowling rearward. -
NOTE
* Be careful not to damage the front of the cowling.
Install the seat cowiing, while inserting the hook of the
cowling under the frame.
Insert the bosses into the grommet by pushing the rear of
the cowling.
Install the rear seat, aligning the hook with the cowling, and
push the seat down to lock the seat.
NOTE — - a
* Grease the seat striker and latch,
+ The rear seat is not installed securely if any obstruc-
tions are under the seat.
* Be careful not to bind the wire harness etc.
Upper Fairing Removal/Installation
Disconnect the left and right turn signal wire connectors.
Remove the following:
— both side fairings (page 2-3).
— front panel {page 2-4).
— both rearview mirror mounting nuts. TC
— both rearview mirror. -
— both rearview mirror mounting rubbers.
— both turn signal lights.
— screw.
— upper fairing.
Install the upper fairing in the reverse order of removal. 7
CAUTION
* Be careful not to bind the mounting rubber.
(3) REAR SEAT
(2) SEAT COWLING
° (6)
{4) BOSSES
GROMMETS
{1) REARVIEW MIRROR
(2) MOUNTING RUBBER
(3) MOUNTING NUT
(6) SCREW
(5) UPPER FAIRING
(4) TURN SIGNAL LIGHT
2-2
Side Fairing Removal/Installation
(5)
(2)
Frame/Body panels/Exhaust System
(3)
(2)
(4)
CAUTION
Be careful not to damage the tabs.
+ Make sure that the clip nut for the tapping screw is installed properly. If it is missing, install it securely with the threaded side
facing down.
Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Quick screw 4
(2} | Screw 2
(3) | Tapping screw 2
(4) | Left side fairing 1
(5) | Right side fairing 1
2-3
Hr
a
Frame/Body panels/Exhaust System
Lower Fairing Removal/Installation
===_— — - — —— —
{7)
(5)
(3)
| (4)
CAUTION ] o o o
+ Make sure that the clip nut for the tapping screw is installed properly. If it is missing, install jt securely with the threaded side
facing down. ] So a | В _
Procedure a Q'ty Remarks
Removal Order - a. Installation is in the reverse order of removal.
{1} | Trim clip screw/nut 4
(2} | Front panel screw 3
(3} | Front panel 1 NOTE
At installation, insert the top ends under the tab of the
upper fairing properly as shown.
(4) { Mounting screw 2
(5) | Mounting boit/washer 2
(6) | Mounting collar 2
(7} | Lower fairing assembly 1
2-4
Frame/Body panels/Exhaust System
— че Tank Removal/Installation
Gasoline is extremely flammable and is explosive under cer-
tain conditions. Work in a well ventilated area. Smoking or al-
towing flames or sparks in the work area or where gasoline
is storad can cause a fire or explosion.
— — — — ——
(1) BREATHER TUBE (2) MOUNTING BOLT
Remove the seat cowling (page 2-2).
Turn the fuel valve OFF.
Disconnect the fuel tank breather tube from the tank.
Remove the fuel tank mounting bolt,
Raise the rear of the tank and disconnect the fuel line and vacuum
tube from the fuel valve.
Install the fuel tank in the reverse order of removal
NOTE
+ Make sure that the fuel tank mounting rubber is installed.
onto the frame properly before installing the tank.
(3) FUEL TANK
=
Y
After connecting the fuel line, connect a vacuum pump to the auto
fuel valve vacuum joint and apply vacuum,
Turn the fuel valve ON and check the fuel line for leakage.
2-5
Frame/Body panels/Exhaust System
Windshield Removal/lnstallation
(3)
Ве
|
i
®
(2) | PA
a
nt em
X AN
1. Put the kerf around the circumfer-
ence of the pin.
2. Cut the pin at the kerf, being care-
ful not to deform the pin. Pull out
the remaining pin.
3. Install with using new pins.
“трон
pn
___ NOTE
т —
| + Be careful not to damage the windshield.
М
Frame/Body panels/Exhaust System
Q'ty
Procedure ‘Remarks
Removal Order
(1) | Rearview mirror mounting nut 4 NOTE
Loosen until the clearance is made.
(2) | Set pin/ring 6 NOTE
Cut the pin to remove.
(3) | Windshield 1
Installation Order о )
(3) | Windshield 1
(2) | Set pin/ring 6 NOTE
Temporarily install the set rings, position the windshield
properly and fit the pins.
(1) | Rearview mirror mounting nut 4
2-7
Frame/Body panels/Exhaust System
Muffler Removal/Installation
(8)
(4)
2-8
Frame/Body paneis/Exhaust System
na
+ Do not service the exhaust system while it is hot. о |
CAUTION
| « Do not bend or twist the brake hose. Support the removed right step assembly so that it does not hang from the brake hose. |
ijt
Requisite Service
« Seat cowling removal/installation (page 2-2}
« Lower fairing removal/instaliation (page 2-4)
gr
Procedure ] — | Qt Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Heat guard mounting bold 1
(2) | Right step bolt 2
(3) | Right step 1 NOTE
Remove together with the heat guard. Never hang it from
the brake hose.
(4) | Exhaust pipe band bolt 2 NOTE
Loosen the bolts.
(5) | Exhaust pipe nut 3
(6) | Muffler, mounting bolt/nut 1/2 МОТЕ На
At installation, loosely install the bolt and nuts, tighten the
exhaust pipe nuts and band boits first, then tighten them.
(7) | Left pillion step 1
(8) | Muffler assembly 1
(9) | Gasket 2
2-9
Frame/Body panels/Exhaust System
Exhaust Pipe Removal/Instaliation
(5)
+
a
CAUTION
„ Cover the radiator fins to prevent them from damaging when servici
Requisite Service
Muffler removal/installation (page 2-8)
Frame/Body panels/Exhaust System
ng the front exhaust pipe.
== — = о -
|
|
Ч
Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Rear exhaust pipe joint nut 4
(2) | Rear exhaust pipe 1
(3) | Lower radiator mounting bolt 2 NOTE
Remove the bolts, move the radiator forward and hold it
with a string.
(4) | Front exhaust pipe joint nut 4
(5) | Front exhaust pipe 1
(6) | Gasket 4
+
2-11
Frame/Body panels/Exhaust System
Sub-Frame Removal/installation
e
9 (0.9, 7)
(8)
(10)
to
y
E
y
(tua =
(3)
(6)
(4)
Frame/Body panels/Exhaust System
¡ui
CAUTION
» Turn the ignition switch OFF and disconnect the battery negative cable from the battery terminal.
. Be careful not to bind the wire harness when installing the sub-frame.
« Route the wire harness, cable, etc. {page 1-21).
|
Requisite Service
« Seat cowling removal/installation (page 2-2)
. Fuel tank removalfinstaliation (page 2-5)
. Battery removalfinstaliation {page 15-4}
Procedure Q'ty Remarks
Removal Order Installation is in the reverse order of removal.
(1) | Spark plug cap/primary wire connector 2/2
(2) | Regulator/rectifier connector 1
(3) | Tum signal relay connector 1
(4) | Spark unit wire connector 2
(5) | Rear turn signal wire connector 4
(6! | License light wire connector 2
(7) | Fuse box 1
(8) | Right grab rail 1
(9) | Shack absorber reservoir/bracket 1
(10) | Rear brake reservoir 1 CAUTION
- Keep the reservoir level to prevent air from entering the
system.
(11) | Radiator reserve tank 1
{12} | Muffler mounting bolt/nut 1/2
(13) | Sub-frame mounting bolt 4 NOTE
Remove the main wire harness from the clamp.
(14) | Rear fender boit 1
==] EEE Es UN EE ==
2-13
A