Honda XR50R Service Manual 2000 2003

•
•
HOW TO USE THIS MANUAL CONTENTS
This service manual describes the service procedures
for the XR50R. GENERAL INFORMATION
Follow the Maintenance Schedule (Section 3) recom-

mendations to ensure that the vehicle is in peak
operating condition and the emission levels arB MAINTENANCE
within the standards set by the California Air
Resources Board.
LUBRICATION SYSTEM
Performing the first scheduled maintenance is very
important. It compensates for the initial wear that z FUEL SYSTEM
~
occurs during the break-in period.
ENGINE REMOVAL/INSTALLATION
Sections 1 and 3 apply to the whole motorcycle. W
Section 2 illustrates procedures fo r removall
installation of components that may be required to a:Q> CYLINOER HEAO/VALVES
perform service described in the following sections.
Q
Section 4 through 14 describe parts ofthe motorcycle, Z CYLINOER/PISTON
grouped according to location. ..:
w
~ CLUTCH/GEARSHIFT LINKAGE
Find the section you want on this page, then turn to
the table of contents on the first page of the section. C>
Z
w ALTERNATOR/CAM CHAIN TENSIONER
Most sections have an assembly or system
illustration, service information and troubleshooting
for the section.
The subsequent pages give detailed procedures.
If you do not know the source of the trouble, go to

section 16, Troubleshooting.
IGNITION SYSTEM
WIRING OIAGRAM
TROUBLESHOOTING
INOEX
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. •
-!1lI!"
Replace the part/5) w ith new one(s) before assembly.
,
~ Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
-~
Use multi-purpose grease (lithium based multi-purpose grease NLG I # 2 or equivalent).
Use molybdenum disulfide grease (containing more than 3 % molybdenum disulfide, Nl GI # 2 or

~ equivalent).
Example: Molykotetl BR-2 plus manufactured by Dow Corning, U. S. A.
Multi-purpose M-2 manufactured by Mitsubishi Oi l, Japan
Usa molybdenum disulfide paste (containing more than 40 % molybdenum disulfide, NLGI # 2 or
equivalent).
Example: Molykotee G-n paste, manufactured by Dow Corning, V. S. A.
~ Honda Moly 60 (V. S. A. only)
Rocol ASP manufactured by Roeol Limited, V. K.
Rocol Paste manufactured by Sumico Lubricant, Japan
•
...- Use silicol)e grease.
L1a Apply a locking agent. Vse a medium strength locking agent unless otherwise specified .
.lGl! Apply sealant.
..• Use DOT 4 brake fluid. Vse the recommended brake fluid unless otherwise specified .
Use fork or suspension fluid.

1. GENERAL INFORMATION
GENERAL SAFETY 1-1 TOOLS 1-12
SERVICE RULES 1-2 LUBRICATION & SEAL POINTS 1-13
MODEL IDENTIFICATION 1-3 CABLE & HARNESS ROUTING 1-14
SPECIFICATIONS 1-4 EMISSION CONTROL SYSTEMS 1-17
TORQUE VALUES 1-10 EMISSION CONTROL INFORMATION
LABEL IExcopt Canada typo) 1-18
GENERAL SAFETY
CARBON MONOXIDE HOT COMPONENTS
If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine in an
enclosed area.
Engine and Bxhaust systBm parts become very hot lind
uw;nn", remain hot for some timtt aftttr the engine is run. Wttar
insulated glo"8s or waft until the engine and exhaust
The exhaust contains poisonous carbon monoxide gas system have cooled before handling these parts.
that clln cause loss of consciousness lind may lead to
dtlath.
USED ENGINE OIL
Run the engine in an open area or with an exhaust evacua-

tion system in an enclosed area.
• .,.,,1,,,'"
Used engine oil may cause skin cancer if repeatedly left in
GASOLINE contact with the skin for prolonged periods. Although this
Work in a well ventilated area. Keep cigarettes, flames or is unlikely unless you handle used oil on a daily basis, It is
sparks away from the work area or where gasoline is still advisable to thoroughly wash your hands with soap
stored. and water 85 soon as possible after handling used oil. KEEP
OUT OF REACH OF CHILDREN.
"""d''''lI
Gasoline is extremftJy flammable and is explosive under
certain conditions. KEEP OUT OF REACH OF CHILDREN.
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's
design specifications may causa damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
•
fasteners.
4. Install new gaskets, D-rings, cotter pins. and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a parti cular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sl iding surfaces before reassembly.
7. After reassembly, check aU parts for proper installation and operation.
8. Aoute all electrical wires as shown on pages 1-14 through '·16, Cable and Harness Routing.
1-2
GENERAL INFORMATION
MODEL IDENTIFICATION
FRAME SERIAL NUMBER
111 The frame serial number is stamped on the left side

of the steering head.
ENGINE SERIAL NUMBER

(2) The engine serial number is stamped on the lower (3) The Vehicle Identification Number (VIN) is located
left of the crankcase. on right side of the steering head on the Safety Cer-
tification Label.
(4) The carburetor identification number is stamped on (5) The color label is attached on the left side of the
the left side althe carburetor body as shown. main frame. When ordering color-coded parts,
always specify the designated color code.
1-3
GENERAL INFORMATION
•
SPECIFICATIONS
,- GENERAL
DIMENSIONS
ITEM
Overall length 1,305 mm (5 1,4 in)
SPECIFICATIONS •
Overall w idth 583 mm (23.0 in)
Overall height 780 mm (30.7 in)
Wheelbase 915 mm (36.0 in)
Seat height
Footpeg height
Ground clearance
550 mm (21.7 in )
215 mm (S.5 in )
1S0 mm (5.9 in)
•
Dry weight 47 kg (104Ibs)
Curb weight 50kg( 110Ibs)
Maximum weiaht capacity 40 ka (88 Ibs)
FRAME Frame type Back bone
Front suspension Telescopic f ork
Front wheel travel 87 mm (3.4 in)
Rea r suspension Swingarm
Rear wheel travel 70 mm (2.8 in)
Rear damper Conventional type oil damper
Front tire size 2.50-10 33J
Rear tire size 2.50-10 33J
Tire brand CHENG SHIN Front/Rear: C- 183A
Front brake Internal expanding shoe
Rear brake Internal expanding shoe
Caster angle 25°30'
Trail length 35 mm (1.4 in)
Fuel tank capacity 3.0 II (0.79 US gal, 0.66 Imp gal)
Fuel tank reserve caoacit\l 0.9 11 (0.24 US oal , 0.20 Ime oal)
ENGINE Bore and stroke 39.0 x 41.4 mm (1.54 x 1.63 in)
Displacement 49 cm 3 (3.0 cu-in)
Compression ratio 10.0: 1
Valve train Chain driven OHC with rocker arm
Intake valve OP.nsf "1mm
closes (0.04 in)
7 SBTDC
12SABDC
Exhaust valve opens
closes
Lubrication system
lift
.
22.5°BBDC
2SBTDC
Forced pressure and wet sump
•
Oil pump type Trochoid
Cooling system Aircooled
Air fi ltration Oiled polyurethane foam
Crankshaft type
Engine dry weight
Cylinder arrangement
Assembled type
17.2 kg 137.9 Ibs)
Single cylinder inclined 80° from vertical
•
1-4
GENERAL INFORMATION
- GENERAL (Cont'd)
ITEM SPECIRCATIONS
CARBURETOR Carburetor type Piston valve
Throttle bore 13 mm (0.5 in)
DRIVETRAIN Clutch system Multi-plate, wet
Clutch operation system Automatic centrifugal
Transmission 3·speed
Primary reduction 4.058 (69/ 17)
Final reduction
Gear ratio ,,, 2.642
3.272
(37{14)
(36/")
2nd 1.667 (25/15)
3,d 1.190 (25/21)
Gearshift oattern l eft foot oarated return system N- 1-2-3
ELECTRICAL Ignition system COl (Capacitive Discharge Ignition)
Starting system Kickstarter
1-5
GENERAL INFORMATION
•
LUBRICATION SYSTEM
ITEM STANDARD SERVICE LIMIT
oil
mater oil
API service classification SF or SG
il pump rotor
•
FUEL SYSTEM - - - - - - - - - - - - - - - , - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
ITEM SPECIFICATIONS
Carburetor identification number
Main 'et
Slow 'at
PA42A
# 58
#35x#35
•
Jet needle eli osition 2nd rcove from to
Air screw initial 0 enin '-1/2 turns out
Float level 12.7 mm (O.50 in)
Idle seed 1700 ± 100r m
Throttle ri free la 2.0 - 4.0 mm (1/16 - 3/16 in)
CYLINDER HEAD/VALVES ---------,--------------------------;,---='-""''-''''1

valve guide
I .
1-6 •
GENERAL INFORMATION
CYLINDER/PISTON
piston rings
Piston end gap
Unit: mm lin)
- CLUTCH/GEARSHIFT LINKAGE
ITEM STANDARD SERVICE UMIT
Clutch disc thickness A 2.52 2.68 {O.a9S 0.106 2.3 (0.09)
8 3.32 - 3.48 (0.13 1 0.137) 3.0 (0.12)
Clutch late war a e 0.20 O.OOB)
Centrifugal clutch sprin free len th 22.4 0.88 19.4 (0.76)
Prima drive ,gear 1.0. 21.000 21.021 (0.8268 0.8276 21.05 (0.829)
Clutch center guide 1.0. 16.988 17.006 (0.6688 0.6695) 17.04 (0.671)
0.0. 20.930 20.950 (0.8240 0.8248) 20.90 (0.823)
Crankshaft 0 .0. at clutch center uide 16.966 16.98410,6680 0.6687) 16.90 (0.665)
Unit: mm (in)
r ALTERNATOR/CAM CHAIN TENSIONER
Cam chain tensioner Push rod 0 .0 . 11.985 12.000 (0.4718 0.4724) 11.94 (0.470)
5 ri n free len th 111.3 (4.38) 100 (3.9)
1-7
GENERAL INFORMATION •
CRANKSHAFT/TRANSMISSION/KICKSTARTER -,--------------,------"""'-"''''-'"'\
•
I.
; I
1-8 •
GENERAL INFORMATION
Unit: mm(in)
,- FRONT WHEEL/BRAKE/SUSPENSION/STEERING
Minimum tire tread de th 3.0 {a.l21
Cold tire (essure 100kPa(1.0k ffern 2 15 si)
Axle runout 0.20 (0.008)
Wheel rim-te-hub distance 6.3 ± 1.0 (0.25 ± 0.04
Wheel rim (uno ut Radial 2.0 0.08
Axial 2.0 (0.08)
Brake Brake lever free 18 10 20 3/8 13/16)
Brake drum I. D. 80 (3.1) 80. 5 (3.17
Brake l ini ng thickness 3.5 0. 14) 2.0 10.08)
Fork 5 rin free len th 160.8 (6.33) 158.3 (6.23
U nl:mmtn
't r)
- REAR WHEEL/BRAKE/SUSPENSION
Minimum tire tread de th 3.0 (0.12)
Cold tire pressure 125 kPa 11.25 k flcm 2 1. si)
Axle (unout 0.20 10.008)
Wheel rim-te-hub distance 25 ± 1.0 (1.0 ± 0.04)
Wheel rim runout Radia! 2.0 (0.08)
Axial 2.0 (0.08
Drive chain Size/link DI D420MBK1(78
Stack 15 25 (9/ 16
Brake Brake dal free I. 10 20 (3/8 13/16"
Brake drum 1.0. 80 (3. 1) 80.5 3.11
Brake lini ng t hickness 3. 5 (0.14) 2.0 (0.08)
IGNITION SYSTEM
ITEM SPECIFICATIONS
plug
; I
1-9
TORQUE VALUES
STANDARD-------,----------r----------------,----------,
FASTENER TYPE
TORQUE
N·m (kgf.m,lbf.ft)
FASTENER TYPE
TOROUE
N-m (kgf.m, Ibf·ft)
•
5 mm hex bolt and nut 5 (0.5,3.6) 5 mm screw 4 (0.4,2.9)
6 mm hex bolt and nul 10 (1.0,7) 6 mm screw 9 (0.9,6.5)
8 mm hex bolt and nut 22(2.2,16) 6 mm flange bolt (8 mm head, 100.0 , 7)
10 mm hex bolt and nut 34 (3.5.25) small flange l
12 mm hex bolt and nut 54 (5.5,40) 6 mm flange bolt (8 mm head, 12(1.2,9)
large flange )
6 mm flange bolt (10 mm head) 12(1.2,9)
and nut
8 mm flange bolt and nut 26 (2.7,20)
10 mm flange bolt and nul 39 (4.0 ,29)
• Torque specifications listed below are for important fasteners .

•
• Others should be tightened to standard t orque values listed above.
NOTES: 1.Apply oil to the threads.

2. Apply grease to the seating surface.
3. U-nut.
4. ALOe bolt; replace w ith a new one.
r- ENGINE
THREAD TOROUE
ITEM Q'lY
DIA.(mm)
REMARKS
N·m (kgf.m, Ibf·ft)
MAINTENANCE:
Spark plug 1 10 12(1.2,9)
•
Oil drain bolt 1 12 25 (2.5 , 18)
Valve adjuster hole cap 2 30 12 (1.2,9) NOTE 1
Valve adjuster lock nut 2 5 9 (0.9,6.5)
Clutch adjuster lock nut 8 12 (1. 2 ,9)
•
1
LUBRICATION SYSTEM:
Oil pump mounting screw 3 6 8 (0.8,5.8)
Oil pump cover screw 3 5 5 (0.5,3.6)
ENGINE REMOVAL/INSTALLATION:
Drive sprocket fixing plate bolt 2 6 12( 1.2,9)
CYLINDER HEAD/VALVES:
Cylinder head nut
Cylinder head right side cover bolt
•
2
6
6
11 (1.1 ,8)
10( 1.0,7)
Cam sprocket bolt 2 5 9 (0.9,6.5)
CYLINDER/PISTON:
Cam chain guide railer pin bolt 1 8 10 (1.0,7)
CLUTCH/GEARSHIFT LINKAGE:
Clutch outer cover screw
• ,.
5 5 (0.5 .3.6)
Clutch lock nut
Clutch assembly screw
Shift drum stopper arm bolt
1
•
1
5
6
42 (4.3,31)
6 (0.6,4.3)
13(1.3 ,9)
•
Shift return spring pin 1 8 29 (3.0,22)
Gearshift cam plate bolt 1 6 1711.7 , 12)
ALTERNATOR/CAM CHAIN TENSIONER:
Flywheel nut
Cam chain tensioner sealing bolt
Cam chain tensioner pivot bolt
1
1
1
,.
10
8
41(4.2,30)
23/2.3,17)
16(1.6,12)
CRANKSHAFT/TRANSMISSION/KJCKSTARTER:
Shift drum bolt 1 6 12(1 .2,9)
1-10 •
GENERAL INFORMATION
, FRAME
THREADDIA. TORQUE
ITEM Q'TV REMARKS
(mml N'm (kgf·m, lbf.ftl
FRAME/BODY PANELS/EXHAUST SYSTEM:

Side stand pivot bolt 1 10 - page 2-5
Muffler mounting bolt 1 8 26/2.7,20)
Exhaust pipe protector bolt 3 6 15(1.5,11'
Exhaust pipe cover screw 4 5 6(0.6, 4.3)
MAINTENANCE:
Fuel valve mounting boll 2 6 9 (0.9.6.5)
FUEL SYSTEM:
Connecting tube band screw 1 4 1 (0.1 , 0.7)
ENGINE REMOVAL/INSTALLATION:
Engine hanger nut 2 8 31 (3.2 , 23)
FRONTWHEEl/BRAKE/SUSPENSION/STEERING:
Handlebar mounting nut 2 8 20(2.0, 14)
Engine stop switch/thronle hounsing screw 2 5 3 (0.3,2.2)
Brake lever pivot bolt 1 5 3 (0.3,2.2)
Brake lever pivot nut 1 5 310.3,2.2)
Spoke nipple 28 BC2 .3 2 (0.2,1.4)
Front axle nut 1 12 47 (4.8.35) NOTE 3
Front brake arm pinch bolt 1 5 6 (0.6, 4.3) NOTE 4
Fork protector bolt 4 6 10 (1.0,7)
Steering stem nut 1 22 74 (7.5 ,54)
Steering stem top thread 1 22 - page 12-17
REAR WHEEL/BRAKE/SUSPENSION:
Spoke nipple 28 BC2.3 2 (0.2, 1.4)
Rear axle nut 1 12 47 (4.8 ,35) NOTE 3
Driven sprocket nut 4 8 32 (3.3,24) NOTE 3
Rear brake arm pinch bolt 1 5 6 (0.6 , 4.3) NOTE 4
Swingarm pivot nut 1 10 39 (4.0,29) NOTE 2,3
Shock absorber mounting nut · 2 10 34 (3.5,25) NOTE 3
Drive chain slider nut 1 6 12(1.2 ,9) NOTE 3
IGNmON SYSTEM:
Ignition coil mounting bolt 1 5 6 (0.6,4.3)
1-11
TOOLS
NOTES: 1. Equivalent commercially available in U.S.A
2. Not available in U.S.A.
3. Alternative tool.
•
DESCRIPTION TOOL NUMBER REMARKS REF. SEC.
Carburetor float level gauge 07401 0010000 5
Spoke wrench, 4.1 X 4.5 mm 07701 - 0020100 NOTE 1 3,12,13
Pin spanner 07702 - 0020001 '2
I/alve adjusting wrench, 8 X 9 mm 07708 - 0030100 NOTE 1 3
Valve adjuster B 07708 - 0030400 NOTE 3: 3
0790B-KE90200 (U.S.A. only)
Lock nut w rench, 20 x 24 mm 07716 - 0020100 9
Extension bar 07716 - 0020500 NOTE 1 9
Universal holder
Flywheel holder
Anachment, 32 x 35 mm
07725 -
07725 -
07746 -
0030000
0040000
0010100
NOTE 1
'0
9
12, 13
•
Attachment, 37 x 40 mm 07746 - 0010200 1 " 12
Pilot, 12 mm 07746 - 0040200 12, 13
Pilot. 17 mm 07746 - 0040400
"
Bearing remover shaft
Bearing remover head, 12 mm
Driver
Valve spring compressor
07746 - 0050100
07746 - 0050300
07749 - 0010000
07757 - 0010000
NOTE 1
NOTE 1
12, 13
12, 13
11 , 12,13
7
•
Valve seat cutter NOTE 1 7
Seat cutter, 24 mm (45 0 IN) 07780-00 10600
Seat cutter, 20.5 mm (45 0 EX) 07780 - 001 1000
Flat cutter, 24 mm (320 IN) 07780-0012500
Flat cutter, 21.5 mm (32 0 EX) 07780 - 0012800
Interior cutter, 22 mm (SO" IN/EX) 07780 - 0014202
Cutter holder, 5 mm 07781 - 0010400
Flywheel puller 07933 - GEOOOOO NOTE 2, 3: '0
07933-0010000
Valve guide driver, 5.0 mm 07942 - MA60000 7
Ball race remover 07944 - 1150001 '2
Steering stem driver 07946 - GC400oo NOTE 3: '2
07946-MBOOOOO
07946-GC4000A (U.S.A. only)
Valve spring compressor attachment 07959 - KM30101 7
Valve guide reamer, 5.0 mm 07984 - MASOO01 NOTE 3: 7
07984-MA6000c (U.S.A only)
Peak vohage adaptor 07HGJ - 0020100 NOTE 3 '4
Peak voltaa9 tester (U.S.A. onlv)
1-12 •
GENERAL INFORMATION
LUBRICATION & SEAL POINTS

- ENGINE
LOCATION MATERIAL REMARKS
Cylinder bore surface Engine oil

Valve adjuster hole cap threads
Connecting rod big end bearing Pour 1 -2cm'
Connecting rod small end inner surface
Piston outer surface. piston pin hole and ring grooves
Piston pin outer surface
Piston ring (whole surface)
Valve stem sliding surface
Camshaft lobes
Cam chain
Cam chain guide roller inner surface
Rocker arm inner and slipper su rfa ces
i' Cam chain tensioner push rod (inside)
Oil pump rotors
Fill with 1-2 em' (page 10·6)
Fill with 0.5 - 1 em'
Clutch center guide (whole surface)
Clutch discs
Primary drive gear teeth and inner surface
Primary driven gear teeth
Mainshaft sliding surface
Countershaft sliding surface
Transmission gear sliding surface, gear teeth
and shifter groove
Shift drum outer surface
Kickstarter spindle sliding surface
Other rotating and sliding area
Each bearing rotating area
Each oil seal lips
Each O-rinn .
r- FRAME
LOCATION MATERIAL REMARKS
Air cleaner housing cover mating groove MUlti-purpose grease

Throttle grip pipe flange
Steering head bearing and ra ce sliding surface
Wheel hub dust seal lips
Wheel bearing cavities
Brake panel anchor pin sliding surface
Brake cam spindle and sliding surfaces
Brake pedal pivot
Fork dust seal lips
Fork slider outer surface (slider guide sliding surface) Apply5-6g
Fork slider guide outer groove Apply5-6g
Fork spring whole surface Pack with 14 g
Swingarm pivot nut seating surface
Side stand ;"ivot and sl idin;' surface
Brake cam dust seal En ine oil
Throttle cable outer inside Cable lubricant
Brake cable outer inside
Handlebar grip rubber inside Honda bond A or
Air cleaner connectin'" tUbe-to-housinn matina area eauivalent
1-13
GENERAL INFORMATION
CABLE & HARNESS ROUTING
•
THROTTLE CABLE
BRAKE CABLE
•
ENGINE STOP SWITCH WIRE
FUEL TANK BREATHER TUBE
AIR CLEANER HOUSING
FUEL TUBE
WIRE BANDS FUEL TUBE
THROTTLE CABLE
•
BRAKE CABLE
ENGINE STOP SWITCH WIRE
1-14
GENERAL INFORMATION
IGNITIClN COIL
THROTTLE CABLE
"SPIIRKPLUG WIRE
CARBURETOR AIR VENT TUBE
IGNITION,--~~~§~-1--- ENGINE STOP SWITCH WIRE

SWITCH
WIRE
CRANKCASE BREATHER
STORAGE TANK
THROTTLE CABLE
CUP
o
5 - 1Qmm ~~~~
IGNlnON SWITCH WIRE
CLAMP
CRANKCASE BREATHER TUBE CARBURETOR DRAIN TUBE
1-15
GENERAL INFORMATIO;;,;N..:....._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
IGNITION CONTROL MODULE (leM)
=
o
o
..........
CLAMP
MAIN WIRE HARNESS
1-16 •
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS

The California Air Resources Board (CAR B) requires manufacturers to certify that their motorcycles comply with applicable
exhaust emissions standards during their useful life. when operated and maintained according to the instructions provided.
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide end hydrocarbons. Controlling hydrocarbon emissions is very
important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon
monoxide does not resct in the same way, but it is toxic.
Honda Motor Co .• Ltd. utiliz.es lean carburetor senings as well as other systems, to reduce carbon monoxide and
hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of a lean carburetor setting. and no adjustments should be made except
idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase
emission control system.
CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned t o the combus tion cham ber through the air cleaner and carburetor.
AIR CLEANER
CAR8URETOR--______:=~~
CRANKCASE BREATHER
STORAGE TANK
CRANKCASE BREATHER TUBE
¢:J FRESH
AIR
- BLOW-BY GAS
1-17
GENERAL INFORMATION
EMISSION CONTROL INFORMATION

LABEL (Except Canada type)
The Vehicle Emission Control Information Label is
attached on the reverse side of the left fuel tank
shroud.
EMISSION CONTROL INFORMATION LABEL
. 1-18
2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION 2-' NUMBER PLATE 2-3
TROUBLESHOOTING 2-' FRONT FENDER 2-3
SEAT 2-2 EXHUST SYSTEM 2-4
FUEL TANK 2-3 SIDE STAND 2-5
SERVICE INFORMATION
GENERAL
mm,n"".
• Gasoline Is eXfrem"r flammable Bnd is explosive undttr c8rtain conditions. KEEP OUT OF REACH OF CHILDREN.
• Serious burns may rHu/t if the exhaust system ;s not allowed to cool before components are removed or sflrviced.
• Work in a well venti lated area. Smoking or allowing flames or spa rks in the work area or where gasoline is st ored can
cause a fire or explosion.
• This section covers removal and installation of the body panels, fuel tank and exhaust system.
• Always replace the exhaust pipe gasket after removing the exhaust system from the engine.
• When installing the exhaust system, loosely install all of the fasteners. Always tighten the exhaust pipe joint nuts first,
then tighten the mounting fastener. If you tighten the mounting fasteners fi rst, the exhaust pipe may not seat properly.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Side stand pivot bolt See page 2-5
Muffler mounting bolt 26 N·m (2.7 kgf.m , 20 Ibf·ft)
Exhaust pipe protector bolt 15 N·m (1.5 kgf.m, l1Ibf·ft )
Exhaust pipe cover screw A 6 N·m (0.6 kgf.m , 4.3 Ibf·ft)
Exhaust pipe cover screw B 6 N·m (0.6 kgf.m , 4.3 Ibf·ft)
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deform ed exhaust system
• Exhaust gas leak
• Clogged m uffler
2-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL
Remove the two trim clips.
Remove the two screws and bolts.
Pull the seat assembly back and remove it.

SEAT ASSEMBLY CLIPS
INSTALLATION
Install the seat assembly by inserting the prongs
into the retainers on the frame.
Install the bolts and screws and tighten them. r~:}7lt---- SCREWS
Install the trim clips and lock them by pushing the
center pin flush.
BOL •
PRONGS
•
DISASSEMBLY/ASSEMBLY
TANK SHROUDS SCREWS
REAR FENDER
SEAT
2-2 •
FUEL TANK
.",;If!!,,,
Gasoline ;s extremely flammable and Is explosiVft BREATHER
under csrta;n conditions. KEEP OUT OF REACH OF
CHILDREN.
BOLT AND COLLAR ~+t-~

Remove the seat assembly (page 2-2).
Remove the breather tube from the number plate.

Turn the fuel valve OFF and disconnect the fuel
tube from the fuel valve.
Remove the two bolts, washer and collar.

For fuel strainer Remove the fu el tank.
service, see
page 3-4. Installation is in the reverse order of removal.
FUEL TANK FUEL TUBE

BREATHEATUBE
NUMBER PLATE NUMBER PlATE
Remove the breather tube from the number plate.

Remove the fender mounting bolt.
Remove the number plate from the steering stem

nut and front fender.
Installation is in the reverse order of rem oval.
BOLT
FRONT FENDER
Remove the three bolts and the front fender.
Instailation is in the reverse order of removal.
FENDER---'
BOLTS
2-3
EXHAUST SYSTEM
Serious burns may result if the exhaust system ;5

not allowed to cool bafor8 components are
removed or s8lVieed.
For spark REMOVAL

arrestef mainte-
nance, refer to Remove the seat assembly (page 2-2),
page 3-17
Remove the exhaust pipe joint nuts.
Remove the mounting bolt and the muffler.
Remove the exhaust pipe joint gasket.
INSTALLATION
Install a new joint gasket into the exhaust port.
Set the exhaust pipe onto the engine by aligning
the exhaust pipe flange with the cylinder head
studs, then install the joint nuts and the mounting
bolt.
Tighten the joint nuts.
Tighten the mounting bolt.
TORQUE: 26 N-m (2.7 kgf-m, 20 Ibf·ft)
Install the seat assembly (page 2-2),
MUFFLER
•
SPARK ARRESTER
MOUNTING BOLT
26 N·m (2.7 kgf.m. 20 Ibf·ft) - -lilY
EXHAUST PIPE PROTECTOR
GASKETe/ •
15 N ·m (1.5 kgf.m, 11 Ibf·ft)
JOINT NUTS
6 N·m (0.6 kgf.m, 4.3 Ibf·ft)
EXHAUST PIPE COVER
2-4 •
SIDE STAND
REMOVAL
Support the motorcycle securely with a hoist or
equivalent.
Retract the side stand and remov e the following:

- return spring
-pivot nut
- pivot bolt
-side stand
INSTALLAnON
Apply grease to the side stand pivot and sliding
surfaces.
Install the side stand with the pivot bolt.
Tighten the pivot bott.
TORQUE: 10 N·m (1.0 kgf.m, 7Ibf·ft)
Loosen the pivot bolt 45 - 90 Q

•
Install the pivot nut and tighten it while holding the

pivot bolt.
Install the return spring as shown.
Check the side stand operation for freedom of

--
movement.
2-5
•
MEMO
•
•
•
3. MAINTENANCE
SERVICE INFORMATION 3-1 DRIVE CHAIN 3-12
MAINTENANCE SCHEDULE 3-3 DRIVE CHAIN SLIDER 3-14
FUEL LINE 3-4 BRAKE SHOE WEAR 3-14
THROTTLE OPERATION 3-4 BRAKE SYSTEM 3-14
AIR CLEANER 3-5 CLUTCH SYSTEM 3-16
SPARK PLUG 3-6 SIDE STAND 3-16
VALVE CLEARANCE 3-7 SUSPENSION 3-16
ENGINE OIL 3-8 SPARK ARRESTER 3-17
ENGINE OIL STRAINER SCREEN 3-10 NUTS, BOLTS, FASTENERS 3-18
ENGINE OIL CENTRIFUGAL FILTER 3-10 WHEELS/TIRES 3-18
ENGINE IDLE SPEED 3-11 STEERING HEAD BEARINGS 3-19
SERVICE INFORMATION
GENERAL
""';II'UM
• Gasoline ;s extremely flammable and is explosive undflr cBrtain conditions. Work in " well ventilated .rea. Smoking or
allowing flames or sparks in the. work area or where the gasoline is stored can cause" fir. or explosion.
• When the engine must be running to do some work, make sur. th. ar•• is well-ventilated. Never run the engine in an
,mclosBd .re". The exhaust contains poisonous carbon monoxide g85 that may c.use loss of consciousnflSS and I.ad to
death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
• Place the motorcycle on a level ground before starting any work.
SPECIFICATIONS
ITEM SPECIFICATIONS
plug
3-1
MAINTENANCE
•
ITEM SPECIFICATIONS
Eng;;;e TAt 1.6 i 10.6 US at. 0.51mo at>
~
I
"yl , t motm 0;1
&~~~"moa,;on SF 0' SG
I . l00,om
,-ado f, •• ole' . .'[B£; (1f ;; nl
'elv. I
EX ' i & . m m 10.~02 ± 0.001 Inl
D,lv. , I
)
",,"v-
~13/16)nl
"""'"
~Sl"
I
",. bcand
T),.
; SHIN
I."
',ont
If3J
100 'Pe 11.0 I
1.
~sl)
•
Minimum tire tread depth Fcont 3.0 mm 10.12 Inl
)
TORQUE VALUES
Fuel valve mounting bolt 9 N·m (0.9 kgf·m , 6.5 Ibf·ft)
Spark plug 12 N·m (1.2 kgf.m , 9Ibf·ft)
Valve adjuster hole cap 12 N·m (1.2 kgf.m, 9Ibf·ft) Apply engine oil to the threads
Valve adjuster lock nut 9 N·m (0.9 kgf.m , 6.5 Ibf·tt)
Oil drain bolt 25 N·m 12.5 kgf·m , 18 Ibf·ft)
Clutch adjuster lock nut 12 N·m (1.2 kgf.m, 9 Ibf·ft)
Rear axle nut 47 N·m (4.8 kgf·m ,35Ibf·ft) U-nut
TOOLS
Valve adjusting wrench, 8 X 9 mm
Valve adjuster B
Spoke wrench, 4.1 X 4.5 mm
07708-0030100
07708-0030400
Equivalent commercially available in U.S.A.
or 07908-KE90200 (U.S.A. only)
•
07701-0020100 Equivalent commercially available in U.S.A.
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the PRE-AIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary.
C: Clean A: Replace A: Adjust L; lubricate
I I
Refer to
page
~
!H~
I ~~~
3- 12
3-17
• Should be serviced by your Honda dealer. unless the owner has proper tools and service data and is mechanically
qualified.
•• In the interest of safety, we recommend these items be serviced only by your Honda dealer.
NOTE: 1. Service more frequently when ridden in wet or dusty conditions.
3-3
MAINTENANCE
FUEL LINE
Check the fuel line for deterioration, damage or
leakage. Replace the fuel line if necessary.
FUEL STRAINER SCREEN
• Gasoline i. extremely flammabl" lind Is

explosive unci« Cflrlllin conditions. Work in a
well v.ntilllted .rell. Smoking or allowing flllmB.
or SPllrk. In the work II'''. or where tM ga.olinll
is stored can ,;au.It II fire or lIxplosion .
• Wipe spilled gasoline at once.
Turn the fuel valv8 OFF and disconnect the fuel

tube.
Place a drain pan under the fuel tube and turn the
fuel valve ON to drain the fuel tank.
After the tank. has drained completely. remove the
two bolts and collars, and remove the fuel valve
O-RING
and strainer screen.
Wash the fuel strainer screen in non-flammable or

high flash solvent.
STR AINER
Check the a-ring is in good condition, rein stall the SCREEN
fue l valve.
Tighten the fuel valve mounting bolts to the speci-
fied torque.
TORQUE: 9 N·m (0.9 kgf.m, 6.5Ibf·ft)
After installation, check for fuel leaks.
THROTTLE OPERATION
Check for smooth throttle grip full opening and au-
•
tomatic full closing in all steering positions.
Check the throttle cable and replace it if it is deterio-
rated, kinked or damaged.
lubricate the throttle cable. if throttle operation is
not smooth.
Measure the free play at the throttle grip flange.
FREE PLAY: 2.0-4.0 mm (1 / 16 - 3/16 in)
3-4
MAINTENANCE
Throttle grip free play can be adjusted at the upper

end of the throttle cable. LOCK NUT
ADJUSTER
Remove the dust cover from the adjuster.
Adjust the free play by loosening the lock nut and
turning the adjuster.
Tighten the lock nut and install the dust cover
properly.
Recheck the throttle operation.
AIR CLEANER
Remove the two screws and the air cleaner housing
cover.
SCREWS
Remove the. air cleaner element holder and ELEMENT

element from the housing.
HOLDER
Wash the element in non-flammable or high flash

point solvent, and let it dry thoroughly.
~
Soak the element in Pro Honda Foam Filter Oil or
equivalent, and squeeze out any excess oil.
I. :; . . ...
?~~t-~t-
" '~
.
I' ' ..
WASH IN SQUEEZE PRO SQUEEZE

SOLVENT OUT HONDA OUT
SOLVENT FOAM EXCESS
THOROUGHLY FILTEA OIL OIL
3-5
MAINTENANCE •
Reinstall the air cleaner element and the element GROOVE
holder by aligning the cutout with the projection on
PROJECTION
the housing.
Apply grease into the mating groove in the air

cleaner housing cover.
•
Align the groove in Install the housing cover and tighten the screws.
the cover with the
projection on the
housing.
COVER
CUTOUT ELEMENT
SPARK PLUG
REMOVAL
•
Clean around the Disconnect the spark plug cap.
spark plug base
with compressed Remove the spark plug using a spark plug wrench
air before or an equivalent.
removing, and be
sure that no debris Inspect or replace as described in the maintenance
is allowed to enter schedul e (page 3·3).
the combustion
chamber. CAP
INSPECTION
CENTER ELECTRODE
Check the following and replace if necessary (rec-
ommended spark plug: page 3-1)
• Insulator for damage
• Electrodes for wear
• Burning condition, coloration; ElECTRODE
-dark to light brown indicates good condition.
-excessive lightness indicates malfunctioning ig-
nition system or lean mixture.
-wet or black sooty deposit indicates over-rich
mixture.
INSU LATOR
•
REUSING A SPARK PLUG
Clean the spark plug electrodes with a wire brush
or special plug cleaner.
Check the gap between the center and side
•
electrodes with a wire-type feeler gauge.
If necessary, adjust the gap by bending the side
electrode carefully.
SPARK PLUG GAP:

0.60-0.70 mm (0.024-0.028 in)
3-6 •
MAINTENANCE
CAUTION:
To prevent damage to the cylinder head, hend-

B wrtmch to
tighten thtl spark plug before using
tighten to the specified torque.
Reinstall the spark plug in the cylinder head and

hand tighten, then torque it using a spark plug
wrench.
TORQUE: 12 N·m (1.2 kgf·m, 9 Ibf.ft)
REPLACING A SPARK PLUG

Set the plug gap to specification with a wire-type
feeler gauge (see p revious page).
CAUTION:
Do not overtighten the spark plug.
Install and hand tighten the new spark plug, then

tighten it about 1/2 of a turn after the sealing
washer contacts the seat of the plug hole.
Install the spark plug cap.
VALVE CLEARANCE
INSPECTION
Inspect and adjust Remove the valve adjuster hole caps.
the valve
clearance while
the eng/fIB/s cold
(below
95°F/ 35 °C).
Remove the l eft crankcase cover (page 10-2).
Turn the crankshaft counterclockwise and align the

"T" mark on the flywheel with the i ndex notch on
the left crankcase.
Make sure the piston at roc (Top Dead Center) on
the compression stroke.
This position can be obtained by confirming that
there is slack in the rocker arm.
If there is no slack, rotate the crankshaft one full
turn counterclockwise and match up the ''Too mark
again.
" T "MAAK
3-7
MAINTENANCE
•
Check the valve clearance by inserting a feeler
gauge between the valve adjusting screw and valve
stem.
VALVE CLEARANCE:
IN/EX: 0.05 ± 0.02 mm (0.002 ± 0.001 in)
ADJUSTMENT
Adjust by loosening the lock nut and turning the ad-
justing screw until there is a slight drag on a feeler
gauge.
Hold the adjusting screw and tighten the lock nut.
TOOLS:
Valve adjusting wrench, 8 X 9 mm
07708-0030100
(Equi valent com-
mercially available
in U.S.A.)
Valve adjuster B 07708-0030400 or
07908 - KE90200
(U.S.A. only)
TORQUE: 9 N·m (0.9 kgf.m ,6.5 Ibf·ft)
Recheck the valve clearance.
Check the valve adjuster hole cap O-ring is in good

condition, replace if necessary.
Coat the O-rings with clean engine oil and install
them in the valve adjuster hole caps.
Apply clean engine oil to the threads, install and

tighten the valve adjuster hole caps t o the specified
t orque.
TOROUE: 12 N·m (1.2 kgf·m, 9 Ibf·tt)
ENGINE OIL
Install the lett crankcase cover (page 10-8).
•
OIL LEVEL INSPECTION
Support the motorcycle in an upright position on
level ground.
Remove the oil filler cap/dipstick and wipe it clean.

Check the oil level by inserting the oil filler cap/
dipstick into the oil fille r hole without screwing it in.
3-8 •
MAINTENANCE
The engine contains a sufficient amount of oil if the

oil level is between the upper and lower level
marks on the dipstick.
If the level is near or below the lower level mark,

add the recommended oil up to the upper level
mark.
_ _-UPPER
r - - -- LOWER
RECOMMENDED ENGINE Oil:
HONDA GN4 4-stroke oil or equivalent motor oil
API service classifi ca tion: SF or SG
Viscosity: lOW-30
NOTE:
Other viscosities shown in the chart may be used

when the average temperatu re in your riding area
is within the indicated range.
Reinstall the filler cap/dipstick.
ENGINE OIL CHANGE

='--:":--~':':---;":----":::----::100 'f
.~,,:--.~,,:--::,--:,::,--:,::,---;:,,:----;:~ ·c
When the engin8 must b" running to do some

work. make sure the area is well-ventilsted. Never
run the engine in an enclosBd area. The exhaust
contains poisonous carbon monoxidiJ gas that may
causs loss of consciousness and lead to deeth. Run
the engine in en open area or with an exhaust
evacuation system In an enclosed area.
Change /he Warm up the engine.

engine oil with
the engine warm Stop the engine and remove the oil filler cap/dip-
end/he stick and drain bott.
motorcycle on Drain the oi l completely.
level ground 10
assure complete
draining. • .?'M'!"
Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for
profongBd periods. Although this is unlikftfy 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 aft.r handling
used oil. KEEP OUT OF REACH OF CHILDREN.
3-9
MAINTENANCE
Check that the sealing washer on the drain bolt is in

good condition, replace jf necessary.
Install end tighten the drain bolt.
TORQUE: 25 N'm (2.5 kgf·m. 18Ibf·ft)
Fill the crankcase w ith recommended engine oil

(page 3·8).
OIL CAPACI1Y:
0.6 fj (0.6 US Qt, O.Slmp qt) at draining
0.8 a(0.8 us qt. 0.7 Imp qt) at disassembly
Install the oil filter cap/dipstick.
Start the engine and let it idle for 2 to 3 minutes.

Stop the engine and recheck the oil level.
Make sure there are no oil leaks.
ENGINE OIL STRAINER SCREEN

CLEANING
Remove the right crankcase cover (page 9-3) .
Remove the oil strainer scree n and clean it.

Check the screen for damage and the sea ling
rubber fo r damage o r det er ioration.
Reinstall the oil strainer screen and right crankcase

cover (page 9- 17).
ENGINE OIL CENTRIFUGAL FILTER

CLEANING
Remove the right crankcase cover, ball retainer and
clutch lifter lever (page 9·3).
Remove the four screws and clutch outer cover.
3-10
MAINTENANCE
Clean the clutch outer cover and inside of the clutch

outer using a clean lint-free cloth.
CAUTION;
• Do not Bflow dust and dirt to enter the crank-

shaft oil passage.
• Do not use comp",ssed air.
Reinstall the clutch outer cover using a new gasket

(page 9-13).
ENGINE IDLE SPEED
When the engine must be running to do some

work.. make sur. the .'8.
;s well-ventifated. Never
run the engine in 8n Ilnclosed .,••. Th. fJxh.ust
contillns poisonous carbon monoxide g85 that mey
cause lass of consciousness and lead to death. Run
the engine in 8n o".n area or with an exhaust
evacuation system In an enclosttd .rllll.
NOTE:
• Inspect and adjust the id le speed after all other

engine maintenance items have been performed
and are within speCifications.
• The engi ne must be warm for accurate idle speed
inspection and adjustment.
Warm up the engine for about ten minutes.

Connect a tachometer.
Turn the throttle stop screw as required to obt ai n
the speCified idle speed.
IOl£SPEED: 1,700 ± 100 rpm
3-11
MAINTENANCE
•
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION 0 o c
Never inspect and adjust the drive chain while the

engine;s running.
~
Turn off the engine, place the motorcycle on its
side stand and shift the transmission into neutral.
« 1 .."",.,.."
• ~. ,. - .f"Jtair
)
Check the slack in the drive chain lower run mid· 1
way between the sprockets. 15 - 25 mm (5/8 - 1 in)
CHAIN SLACK:1S-25 mm (5/8-1 in)

AXLE
CAUTION:
EXC8SS;V8 chain slack, 4D mm (1·1/2 in) or more,

may damage the frame.
ADJUSTMENT
Loosen the rear axle nut.
Loosen the adjuster lock nuts and turn both
adjusting nuts an equal number of turn until the
correct drive chain slack is obtained.
Make sure th~ index marks on both adjusters are

aligned with the index lines on the swingarm .
Tighten the. rear axle nut to the specified torque.
TORQUE: 47 N·m /4.8 kgf·m, 35 Ibf·ft)
Tighten both lock nuts.
Recheck the drive chain slack and free wheel rota-

tion.
Check the rear brake pedal free play (page 3- 15),
adjust if necessary.
Lubricate the drive chain wi th #80 - 90 gear oil.
Wipe off the excess oil.
CLEANING INSPECTION AND

LUBRICATION
If the drive chain becomes extremely dirty, it
•
should be removed and cleaned prior to lubrication.
Remove the left crankcase cover (page 10-2).
Carefully remove the retaining clip w ith pliers.

Remove the link plate, master link and drive chain.
3-12 •
MAINTENANCE
Clean the chain with non-flammable or high flash NON-FLAMMABLE OR

point solvent and wipe it dry. HIGH FLASH POINT SOLVENT
~.~
Be sure the chain has dried completely before
lubricating.
Lubricate the drive chain with 1:. 80 - 90 gear oil.
Wipe off the excess gear oil.
CLEAN
WIPE AND DAY c

r"'/ "-: ~
•~ J ;>.ifGEAR OIL
........---tSAE ·~fao OR 90
LUBRICATE ' -
Inspect the drive chain for possible damage or

wear.
Replace any chain that has damaged rollers, loose
41 PINS (40 LINKS)
fitting links. or otherwise appears unserviceable.
Measure the drive chain length between a span of

41 pins (40 links) from pin center to pin center with
the chain held taut and any kinked joint
,
straightened. lc OliO 0 o OliO oK0 0 leo >l
SERVICE UMIT: 511 mm (20. 1 in)
Installing a new chain on badly worn sprockets will

cause the new chain to wear quickly.
Inspect the drive and driven sprocket teeth for wear
or damage. Replace if necessary.
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good
condition, or the new repl acement parts will wear
rapidly.
Check the attaching bolts and nuts on the drive and

driven sprockets.
If any are loose, torque them.
Install the drive chain onto the sprockets.

MAST~'R LINK
Install the master link and link plate.
Install the retaining clip so that its open end is
opposite the nomal rotation of the chain.
LINK PLATE
I I CLIP
3-13
MAINTENANCE
DRIVE CHAIN SLIDER DRIVE CHAIN SLIDER

Check the drive chain slider for wear or damage.
Replace the drive chain slider if the wear limit

guide lug is worn out or it has been damaged.
•
GUIDE LUG
BRAKE SHOE WEAR FRONT:

"6" MARK
Check the brake shoes and brak~ drum jf the arrow
on the indicator plate aligns w ith the" A" mark on
the brake panel when the brake lever is applied.
Refer to page 12·10 or 13·8 for brake shoe and

brake drum inspection.
REAR:
ARROW
"A" MARK
•
BRAKE SYSTEM
FRONT BRAKE
10 - 20 mm (3/8-13/16 in)
•
Measure the front brake lever free play at the tip of
the lever.
FREE PLAY: 10 - 20 mm (3/8-13/1Sin)
3-14 •
MAINTENANCE
Make surs the Adj ust the brake lever free play by turning the
culouf on the adjusting nut.
adjusting nul is
S6ated on the joint
pin.
REAR BRAKE
Check the brake pedal free play.
FREE PLAY: 10 - 20 mm (3/8- 13/16 in)
Make sure/he Adjust t he brake peda l free play by tu rning the ad-
cutout on the justing nut.
adjusting nut Is
S6aled on the Joint
pin.
3-15
MAINTENANCE
•
CLUTCH SYSTEM
If the clutch does not operate properly, adjust the
following:
loosen the clutch adjuster lock nut and turn the
adjusting bott one full turn counterclockwise.
Slowly turn the adjusting bolt clockwise until

resistance is felt.
Turn the adjusting bolt 1/8 turn counterclockwise
from this position, and tighten the lock nut while
holding the adjusting bolt.
Check that the clutch is not slipping and is properly

disengaging by operating gearshift pedal.
SIDE STAND
Support the motorcycle on a level surface.
Check the sjd~ stand spring for damage or loss of

tension.
Check the side stand assembly for freedom of
movement and lubricate the side stand pivot if
necessary.
•
SUSPENSION
SIDE STAND
Loose, worn or damaged suspension parts impair

motorcycle stability and control. Repair or replace SPRING
any damaged components before riding. Riding a
motorcycle with faulty suspension increases your
risk of an accident and possible injury.
FRONT SUSPENSION INSPECTION

Check the action of the fork legs by operating the
•
front brake and compressing the front suspension
several times.
Check the entire assembly for signs of leaks,
damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Aefer to section 12 for fork service.
3-16
MAINTENANCE
REAR SUSPENSION INSPECTION

Support the motorcycle on safety stand or box and
raise the reaf wheel off the ground.
Hold the swingarm and move the rear w heel

sideways with force to see if the wheel bearings are
worn.
Check for worn or loose suspension pivot

components by grabbing the swingarm and
attempting to move the 5wingarm side to side.
Check each fastener of the swingarm and shock
absorber, if any are looseness is noted.
Also, check the pivot bushings for wear or damage.
Check the action of the shock absorber by compres-

sing it several times.
Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
I
Tighten all nuts and bolts.
Refer to sect ion 13 f o r shock absorber and

swingarm service.
SPARK ARRESTER
• Wait until theaxhaust system has cooled before

removing or installing the spark affester.
• Perform this operation in a well-ventilated area
free from combustible materials.
Remove the three bolts, spark arrester and gasket

from the muffler.
3-17
MAINTENANCE
Use a soft brush to remove carbon deposits from

the screen mesh, being caref ul not to damage it.
The spark arrester must be free of breaks and holes.
Replace if necessary.
Install the spark arrester with a new gasket into the

muffler.
Tighten the three bolts securely.
NUTS,BOlTS,FASTENERS
Check that all chassis nuts and bolts are tightened
to their correct torque values (page ,- 10).
Check that all safety clips, cramps and cable stays
are in place and properly secured.
WHEELS/TIRES
Tire pressure RECOMMENDED TIRE PRESSURE AND TIRE SIZE:
should be checked
when the tires are FRONT REAR
COLD. Tire pressure 100 (1.0 ,15) 125 (1.25 , 18)
kPa (kgf/cm z, psi)
Tire size 2.50-10 33J 2.50-10 33J
Tire bland c- 183A C- 183A
(CHE NG SHIN )
Check the tires for cuts, embedded nails, o r other

damage.
Check the front and rea r wheels for trueness (ref er
to secti on 12 and 13).
Measure the tread depth at the cente r of the t ires.
Replace the tires when the tread depth reaches the
following limits.
MINIMUM TREAD DEPTH:

FRONT/REAR: 3.0 m m (0. 12 in)
•
3-18
MAINTENANCE
Tighten any loose spokes.
TOOL:
Spoke wrench. 4.1 X 4.5 mm 07701-0020100
(Equivalent com-
mercially available
in U.S.A.)
STEERING HEAD BEARINGS

Ch8ck that the Support the motorcycle securely and raise the front
control cables do wheel off the ground.
not interfere with
handlebar Check that the hand lebar moves freely from side to
rotation. side.
If the handlebar moves unevenly, binds, or has ver-
tical movement. inspect the steering head bearings
(page 12-15).
]
3-19
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
ROCKERAAM
CAMSHAFT
PUMP
PISTON ----nf--t::£~~
Oil THROUGH
CRANKSHAFT
OIL FILTER ROTOR
COUNTERSHAFT I~~J~:t~~l~lr
OIL STRAINER
KICKSTAATER
4-0
4. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM 4-0 TROUBLESHOOTING 4-1
SERVICE INFORMATION 4-1 Oil PUMP 4-2
SERVICE INFORMATION
GENERAL
• When the engine must be running to do some work, make sura the .r"a Is well-ventilated. Never run the engine in an
,meID.eeI area. The exhaust cont.ins poisonous carbon monoxide gas that may CIIU'. loss of consciousness and lead to
death. Run the engine In an open 8rea or with an flxhausf evacuation system in 8n enclosed arBa.
• Used engine oil may ca use skin cancer if repeatedly left In contact with the skin for prolonged periods. Although this is
unlikely unless you handle us.d oil on " daily basis, if is still advisable to thoroughly wash your hands with soap and
w afe, 85 soon as possible after handling usttd oil. KEEP OUT OF REACH OF CHILDREN.
• The oil pump can be serviced w ith the engine installed in the frame.
• The service procedures in this section must be perform ed w ith the eng ine oi l drained.
• When removing and installing the oil pump, use care not to allow dust or di rt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks.
SPECIFICATION S

. I
. I
4-stroke oil or equ ivalent
motor oil
API service classification SF or SG
pump rotor
TORQUE VALUES
Oil pump mounting screw 8 N·m (0.8 kgf·m , 5.8 Ibf· ftl
Oil pu mp cover screw 5 N·m (0.5 kgf.m , 3.6Ibf·ft)
TROUBLESHOOTING
Engine oil level too low - high oil consumption Oil contamination
• Norm al oil consu mption • Oil not change often enough
• Extern al oil leak • Worn piston ring or incorrect piston ring installation
• Worn piston ring or incorrect piston ring installation • Worn valve guide or stem seal
• Worn cylinder • Clogged oil strainer screen
• Worn valve guide or stem seal
• Oil pump worn or da maged
4-1
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
Remove the clutch assembly (page 9-4),
When the oil pump is ready to be disassembled,

loosen the pump cover screws.
Remove the three screws and oil pump assembly.
DISASSEMBLY
Remove the three screws and oil pump cover.
Remove the oil pump shaft, then remove the inner

and outer rotors from the oil pump body.
INSPECTION
If My portion of Temporarily install the outer and inner rotors into
the oil pump is the oil pump body.
worn beyond the Install the oil pump shaft.
specified service
IIml/, rep/ace the Measure the tip clearan ce between the inner and
01/ pump 8S an outar rotors.
assembly.
SERVICE LIMIT: 0.20 mm (0.008 in)
Measure the pump body clearance between the

outer rotor and pump body.
4-2
LUBRICATION SYSTEM
Measure the side clearance using a straight edge

and feeler gauge.
ASSEMBLY
OUTER ROTOR
OIL PUMP SHAFT
OIL PUMP BODY
INNER ROTOR
Oil PUMP COVER
Install the inner and outer rotors into the oi l pump

body.
Install the oil pump shaft aligning the flat su rfaces
of the shaft and inner rotor.
Fill the oil pump with 0.5 - 1 cm~ of engine oil.
4-3
LUBRICATION SYSTEM
Install the oil pump cover and tighten the screws to

the specified torque.
TORQUE: 5 N·m (0.5 kgf.m ,3.6Ibf·ftJ
INSTALLATION
Install the rotor shaft collar i nto the crankcase.
Install a new gasket ont o the oil pump body.
Install the oil pump into the crankcase while align-

ing the pump shaft groove w ith the cam chain
guide spindle lug .
Install and tigh.ten the three screws to the specifi ed

torque.
TORQUE: 8 N·m IO,B kgf.m , 5.8Ibf·ft)
Install the clutch assembly (page 9-12),
4-4
MEMO
FUELSVSTEM
1 N·m (0.1 kgf.m . 0.7 Ibf·ft)
5-0
5. FUEL SYSTEM
SERVICE INFORMATION 5-1 CARBURETOR ASSEMBLY 5-6
TROUBLESHOOTING 5-2 CARBURETOR INSTALLATION 5-8
AIR CLEANER HOUSING 5-3 AIR SCREW ADJUSTMENT 5-10
CARBURETOR REMOVAL 5-3 CRANKCASE BREATHER 5-11
CARBURETOR DISASSEMBLY 5-5
SERVICE INFORMATION
GENERAL
• Gasoline is extremely flammable and Is Bxplosiv. under certain conditions. KEEP OUT OF REACH OF CHILDREN.
• Sending or twisting thlt control cabl. will imp.;r smooth oPflrlJtion and could tBUS. the cabl. to stick or bind, resulting
in loss of vehicle control.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
• Refer to section 2 for fue l tank removal and installation.
• When disassembling fuel system parts, note the location of the O-rings. Replace them with new ones on reassembly.
• Before disassembling the carburetor, place the suitable container under the carbu retor drain tube. loosen the screw and
drain the carburetor.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with piece of tape t o
prevent any fo reign material from dropping into the engine.
NOTE :
If the vehicle is to be stored for more than one month, drain the float bowl. Fuel left in the float bowl may cause clogged
jets, resulting in hard starting or poor driveability.
SPECIFICATIONS
ITEM SPECIFICATIONS
Carburetor identification number PA42A
Main jet # 58
Slow 'et #35 x #35
Jet needle eli osition 2nd rcove from to
Air screw initia l opening 1-1 2 turns out
Float level 12.7 mm (0.50 in
Idle speed 1 700 ± 100 rpm
Throttle grip free play 2 .• 4.0 mm (1/16 3116 in)
TOROUE VALUE
Connecting tube band screw 1 N·m (0. 1 kgf.m ,0.7 Ibf·fi)
TOOL
Carburetor float level gauge 07401 - 0010000
5-1
FUELSVSTEM
•
TROUBLESHOOTING
Engine won't to start
• Too much fuel gening to the eng ina
-Air cleaner clogged
Engine stall, hard to start, rough idling
•
•
Fuel line restricted
Ignition malfunction
•
-Flooded carburetor • Fuel mixture too lean/rich
-Intake air leak • Fuel contaminated/deteriorated
• Fuel contaminated/deteriorated • Intake air leak
• No fuel to carburetor • Idle speed misadjusted
-Fuel strainer clogged
-Fuel tube clogged
-Float level misadjusted
•
•
•
Float level misadjusted
Fuel tank breather tube clogged
Air screw misadjusted
•
-Fuel tank breather tube clogged • Slow circuit clogged
Lean mixture Afterburn when engine braking is used

• Fuel jets clogged • Lean mixture in slow circuit
• Float valve faulty
•
•
Float level too low
Fuel line restricted
Backfiring or misfiring during acceleration
• Ignition system malfunction
•
• Carburetor air vent tube clogged • Fuel mixture too lean
• Intake air leak
• Throttle valve faulty Poor performance (driveabilityl and poor fuel economy
Rich mixture
• Choke lever in CLOSE position
• Float valve faulty
• Fuel system clogged
• Ignition system malfunction
•
• Float level too high
• Air jets clogged
• Air cleaner element contaminated
• Flooded carburetor
•
5-2 •
FUEL SYSTEM
AIR CLEANER HOUSING

REMOVAL/INSTALLATION
NOTE:
Refer to page 3-5 for air cleaner element service.
Disconnect the crankcase breather tubes.

Loosen the connecti ng tube band screw.
Remove the bott and the air cleaner housing assem-
bly.
Ar instal/ation, Installation is in the reverse order of remova l.

HOUSING COVER
secure the ground
eyelat with the ai r
clesner housing
mounting bolt.
AIR CLEANEA HOUSING
CARBURETOR REMOVAL
Gasoline i. extremely flammable snd is explosive

under certain conditions. KEEP OUT OF REACH OF
CHILDREN.
THROTTLE VALVE
l oosen the carburetor top.
Remove the carburet or top and throttle valve from

the ca rburetor.
5-3
FUEL SYSTEM
Remove the throttle cable from the throttle valve

while compressing the throttle valve spring.
•
Remove the jet needle retainer and jet needle.
Check the throttle valve and jet needle for scratches,

wear or damage.
RETAINER
•
JET NEEDLE
CARBURETOR BODY
Gasoline is extremely flammable and ;s explosive

under cflrtain conditions. Wor k in B well ventilated
Brea. Smoking or allowing flames or sparks in the
•
work area or where the gasoline is stor ed can
cause II fire or explosion.
Loosen the drain screw and drain the fuel from the
float chamber into an approved gasoline container.
Disconnect the fuel tube, air vent tube and drain

tube from the carburetor body.
loosen the carburetor connecting tube band screw.

Remove the carburetor mounting bolts, carburetor
and insulator.
•
5-4 •
FUEL SYSTEM
CARBURETOR DISASSEMBLY FLOAT CH,'MllER
Remove the screws and float chamber.
Remove the float pin, float and float valve.
Inspect the float for deformation or damage.
Inspect the float valve seat for scores, scratches,

clogging and damage.
Check the tip of the float valve where it contacts the
valve seat for stepped wear or contamination.
Replace the valve if the tip is worn or contaminated.
Check the operation of the float valve.
Remove the following:

-Mai n jet
-Needle jet
- Throttle stop screw and spring
VALVE SEAT
Turn the air screw in and carefully count the
number of turns until it seats lightly. Make a note of
this to use as a reference when reinstalling the air
MAIN JET
screw.
Remove the air screw and spring.
NEEDLE JET
CAUTION:
Damaga to tha air screw seat will occur if tha air

screw is tightened against the se."
Inspect each jet for wear or damage and replace if
necessary.
Clean the jets with cleaning solvent end blow open AIR SCREW
w ith compressed air. THROTTLE SCREW
5-5
FUELSVSTEM
CARBURETOR ASSEMBLY , n.Rc.TTLE STOP SCREW
•
NEEDLE JET
MAIN JET •
/ I)R'"INSCAEW
SEAL RIING----'=+11b
•
•
FLOAT CHAMBER
JET NEEDLE
THROTTLE VALVE C-RING

•
Blow open eac.h air and fuel passage in the carbure-
tor body with compressed air.
Install the following:

•
- Throttle stop screw and spring
-Needle jet
-Main jet
CAUTION :
THROTTLE
STOP SCREW
•
Handle alf jets with care. They can easily be scored
or scratched. NEEDLE JET
~ ,~,,~r •
Install the air screw w ith the spring and return it to
its original posit ion as noted during removal.
Perform the air screw adjustment procedure if a
new air screw is installed (page 5- 10).
- ,M
",A" I"N",
J"ET
: ..._ _ AIR SCREW~
5-6 •
FUEL SYSTEM
Hang the float valve onto the float arm lip.

FLOAT
Install the float and float valve in the carburetor
body, then install the float pin through the body
and float.
PIN
FLOAT LEVEL INSPECTION GAUGE
NOTE:
Set the float level gauge so that it is perpendicular

to the float chamber face and in line with the main
jet.
With the float valve seated and the float arm just
touching the valve, measure the float level with the
special toot as shown.
FLOAT LEVEL: 12.7 mm (0.50 in)
TOOL:
Carburetor float level gauge 07401 - 0010000
The float cannot be adjusted.

Replace the float assembly if the float level is out of
specification.
Install 8 new O-ring into the carburetor groove

properly.
Install the float chamber.
Install and tighten the float chamber screws.
5-7
FUEL SYSTEM
CARBURETOR INSTALLATION
CARBURETOR BODY
Install new O-rings into the insulator and carbure-
tor body grooves.
•
Install the carburetor body into the air cleaner
connecting tube and the insulator between the
manifold and carburetor, then install the mounting
•
botts.
Tighten the connecting tube band screw and
mounting bolts.
TORQUE:
Connecting tube: 1 N·m (0.1 kgf.m, 0.7 Ibf·tt)
•
Connect the fu.el tube, drain tube and air vent tube.
THROTTLE VALVE
Install the needle clip on the jet needle.
CLIP
STANDARD POSmON: 2nd groove from top
~ •
5-8
FUEL SYSTEM
Install the jet needle into the throttle valve and THROTTLE VALVE
secure it with the needle clip retainer.
JET NEEDLE
~ "[" '..4
Check the seal ring is in good condition, replace if

necessary.
Install the throttle valve spring onto the throttle
cable.
Connect the throttle cable to the throttle valve while

compressing the throttle valve sprin g.
Install the throttle valva into the carburetor body.

aligning its cut-out with the throttle stop screw.
5-9
FUEL SYSTEM
Tighten the carburetor top securely_
After installing the carburetor, check for the follow-

ing:
-Engine idle speed (page 3-11)
- Throttle grip free play (page 3·4)
AIR SCREW ADJUSTMENT

IDLE DROP PROCEDURE
When the engine must be running to do some

work, make sure the (Jrea is weJf-ventil.tctd. Neve'
run the engine in an enclosed area. The exhaust
contains poisonous carbon monoxide gas that may
cause loss of consclous",'55 lind Iliad to death. Run
the engine in an open ares or with an exhaust
Bvacuerion system in an enclosed ar••.
NOTE:
• The air screw is factory pre-set. Adjustment is not

necessary unless the carburetor is overhauled or
new air screw is installed.
• The engine must be warm for accurate adjust-
ment. Ten minutes of stop-end-go riding is
sufficient.
• Use 8 tachometer with graduations of 50 rpm or
smaller that will accurately indicate 50 rpm
change.
1. Turn the air screw clockwise until it seats lightly.

and then back it out to the specification given.
CAUTION :
Damage to the air screw .seat will occur if the air

screw is tightened ega/nst the seat.
INITIAL OPENING: '-1/2 turns out
2. Warm the engine up to operating temperature.

3. Stop the engine and connect a tachometer ac-
cording to the tachometer manufacturer's instruc-
tions.
4. Start the engine and adjust the idle speed with
the throttle stop screw.
IDLE SPEED: 1,700 ± 100 rpm
5. Turn the air screw in or out slowly to obta in the

highest engine speed.
6. Lightly open the throttle 2-3 times, then adjust
the idle speed with the throttle stop screw.
7. Turn the air screw out gradually until the engine
speed drops by 50 rpm.
S. Turn the air screw in to the final opening from the
position obtain in step 7.
FINAL OPENING: 1/2 turns in
•
9. Aeadjust the idle speed with the throttle stop
screw.
5-10
FUEL SYSTEM
CRANKCASE BREATHER
Remove the crankcase breather lube plug and
empty any deposits if the deposit level can be seen
in the breather t ube.
Install the crankcase breather tube plug and secure

it with the clip securely.
CRANKCASE
BREATHER ~-..o
TUBE PLUG
5-11
•
12 N·m (1.2 . 91bf·ft)
•
•
31 N·m (3.2 kgf.m . IbUt)
6-0 •
6. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 6-' ENGINE INSTALLATION 6-4
ENGINE REMOVAL 6-2
SERVICE INFORMATION
GENERAL
• During engine removal and installation, support the motorcycle securely using a hoist or equivalent.
• Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal.
• The following components can be serviced with the engine installed in the frame.
- Alternator/cam chain tensioner (Section 10)
- Clutch (Section 9)
- Cylinder/piston (Section 8)
- Cylinder head/valves (Section 7)
- Gearshift linkage (Section 9)
- Oil pump (Section 4)
• The crankshaft, tra nsmission and kickstarter require engine removal for service (Section 11).
SPECIFICATIONS
ITEM SPECIFICATIONS
Enaina ~wiiaht 17.2 ko (37.9 Ibs)
En ine oil ca aci at disassembl 0.8 Q 0.8 US t O.71m t)
TORQUE VALUES
Drive sprocket fixing plate bolt 12 N·m (1.2 kgf.m , 9Ibf·ft)
Engine hanger nut (Upper) 31 N·m (3.2 kgf·m ,23 Ibf.ft)
(l ower) 31 N·m (3.2 kgf.m, 231bf·ft)
6-1
ENGINE REMOVAL
Drain the engine oil (page 3-9),

- exhaust system (page 2-5)
-left crankcase cover (page 10-2)
Disconnect the f ollowing:

-spark plug cap
-ignition pulse generator and exciter coi l

•
connectors
•
-crankcase breather tube
Remove the f o llowing from the clamp:

-carburetor drain tube
- crankcase breather tube
6-2
l oosen the rear axle nut and drive chain adjusters

to loosen the drive chain (page 3-12)

- fixing plate bolts
- fixing plate
- drive sprocket
- intake manifold bolts

- C-ring
- brake peda~ return spring
Supporl the - four bolts and footpeg bar

motorcycle
securely.
6-3
-engine hanger nuts and washers
Place the floor jack or other adjustable support

under the engine.
Remove the hanger bolts and the engine from the

•
frame.
CAUTION:
During engine assembly removal, hold the engine

securely and be careful not to damegtl the frame
and engine.
ENGINE INSTALLATION
Install the engine onto the frame in the reverse
•
order of removal.
NOTE :
• Note the installation of the hanger bolts. All bolts

are Installed from left side.
•
• The jack height must be continually adjusted to
relieve stress from the hanger boilS.
Tighten the hanger nuts to the specified torque.
TORQUE: 31 N·m (3.2 kgf·m, 23Ibf.tt)

•
Install the removed parts from engine removal
procedure (page 6-2 to 6-3) in the reverse order of
removal.
NOTE:
•
• Replace the intake manifold D-ring w ith a new
one.
• Note the installation of the brake pedal return
spring.
TORQUE:
•
Fixing plate bolt: 12 N·m (1.2 kgf·m, 9Ibf·ft)

- left crankcase cover (page 10-8)
- exhaust system (page 2-5) •
Adjust the drive chain slack (page 3-12).
Fill the recommended engine oil (page 3-9).
6-4 •
MEMO
CYLINDER HEAD/VALVES
12 N·m (1.2 kgf.m, 9 .

•
11 N·m (1.1 kgf.m • albf·n) •

•
9 N·m (0.9 . 6.5Ibf·ft)
7-0 •
7. CYLINDER HEAD/VALVES
SERVICE INFORMATION 7-1 CAMSHAFT REMOVAL 7-3
TROUBLESHOOTING 7-2 CYLINDER HEAD 7-4

CYLINDER COMPRESSION 7-3 CAMSHAFT INSTALLATION 7-15
SERVICE INFORMATION
GENERAL
• This section covers service of the cyl inder head, va lves and camshaft.
• The cyl inder head, valves and camshaft services can be done with the engine installed in the fra m e.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air befo re
inspection.
• Camshaft lubricating oit is fed through oil passages in the cylinder head. Clean the oil passages before assembling
cylinde r head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
• Refer to section 10 for cam chain tensioner service.
SPECIFICATIONS
valve guide
Valve stem
TOROUE VALUES
Cylinder head nut 11 N·m (1.1 kgf·m ,8 Ibf·ft)

Cylinder head right side cover bolt 10 N·m (1.0 kgf.m, 7Ibf·ft)
Cam sprocket bolt 9 N·m (0.9 kgf·m, 6.5 Ibf·ft)
7-1
•
TOOLS
Valve spring compressor 07751 -00 10000
Valve spring compressor attachment 07959 - KM30101
Valve guide driver, 5.0 mm 07742-MA60000
Valve guide reamer, 5.0 mm D7984 - MA60001 or 07984- MA6000C (U.S.A. only)
Valve seat cutters - These are commercially available in U.S.A.
Seat cutter, 24 mm (45 0 IN) 07780 - 0010600
Seat cutter, 20.5 mm (450 EX) 07780-0011000
Flat cutter, 24 mm (32 0 IN) 07780- 0012500
Flat cutter, 21.5 mm (32 0 EX) 07780 - 0012800
Interior cutter, 22 mm (60° IN/EX) 07780 -0014202
Cutter holder, 5 mm 07781 - 0010400
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by
tracing engine noises to the top-end with a sounding rod stethoscope.
•
• If the performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky check
for a seized piston ring (Section 8).
Compression too low, hard starting or poor performance at excessive noise

low speed • Cylinder head:
• Valves: -I ncorrect valve clearance
- Incorrect valve clearance -Sticking valve or broken valve spring
-Burned or bent valve -Damaged or worn camshaft
-Incorrect valve timing -Loose or worn cam chain
-Broken valve spring -Worn or damaged cam chain
-Uneven valve seating -Worn or damaged cam chain tensioner (section 10)
• Cylinder head: -Worn cam sprocket teeth
- Leaking or damaged head gasket -Worn rocker arm and/or shaft
-Warped or cracked cylinder htlad • Worn cylinder, piston or piston rings (section 8)
• Worn cylinder, piston or piston rings (saction 8)
Rough idle
Compression too high, overheating or knocking • l ow cyli nder compression
• Excessive carbon build-up on piston crown or on combus·
tion chamber
Excessive smoke
• Cyli nder head:
- Worn valve stem or valve guide
-Damaged stem seal
• Worn cylinder, piston or piston rings (section 8)
7-2
CYLINDER COMPRESSION COMPRESSION
Warm up the engine to normal operating tempera-

ture.
Stop the engine and remove the spark plug (page
3-6).
Install a compression gauge.

Shift the transmission in neutral and open the
choke lever (OFF).
Open the throttle all the way and crank the engine
with the kicksterter until the gauge reading stops
rising.
COMPRESSION PRESSURE:
981 - 1,177 kPe (10.0 - 12.0 kgf/cm2 , 142 - 171
psi) at 1,000 rpm
Low compression can be caused by:

- Blown cylinder head gasket
-Improper valve adjustment
-Valve leakage
-Worn piston ring or cylinder
High compression can be caused by:
- Carbon deposits in combustion chamber or on
piston head
CAMSHAFT REMOVAL
Drain the engine oil (page 3-9),
-valv8 adjuster hole cap (page 3-7)
- left crankcase cover (page 10-2)
- sealing bolt, tensioner spring and tensioner push
rod to loosen the cam chain tensioner (page 10-4)
Disconnect the spark plug cap.

loosen the cylinder head side cover 6 mm bolt.
Tap the head of the 6 mm bolt and release the
cylinder head left side cover from the cylinder head.
Remove the 6 mm bolt, seating washer and cylin-
der head left side cover.
Turn the crankshaft counterclockwise, and align the

"0" mark on the cam sprocket with the index
notch on the cylinder head.
Secure the cam Remove the bolts, cam sprocket and dowel pin.
chaIn with a piece
of w/re to pravent
It from faffing into
the cylinder.
7-3
•
Loosen the \/al\le adjusting screw fully to make 8
valve clearance maximum (page 3·8).
Temporarily install the cam sprocket bolts into the
camshaft and remove the camshaft from the cylin-
der head while holding the rocker arms.
INSPECTION
Turn the outer race of the each camshaft bearing
with your finger.
The outer race should turn smooth ly and quietly.
Also check that the bearing inner race fits tightly on
the camshaft.
Replace the camshaft assembly jf the outer race
does not turn smoothly and quietly. or if it fits
loosely on the camshaft.
Using a mjc~ometer. measure each cam lobe

height.
SERVICE LIMITS:
IN : 19.66 m m (0.774 in)
EX: 19.65 mm (0.77 4 in)
CYLINDER HEAD
REMOVAL
- Muffler (page 2-4)
-Camshaft (page 7·3)
Remove the intake manifold bolts.
7-4

- Cap nuts/sealing washers
- Nut/sealing washer
- Cylinder head cover
- Gasket
Remove the cylinder head mounting bolt and cyl in-

der head.
Remove the followi ng:

- Gasket
- Dowel pins
- Collar
- O-ring
C-RING!
COLLAR
DISASSEMBLY RIGHT SIDE COVER

Remove the spark plug.
Remove the bolts and cylinder head right side
cover.
Temporarily install a 8 mm bolt to the rocker arm

shaft and remove the rocker arm shafts and rocker
arms.
7-5
Remove the valve spring cotters using the special

tools as shown.
TOOLS:
Valve spring compressor 07757-0010000
Valva spring compressor attachment
07959-KM30101
CAUTION :
To prevent 1055 of tension. do not compress the

vlllv8 springs more than necessary to remove th"
cotters.
Mark all parts Remove the f ollowi ng:

during -Spring retainer
SPRING SEAT
dlssssembly so -Valve spring
they can be placed -Valve
back in their - Stem seal STEM SEAL
."~~\
origina/locations. - Valve spring seat
RETAINER
INSPECTIQN
CYLINDER HEAD
Remove ca rbon deposits from the combustion
chamber.
AvoId damaging Check the spark plug hole and va lve areas for
the gasket surface. cracks.
Check the cylinder head for warpage with a straight

edge and feeler gauge.
SERVICE UMIT: 0.05 mm (0.002 in)
7-6 •
ROCKER ARM
If either rocker Inspect the rocker arm slipper surfaces for wea r or
arm requires damage.
service or Also check that the oil holes are not clogged.
rep/aeamant,
inspect t!lecem Measure the rocker arm 1.0.
lobes for scoring,
chipping or flat SERVICE LIMIT; IN/EX: 10.10 mm (0.398 in)
spots.
Inspect the rocker arm shafts for wear or damage.
Measure the 0.0. of the rocker arm shaft.
SERVICE LIMIT: IN/EX: 9.91 mm (0.390 in)
VALVE SPRING
Measure the free length of the inner and outer
valve springs.
SERVICE LIMITS: IN/EX: 3 1.8 mm (1.25 in)
Replace the springs if they are shorter than the

service limits.
VALVE
Inspect each valve for bending, burning or abnor-
mal stem wear.
Check valve movement in the guide.
Measure and record each valve stem 0.0.
SERVICE LIMIT: IN/EX: 4.92 mm (0. 194 in)
7-7
•
Ream the guides to remove any carbon deposits
before measuring the guide.
Insert the reamer from the combustion chamber
side of the head and always rotate the reamer
clockwise.
•
TOOL:
Valve guide reamer, 5.0 mm 07984 - MA60001or
07984-MA60aOC
(U.S.A. only)
Measure and record each valve guide 1.0.
SERVICE LIMIT: IN/EX: 5.03 mm (0.198 in)
Subtract each valve stem 0.0. from the correspond-

ing guide 1.0. to obtain the stem-te-guide clearance.
SERVICE LIMITS:
IN: 0.08 mm (0.003 in)
EX: 0.10 mrn (0.004 in)
Reface the ve/V9 If the stem-te-guide clearance is out of specification,

seats whenever detemermine if a new guide with standard dimen-
the valve guides siens would bring the clearance within tolerance. If
are rep/aced so, replace any guides as necessary and ream to fit.
(page '-9). If the stem-to-guide clearance is out of specification
with a new guide, also replace the valve.
•
VALVE GUIDE REPLACEMENT GUIDE DRIVER
Chill new valve guides in the freezer section of a

refrigerator for about an hour.
Heat the cylinder head to 212 - 30rF (100 - 150°C)
with a hot plate or oven. •
To avoid burns, wear heavy gloves whtm handling
the heated cylinder head.
CAUTION:
Do not use a torch to heat the cylinder head; it may

cause warping.
Support the cylinder head and drive out the valve

•
guides out of the cylinder head from the
combustion chamber side.
TOOL:
Valve guide driller, 5.0 mm 07942- MA60000
7-8 •
Coat new O-rings with eng ine oil and install them
onto new valve guides.
While the cylinder is still heated, drive the guides in
the cylinder head from the camshaft side until they
are fully seated.
TOOL:
Valve guide driver, 5.0 mm 07942 - MA60000
Let the cylinder head cool to room temperature.
Ream the new valve guide after installation.

Insert the reamer from the combustion chamber
side of the head and always rotate the reamer
clockwise.
TOOL:
Valve guide reamer, 5.0 rnm 07984 - MA60001 or
07984 - MA6000C
(U.S.A. only)
NOTE:
Use cuning oil on the reamer during this operation.
Clean the cylinder head thoroughly to remove any

metal particles.
Reface the valve seat (see below)
VALVE SEAT INSPECTION/REFACING

Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to the valve
seats. lap the valves and seats using a rubber hose
or other hand·lapping tool.
Remove and inspect the valves.

CAUTION:
The valves cannot be ground. If a valve face i,

burned or badly worn or if it contacts the seat
unevenly, replace the valve.
//~
Inspect the width of each valve seat.
t
STANDARD: 1.0 - 1.3 mm (0.04-0.05 in)
If the seat is too wide, too narrow or has low spots,

\
the seat must be ground.
7-9
•
VALVE SEAT REFACING VALVE SEAT CUnERS (EQUIVALENT COM-
MERCIAl LYAVAILABLE IN U.S.A.)
Valve seat cutters/grinders or equivalent valve seat
refacing equipment are recommended to correct
worn valve seats.
•
NOTE:
Follow the refacing manufacturer's operating in-

structions. IN: 07180 - 0012500 (24 mm/30·)
EX: 077S0 - 0012800 (21.5 mm/32°)
IN: 07780 - 0010600 (24 mm)

EX: 07780-001 1000 (20.5 mm)
IN, EX 07780 - 0014202 (22 mm)
Refaee the seat Use a 45·dsgree cutter to remove any roughness or

wilha45-degree irregularities from the seat.
ROUGHNESS
cutler whenever a
valve guide is
replaced.
/
Use a 32-degree (IN: 30°) cutter to remove the top

1/4 of the existing valve seat material.
OLD SEAT WIDTH •
7-10 •
Use a 6O-degree cutter to remove the bottom 1/4 of

the old seat.
Remove the cutter and inspect the area you have OLD SEAT WIDTH
retaced.
Install a 45-degree finish cutter and cut the seat to

the proper width.
Make sure that all pitting and irregularities BTe re-
moved.
Refinish if necessary.
45·
Apply 8 thin ,coati ng of Prussian Bl ue to the valve

seat.
Press the valve through the valve guide and onto
CONTACT TOO HIGH
the seat to make a clear pattern.
OLD SEAT
WIDTH
-
NOTE :
The location of the valve seat in relation to the

valve face is very important for good sealing.
If the contact areB is too high on the valve, the seat

must be lowered using 8 32-degree flat cutter.
If the contact area is too low on the valve, the seat

must be raised using a 50-degree inner cutter.
CONTACT TOO LOW
Refinish the seat to specifications, using a 45·
degree finish cutter.
7-11
•
After cutting the seat, apply lapping compound to
the vlIlve face, and lap the valve using light pres-
sure.
DonolBllow After lapping, wash 811 residual compound off the

lapping compound cylinder head and valve.
to entef the guides.
ASSEMBLY
CYLINDER HEAD ®~
~Jf~~
RIGHT SIDE COVEA
GASKET
-\--~---qJ)~
ROCKER ARM SHAFT
•
ROCKER ARM
\0 ~ O-R ING
VALVE GUIDE
iQ STEM SEAL
VALVE SPRING
SPRING RETAINER CAMSHAFT
VALVE COTTERS
Clean the cylinder head assembly with solvent and

blow through all oil passages with compressed air.
SPRING SEAT
Install the valve spring seats.
InstaU new stem seals.
Lubricate the valve stems with engine oil and insert

the va lve into the va lve guide.
To avoid damage to the stem seal. turn the valve
slowly when inserting.
Install the va lve springs with the tightly wound

coils fa cing the combustion chamber.
Install the va lve spring retainer. RETAINER
7-12 •
I'
Install the valve cotters using the special tool as

shown.
TOOL:
Valve spring compressor 07757 - 0010000
Valve spring compressor attachment
07959 - KM30101
CAUTION:
To prellent loss of tension, do not compr&ss the

valvB spring mora than nfJCessary.
Tap the va lve stems gently with two plastic

hammers as shown to seat the cotters firmly.
CAUTION :
Support the cylinder hBad above the work bench

50 that the valve hll.ds will not contact anything
that cause damage.
Apply engine.oil to the rocker arm inner and slipper

surfaces.
Install thB rocker Install the rocker arms and rocker arm shafts.
8rm shaft with Its
thrasdtKf and
facing th6 right
side.
Install a new gasket onto the cylinder head right SIDE CO',"R
side COV9r,
Install the right side cover onto the cylinder head.
7-13
Install the right side cover bolts. BOLTS
INSTALLATION
Clean off the gasket material from the cylinder sur-
face.
Install the follqwing:

- New O-ring
-Collar
- Dowel pins
-New gasket
Route the cam chain through the cyli nder head and
install the cylinder head.
Ins/all the cylinder Install a new gasket onto the cylinder head and
head cover with then install the cylinder head cover.
its arrow mark
facing down.
7-14 •

-Cap nutS/new sealing washers
- Nut/new sealing washer
NOTE:
Note the position of the washers and nuts.
Tighten the cylinder head cover nuts to the speci-

fied torque.
TORQUE: 11 N·m( 1.1 kgf.m,8tbf·ft)
Install and tighten the cylinder head mounting bolt.

If the cylinder was removed, tighten the cylinde r
mounting bolt.
Install a new a'ring into the groov9 in the intake

manifold.
Install and tighten the intake manifold botts.

- Spark plug (page 3-7)
- Muffler (page 2-4)
- Camshaft (see below)
CAMSHAFT INSTALLATION
Apply clean engine oil to the ca mshaft lobes and
bearings.
Install the camshaft into the cylinder head with its

cam lobes facing the combustion chamber while
holding the rocker arms.
7-15
•
Turn the crankshaft counterclockwise and align the
"T" mark with the index notch on the left crankcase.
Install the dowel pin and cam sprocket.
NOTE:
Install the cam sprocket with its "0" mark with the
index notch on the cylinder head.
Install and tighten the cam sprocket bolts to the

specified torque.
TORQUE: 9 N·m (0.9 kgf.m I 6.5 Ibf·ft)
Install the cyljnder head left side cover onto the

•
cylinder head with a new gasket.
Set the tab on the side cover against the left side of
the stopper on the cylinder head.
Install the 6 mm bolt with a new sealing washer

into the cylinder head and tighten it.
Tighten the two right side cover bolts if the cylinder

head was disassembled.
Install the spark plug cap.
TORQUE: 10 N·m (1.0 kgf·m, 7Ibf.ft)
7-16 •
Install the tensioner push rod, spring and sealing

bolt (page 10-5).
Adjust the valve clearance (page 3-7).

Pour the recommended engine oil (page 3-9).
7-17
CYLINDER/PISTON
•
•
10 N·m (1.0 kgf.m , 7 Ibf·ft)
8-0 •
8. CYLINDER/PISTON
SERVICE INFORMATION 8-1 CYLINDER/PISTON INSPECTION 8-4
TROUBLESHOOTING 8-2 PISTON INSTALLATION 8-7
CYLINDER REMOVAL 8-3 CYLINDER INSTALLATION 8-7
PISTON REMOVAL 8-3
SERVICE INFORMATION
GENERAL
• The cylinder and piston service can be done with the engine installed in the frame .
• Camshaft lubrication oil is fed to the cylinder head through an orifice in the cylinder head, cylinder and crankcase. Be
sure that this orifice is not clogged and that the O-rings and dowel pins BrB in place before installing the cylinder.
SPECIFICATIONS
Unit: mm
I .
piston rings
9'P
TORQUE VALUES
Cam chain guide roller pin bolt 10 N·m (1.0 kgf.m, 7lbf·fU
8-1
CVUNDER/PISTON
TROUBLESHOOTING
-If the performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky. check
for a seized piston ring.
Cylinder compression is too low, or engine is hard to start Piston sounds

• Blown cylinder head gasket • Worn cylinder, piston and/or piston ring
• Worn, stuck or broken piston ring • Worn piston pin hole and piston pin
• Worn or damaged cylinder or piston • Worn connecting rod small end
Cylinder compression is too high, or engine overheats or Excessive smoke

knocks • Worn, stuck or broken piston ring
• Carbon depositas on the cylinder head and/or piston crown
8-2 •
CYLINDER/PISTON
CYLINDER REMOVAL
Remove the cylinder head (page 7 -4).
Remove the cam chain guide roUer pivot boll,

washer and guide roller.
Remove the mounting bolt and cylinder.

-Rubber packing
-Gasket
-Dowel pins
PISTON REMOVAL
Do nollet the Remove the piston pin clip with pliers.
piston pin clips fall
into the cranKcase. Press the piston pin out of the piston and remove
the piston.
Do not damage the Remove the piston rings.

pis/on rings during
removal.
8-3
CYLINDER/PISTON
CYLINDER/PISTON INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder 1.0. in X and Y exis at three
levels.
Take the maximum reading to determine the cylin-
der wear.
Calculate the piston-to-cylinder clearance.

Take a maximum reading to determine the clear-
ance.
Refer to page 8·5 for measurement of the piston O.
O.
SERVICE LIMIT: 0.15 mm (0.006 in) y
Calculate the taper and out of round at three levels

in X and Y axis. Take the maximum reading to
r,1':
determine them.
TOP x
SERVICE UMITS: MIDDLE
Taper: 0.10 mm (0.004 in)
Out of round: 0.10 mm (0.004 in) I
BOTTOM t'--
The cylinder must be rebored and an oversize
piston fitted if the service limit s are exceeded.
The following oversize pistons are available:

0.25 mm (0.010 in)
0.50 mm (0.020 in)
The piston to cylinder clea rance for the oversize pis-

ton must be: 0.010 - 0.040 mm (0.0004 - 0.0016
in).
Inspect the top of the cylinder f or warpage.
Remove any carbon deposits f rom the piston ring

grooves, using an old piston ring as shown.
8-4
CYLINDER/PISTON
Temporarilv install the piston rings to their proper

position with the mark facing up.
Measure the piston ring-to-ring groove clearance

with the rings pushed into the grooves.
SERVICE LIMITS:
Top: 0.12 mm (0.005 in)
Second: 0.12 mm (D.OOS in)
Inspect the piston for wear or damage.
Measure the diameter of the piston at 8 mm (0.3 in)

from the bottom and 90 degrees to the piston pin
hole.
SERVICE LIMIT: 38.90 mm (1.53 1 in)
Measure the "islon pin bore.
Measure the 0.0. altha piston pin .
SERVICE LIMIT: 12.98 mm (0.51 1 in)
Calculate the piston-ta-piston pin clearance.
8-5
CYLINDER/PISTON
Measure the connecting rod small end 1.0.
Calculate the connecting rod-te-piston pin

clearance.
Push the rings Inlo Insert the piston ring squarely into the bottom of
thacylinder with the cylinder and measure the ring end gap.
the top of the
piston to b8 sure SERVICE LIMITS:
they BrB squarely Top: 0.5 mm (0.02 in)
in lila cylinder. Second: 0.5 mm (0.02 in)
0111,100 ,ail): 1.1 mm (0.04 in)
PISTON RING INSTALLATION

Clean the piston ring grooves thoroughly and
install the piston rings.
NOTE:
• Apply oil to the piston rings. ~--c/TOP RING

• Avoid piston and piston ring damage during
installation.
• Install the piston rings with their marking facing
~~- SECOND RING
up.
• Do not confuse the top and second rings.
Space the piston ring end gaps 120 degrees apart.

Do not align the gaps in the oil rings (side rails).
After installation, the rings should rotate freely in

the ring grooves.
8-6
CYLINDER/PISTON
PISTON INSTALLATION
Apply o il to the piston pin outer surface.
Install the piston with its "IN" mark facing the
intake side.
Install the piston pin and secure it with new piston
pin dips.
NOTE:
• Do not align the piston pin clips end gap with the
piston cut-out.
• Do not let the piston pin clips fall into the
crankcase.
CYLINDER INSTALLATION
Clean off any gasket materials from the crankcase
surface.
Install the dowel pins, new gasket and new rubber

packing.
Coat the cylinder bore, piston outer surface and

piston ring grooves with clean engine oiL
Route the cam chain through the cylinder and
install the cylinder while compresSing the piston
rings.
NOTE:
• Avoid piston ring damage during installation.

• Do not let the cam chain fall into the crankcase.
8-7
CYLINDER/PISTON
Apply engine oillO the guide roller inner surface.

Install the cam chain guide railer, new sealing
washer and pin bolt.
Tighten the cam chain guide roller pin bolt to the
specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 Ibf·ft)
Install the cylinder mounting bolt but do not tighten

it yet.
Install the cylinder head (page 7-14),
~ GUIDE ROI_LEF
8-8
MEMO
CLUTCH/GEARSHIFT LINKAGE
17 N·m (1.7 . ,12Ibf.ft)
13 N·m (1.3 9Ibf·ft)
•
42 N·m (4.3 kgf.m. 31
9-0 •
9. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION 9·1 CLUTCH 9·4
TROUBLESHOOTING 9·2 GEARSHIFT LINKAGE 9·14
RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER
REMOVAL 9·3 INSTALLATION 9·17
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the
frame.
• Use care not to allow dust or dirt to enter the engine.
• Transmission oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the
motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system.
SPECIFICATIONS

disc .
I .
TOROUE VALUES
Clutch outer cover screw 5 N·m (0.5 kgf.m .3.6Ibf·ft)

Clutch lock nut 42 N·m (4.3 kgf·m. 31 Ibf.ft)
Clutch assembly screw 6 N·m (0.6 kgf.m , 4.3Ibf·ft)
Shift drum stopper arm bolt 13 N·m (1.3 kgf.m, 9Ibf·ft)
Shift return spring pin bolt 29 N·m (3.0 kgf.m ,22 Ibf·ft)
Gearshift cam plate bolt 17 N·m (1.7 kgf.m, 12Ibf·ft)
TOO LS
Flywheel holder 07725 - 0040000 Equivalent commercially available in U.S.A.

lock nut wrench, 20 X 24 mm 07716 - 0020100
Extension bar 07716 - 0020500 Equivalent commercially available in U.S.A.
9-1
TROUBLESHOOTING
Clutch slips when accelerating Hard to shift
-Incorrect clutch adjustment • Incorrect clutch adjustment
• Worn clutch disc • loose stopper plate bolt
• Weak clutch springs • Damaged stopper plate and pin
• Faulty clutch weight • Damaged gearshift spindle
• Transmission oil mixed with molybdenum or graphite
additive Transmission jumps out of geBr
• Worn shift drum stopper arm
Motorcycle creeps with clutch disengaged • Weak or broken shift arm return spring
• Incorrect clutch adjustment • Loose st opper plate bolt
• Clutch plate warped
• Faulty clutch lifter Gearshift pedal will not return
• Faulty clutch weight • Weak or broken gearshift spindle return spring
-Incorrect engine oil weight • Bent gearshift sp indle
9-2 •
RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil (page 3-9).
Remove the footpeg bar (page 6-3),
Remove the bolt and kickstarter pedal.
Unhook the brake pedal return spring.

Loosen the rear brake pedal adjusting nut and
lower the brake pedal.
Remove the eight bolts and right crankcase cover.
Remove the gasket and dowel pins.
Remove the clutch adjusting nut. washer and D-

ring.
RemO\lB the clutch lifter/adjusting bolt assembly.
9-3
Check the kickstarter oil seal for damage, replace if

OIL SEAL
necessary.
CLUTCH
REMOVAL
Remove the ball retainer and spring.
Remove the clutch lifter lever.
Remove the oiJ through and spring.

Remove the clutch lifter cam plate.
Remove the screws and clutch outer cover and

bearing.
9-4 •
Straighten the tab of the lock washer.
Hold the clutch outer w ith the flywheel holder and

remove the lock nut using the special tools as
shown.
TOOLS:
Flywheel hold., 07725 - 0040000
(Equivalent com-
mercially available
in U.S.A.)
Lock nut wrench, 20 X 24 mm 07716 - 0020100
Extension bar 07716 - 0020500
(Equivalent com-
mercially available
inU.SA)
Remove the lock washer B, 14 mm lock washer and

clutch assembly.
Remove the primary drive gear.
9-5
Remove the clutch center guide.
Remove the snap ring and primary driven gear

from the mainshaft.
Remove the collar from the crankshaft.
DISASSEMBLY SET RING PLATES AND DISCS

-Set ring
-Clutch plate 8
-Clutch disc A
-Clutch disc B
-Clutch disc A
-Free springs
-Clutch plate A
Remove the clutch center and drive gear outer. CLUTCH CENTER
9-6
Remove the four damper springs.

SCREWS AND WASHERS
Remove the four screws and plain washers.
DAMPER SPRING:
Remove the drive plate assembly and clutch DRIVE "LA I h

springs. ASSEMBLY
Remove the clutch weight stopper ring. CLUTCH WEIGHT/CENTER RING

Remove the clutch weight/center ring.
INSPECTION BEARING
Clutch lifter bearing

Turn the inner face of the lifter bearing with your
finger.
The bearing should turn smoothly and freely
w ithout excessive play.
Also check that the bearing fits tightly in the clutch
outer cover.
If necessary replace the bearing.
9-7
Clutch spring
Measure the clutch spring free length.
Clutch disc
Replace the clutch discs if they show signs of
scoring or discoloration.
Measure the disc thickness of each disc.
SERVICE LIMITS:
Clutch disc A: 2.3 mm (0.09 in)
Clutch disc B: 3.0 mm (0.12 in)
Clutch plate .
Check each disc plate for warpage on a surface
plate using a feeler gauge.
Primary drive gear/clutch center guide

Check the primary drive gear and clutch center
guide for excessive wear or damage.
Measure the 1.0. of the primary drive gear.
Measure the 0.0. and 1.0. of the clutch center guide.
SERVICE LIMITS:
1.0.: 17.04 mm (0.671 in)
0.0.:20.90 mm (0.823 in)
9-8
Crankshaft
Measure the crankshaft 0.0 at clutch center guide.
Drive gear outer/clutch center

Check the drive gear outer and clutch center for
excessive wear or damage.
ASSEMBLY
WEIGHT/CENTER RING
GEAR OUTER
FREE SPRING
_ _ I CLUTCH DISC A
~",__. CLUT'eH PLATE B
CLUTCH OUTER
CLUTCH cEN;TER
CLUTCH PLATE A
9-9
•
Install the clutch weight/center ring onto the drive CLLJTCJY WEI,GHT/I:ENITER RING
plate by aligning the ring end with the plate hole.
Install the stopper ring by aligning the ring end with
the plate groove.
•
STOPPER RING
Install the clutch springs onto the dutch outer holes.

Install the drive plate assembly into the clutch outer
aligning its bosses with the clutch springs.
DRIVE PLATE
ASSEMBLY
•
Install the plaill washers and screws.

Tighten the screws in a crisscross panern in 2- 3
steps.
TOROUE: 6 N·m (0.6 kgf·m , 4.3 Ibf·ft)

•
Install the damper sprin gs as shown.
•
•
9-10 •
Install the drive gear outer and clutch center.

DRIVE GEAR OUTER

-Clutch plate A
-Free springs
-Clutch disc-A
-Clutch disc B
-Clutch disc A
-Clutch plate 8
NOTE:
• Install the clutch disc A with its flat surface facing

the clutch disc 8 .
• Install the clutch plate 8 with its chamfered side
f acing the clutch disc A.
-"10ISCB PLATE B
Install the clutch set ring with its chamfered side

SET RING
facing the clutch plate B.
9-11
INSTALLATION
Install the collar onto the crankshaft.
Install the primary driven gear onto the mainshaft

and secure it with the snap ring.
Apply engine oil to the clutch canter guide and

install it onto the crankshaft.
•
Install the primary drive gear.
Install the clutch assembly onto the crankshaft.
Install a new 14 mm lock washer by aligning its

short tabs with the grooves in the drive plate.
9-12 •
• CLUTCH/GEARSHIFT LINKAGE
Install the lock washer B with its "OUT SIDE" mark

facing out.
Install the lock nut.

Hold the clutch outer with the flywheel holder and
tighten the lock nut to the specified torque using
the special tools as shown.
TOOLS:
Flywheel holder 07125- 0040000
(Equivalent com-
mercially available
in U.S.A.)
locknutwrench,20 x 24mm 07716- 0020100
Extension bar 07716 - 0020500
(Equivalent com-
mercially available
in U.S.A.)
TORQUE: 42 N·m (4.3 kgf.m ,31Ibf·ft)
If the lock nut groove does not align with the lock
washer tab, further tighten the lock nut and align.
Bent up the tab of the 14 mm lock washer into the

groove of the lock nut.
Clean the inside of the dutch outer and outer cover

(page 3-10).
Install the bearing and a new gasket onto the clutch

outer cover.
9-13
CLUTCH/ GEARSHIFT LINKAGE
Install the clutch outer cover and tighten the screws

to the specified torque.
TORQUE: 5 N·m (0.5 kgf.m, 3.6Ibf·ft)

•
Install the clutch lifter cam plate.

Install the oil through spring and oil through.
•
Install the spri.ng, ball retainer and clutch lifter lever.
Install the right crankcase cover (page 9·17).
•
GEARSHIFT LINKAGE
REMOVAL
Remove the clutch and pri m ary dr iven gea r (page
•
9-4).
Clean the Remove the bolt and gearshift peda l.

gearshift spindle
end to prevent dirt
from enltNing the
crankcase.
9-14 •
Remove the bolt, stopper arm and return spring.
Pull down the gearshift arm, then pull oul the

gearshift spindle from the crankcase.
Remove the I.}olt and shift cam plate.
Remove the dowel pins and gearshift drum pins.
9-15
CLUTCH/GEARSHIFT UNKAGE
INSPECTION
Check the gearshift spindle for bends or other
damage.
•
INSTALLATION
Install the four gearshift drum pi ns and two dowel
pins.
•
Install the cam plate a nd tighten the bolt to the
specified torque.
TORQUE: 17 N·m (1.7 kgf.m. 12 Ibf·ft)
Install the gearshift spindle into the crankcase by

aligning the return spring ends w ith the spring pin
while pushing dow n the gearshift arm and set the
gearshift arm to the shift drum pins.
9-16
CLUTCH/GEARSHIFT UNKAGE
Install the return spring and stopper arm as shown

and tighten the bolt to the specified torque.
TORQUE: 13 N·m (1.3 kgf·m, 9Ibf·ft)
Install the gearshift pedal so that it is same height

as the foot peg.
Install the pinch bolt end tighten it.
Install the primary driven gear and clutch assembly

(page 9-12).
RIGHT CRANKCASE COVER INSTALLA-

TION
Install the clutch lifter plate/adjusting bolt into the
right crankcase cover by aligning its pin with the
hole in the crankcase cover.
Coat a new D-ring with engine oil and install it into

the cover groove properly.
Install the washer and lock nut.
9-17
Install the dowel pins and a new gasket.
Install the right crankcase cover.

Install and tighten the eight cover bolts in a
crisscross pattern several steps.
•
Install the kic~starter pedal as shown and tighten
the bolt.
Hook the return spring to the brake pedal and
spring holding pin as shown.
Install the footpeg bar (page 6-4).

Adjust the brake pedal free play (page 3-15).
Pour the recommended engine oil (page 3-9),

Adjust the clutch (page 3-16).
9-18
MEMO
ALTERNATOR/CAM CHAIN TENSIONER
16 N·m (1.6 kgf·m, 12Ibf·ft)
23 N·m (2.3 kgf·m , 17 Ibf·ft) •
•
41 N·m (4.2 kgf·m, 30 Ibf·ft)
10-0 •
• 10. ALTERNATOR/CAM CHAIN TENSIONER
SERVICE INFORMATION 10-1 CAM CHAIN TENSIONER 10-4
TROUBLESHOOTING 10-1 STATOR/FL YWHEEL INSTALLATION 10-6

FLYWHEEL/STATOR REMOVAL 10-2
SERVICE INFORMATION
GENERAL
• This section covers service of the flywheel, alternator and cam chain tensionar. All service can be done with the engine
installed in the frame.
• Refer to section 14 for alternator stator inspection.
SPECIFICATIONS
Unit' mm (in )

Cam chain tensioner Push rod 0.0. 11.985 12.000 (0.4718 0.(724) 11.94 (0.470)
S rin free len th 111.3 (4.38) 100 (3.9)
I"
I TORQUE VALUES
Flywheel nul 41 N·m (4.2 kgf·m , 30 Ibf·ft)

Cam chain tensioner sealing bolt 23 N·m (2.3 kgf.m , 17 Ibf·ft)
Cam chain tensioner pivot bolt 16 N·m (1.6kgf·m . 12Ibf·ft)
TOOLS
Universal holder 07725 - 0030000
Flywheel puller 07933 - GEOOOOO Not available in U.S.A. or 07933 - 0010000 U.S.A.
only
TROUBLESHOOTING
Excessive engine noise
• Worn or damaged cam chain tensioner
• Clogged one-way valve
• Weak or damaged cam chain tensioner spring
Loose cam chain

• Weak or damaged cam chain tensioner spring
• Improper push rod operation
• Clogged one-way valve
• Air in cam chai n tensioner chamber
10-1
ALTERNATOR/CAM CHAIN TENS lONER
FLYWHEEL/STATOR REMOVAL
Disconnect the alternator and ignition pulse genera-
tor connectors. •
Remove the bolt and gearshift pedal.

•
•
Remove the three bolts and left crankcase cover.
Hold the flywheel using the universal holder and

remove the flywheel nut.
TOOl:
Universal holder 07725-0030000
Remove the washer.
10-2 •
Remove the fl ywheel using the special tool.
TOOL:
Flywheel puller 07933 - GEOOOOO
(Not available in U.S.A.)
Flywheel puller 07933 - 0010000
(U.S.A. only)
Remove the woodruff key.
Remove the bolt and wire clamp.

Release the wire grommet from the crankcase
groove.
Remove the four mounting bolts and wire clamp,

and the ignition pulse generator and stator as an
assembly.
10-3
Drain the engine oil (page 3-9).
Remove the screws and stator base.
Remove the O-rings.
CAM CHAIN TENSLONER

REMOVAL
Remove the stator base (page 10-2),
Remove the sealing bolt, tensioner spring and push

•
rod.
SEALING
Remove the pivot bolt, tensioner arm and tensioner

roller.
10-4 •
INSPECTION
Measure the tensioner spring free length .
SERVICE UMIT: 100 mm (3.9 in)
Check the push rod for wear or damage.

Measure the push rod 0.0 .
INSTALLATION
Install the cam chain tensioner roller, tensioner arm
and pivot bolt.
Tighten the pivot bolt to the specified torque.
TORQUE: 16 N·m (1,6 kgf.m . 12Ibf·ft)
Check the sealing washer is in good condition,

replace if necessary.
Install the push rod, spring, washer and sealing bolt.
Tighten the sealing bolt to the specified torque.
TORQUE: 23 N·m 12.3 kgf·m , 17 Ibf·ft)
10-5
Remove the crankcase sealing bolt and washer.

Fill the push rod w ith 1- 2 em' of engine oil
through the filler hole.
Check the sealing washer is in good condition and

install the seating washer and bolt.
Tighten the bolt securely.
STATOR/FLYWHEEL INSTALLATION
Check the stator base oil seat for damage, replace if
necessary.
Apply engine oil to the lip of the oil seal.
Apply engine oil to new O-rings, install them into

the crankcase grooves and stator base groove.
Install the stator base and tighten the screws se-

curely.
CAUTION:
Be careful not to damage the oil sea/lips.
10-6
Install the stator and ignition pulse generator with

the wire clamp and tighten the bolts securely.
Set the wire grommet into the crankcase groove.

Install the wire clamp and tighten the bolt.
Clean any oil from the tapered portion of the

crankshaft and flywheel.
Install the woodruff key into the crankshaft.
Install the flywhee l by aligning the key way In the

flywheel with the woodruff key on the crankshaft.
Install the washer and flywheel nut.
10-7
ALTERNATOR/CAM CHAIN TENS lONER
•
Hold the flywheel using the universal holder and
tighten the nut to the specified torque.
TOOL:
Universal holder 07725 - 0030000
TORQUE: 41 N·m (4.2 kgf·m, 30 tbf·ft)
•
Install the left crankcase cover and tighten the three
bolts.
Install the gearshift pedal so that it is same height

as the footpeg.
Install the pinch bolt and tighten it.
Connect the ignition pulse generator and alternator

connectors.
10-8
MEMO
"
CRANKSHAFT ITRANSMISSION/ KICKSTARTER
12 . ,9Ibf·ft)
11-0
11. CRANKSHAFTITRANSMISSION/KICKSTARTER
SERVICE INFORMATION 11-1 TRANSMISSION 11-6
TROUBLESHOOTING 11-2 KICKSTARTER 11-12
CRANKCASE SEPARATION 11-3 CRANKCASE ASSEMBLY 11-14
CRANKSHAFT 11-4
SERVICE INFORMATION
GENERAL
• The crankcas e must be separated to service the crankshaft, transmission and kickstarter .
• The fo llowing parts must be removed before separating the crankcase.
-Alternator/cam chain tensioner (Section 10)
-Clutch/gearshift linkage (Section 9)
-Cylinder head (Section 7)
-Cylinder/piston (Section 8)
-Engine (Section 6)
-Oil pump (Section 4)
SPECIFICATIONS
ITEM STANDARD
; I
TORQUE VALUES
Sh ift drum bolt 12 N·m 11.2 kgf·m, 9Ibf·ft)
11-1
CRANKSHAFT ITRANSMISSION/KICKSTARTER
•
TOOLS
Driver 07749 - 0010000
Attachment. 37 x 40 mm 07746 - 0010200
Pilot, 17 mm 07746 - 0040400
TROUBLESHOOTING
Hard to shift
• Incorrect clutch adjustment
• Bent shift fork
• Bent fork claw
• Damaged shift drum cam groove
• Incorrect transmission oil weight
Transmission Jumps out of gear

• Worn gear dogs and slots
• Bent fork shaft
• Broken shift drum stopper
Excessive noise
• Worn crankshaft big end bearing
• Worn crankshaft journal bearing
11-2
CRANKSHAFT/TRANSMISSION/KICKSTARTER
CRANKCASE SEPARATION
NOTE:
Refer t o Service Information (page 1 ,-1)

for
removal of necessary parts before separating the
crankcase.
Remove the snap ring from the kickstarter spindle.
Unhook the return spring and remove the retainer

and return spri ng.
Remove the rubber cap.
Remove the shift drum bolt and washer.
Remove the cam chain.
Loosen the seven crankcase bolts in a crisscross

pattern in 2- 3 steps and remove them.
11-3
CRANKSHAFT I TRANSMISSION/ KICKSTARTER
•
Place the crankcase w ith the left side down.
Separate the right and left crankcase halves.
Remove the gasket and dowel pins. DOV~EL PINS
CRANKSHAFT CRANKSHAFT
REMOVAL
Remove the cra nkshaft from the left cran kcase.
If necessary, remove the cam chai n guide spindle

and guide sprocket.
•
11-4
CRANKSHAFTITRANSMISSION/KICKSTARTER
INSPECTION
Measure the connecting rod big end side clearance
with a feeler gauge.
Measure the connecting rod big end radial clear-

ance at symmetrical points as shown.
Turn the outer race of the crankshaft bearing with

your finger.
The bearing should turn smoothly and quietly.
Also check that the inner race of the bearing fits
tightly on the crankshaft.
Check the timing sprocket fo r wear or damage.
If you replacing the timing sprocket, align the cen·

ter of the sprocket teeth with the center of woodruff
key groove as shown .
. 11-5
CRANKSHAfT/TRANSMISSION/KICKSTARTER
Place the crankshaft on a stand or V-blocks and

measure the runout using a dial gauge.
The measuring locations are shown in the illustra-
30 mm 0.2 in) 26 mm (1.0 in )
tion.
INSTALLATION
Install the guide sprocket and guide spindle.
Pour 1 - 2 cm~ of engine oil into the connecting rod CRANKSHAFT

big end bearing.
Install the crankshaft into the left crankcase, being
careful not t o interfere the connecting rod with the
crankcase.
As semble the crankcase halves (page 11 -14).
TRANSMISSION
REMOVAL •
Remove the kicksterter spi ndle (page 11-12).
Remove the mainshaft. countershaft and shift drum

as an assembly,
11-6
TRANSMISSION DISASSEMBLY COUNTERS HAFT
Disassemble the ffiainshaft, countershaft and shift

drum.
TRANSMISSION INSPECTION
Check the gear dogs. dog holes and teeth for abnor·
mal wear or lack of lubrication.
Measure the 1.0. of each gear.
SERVICE LIMITS:
M2: 17.10 mm (0.673 in)
Cl: 23.10 mm (0.909 in)
C3: 20.10 mm 10.791 in)
Measure the 1.0. and 0.0. of C1 gear bushing.
SERVICE LIMITS:
0.0.: 22.93 mm (0.903 in)
1.0.: 20.08 mm (0.791 in)
Calculate the C1 gear-ta-bushing clearance.
Check the shifter groolle of the shifter gear for

excessive wear or damage.
Measure the 0.0. of the mainshaft and counter-

shaft.
SERVICE LIMITS:
At M2 gear: 16.95 mm (0.667 in)
At C1 gear: 19.94 mm (0.785 in)
Calculate the M2 gear-ta-shaft clearance.
Calculate the C1 gear bushing-to-shaft clearance.

C1
11-7
CRANKSHAFT/TRANSMISSION/KICKSTARTER
TRANSMISSION ASSEMBLY
--:711: Gear sliding surface, gear teeth
Assemblv is in the reverse order of disassembly. - II and shifter groove
C3 GEAR (25T)
C2 G,EAR (25T)
GEAR (36T)
COUNTERSHAFT
M3 GEAR (2 1T)
M2 GEAR (15T)
~. ~-.
MAINSHAFT(Ml: l1TJ
GEARSHIFT DRUM DISASSEMBLY SHIFT

Remove the guide pin clips.
Remove the guide pins, then remove the shift forks.
GUIDE PIN
Inspect the shift drum grooves for wear or damage.
Measure the 0.0. of the shift drum.
11-8
Measure the shift fork 1.0.
SERVICE UMIT: 34,14 mm (1.344 in)
Measure the shift fork claw thickness.
SERVICE UMIT: 4.60 mm (0.18 1 in)
SHIFT DRUM ASSEMBLY
SHIFT FORK
GUIDE PIN
SHIFT DRUM
11-9
Apply engine oil to the shift drum outer surface.

Install the shift forks onto the gearshift drum.
Install the guide pins and secure them with the
clips.
CLIP
If the washer has been removed, install a new

washer and bend the tab to lock the washer.
WASHER
TRANSMISSION BEARING REPLACE·

MENT .
Turn the inner race of each bearing with your finger.

The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the crankcase.
Remove and discard the bearing if the race does
not turn smoothly, quietly, or fits loosely in the
crankcase.
Remove the countershaft oil seal.
11-10
CRANKSHAFT ITRANSMISSION/KICKSTARTER
Drive the mainshaft bearing out of the right RIGHT CRANKCASE:

crankcase.
Drive the countershaft bearing out of the left

crankcase.
Drive new bearings into the crankcases using the

special tools as shown.
TOOLS:
Driver 07749-0010000
Attachment, 37 X 4ij mm 07746 - 0010200
Pilot, 17 mm 07746 - 0040400
Apply engine oil to e new countershaft oil seal lip.

Install the countershaft oil seal.
11-11
TRANSMISSION INSTALLATION COUNTERSHAFT

L FORK
Apply clean engine oil to the transmission gears
R. FORK
and shift drum.
Set the right fork into the M3 gear and the left fork
into the C2 gear to assemble the mainshaft,
countershaft and shift drum as shown.
Install the mainshaft. countershaft and shift drum

as an assembly into the left crankcase.
Rotate the shift drum to check the transmission

operation.
Install the kickstarter spindle (page 11-14),
KICKSTARTER KICKSTAATER
SPINDLE
REMOVAL
Remove the kickstarter spindle from the right
crankcase.
DISASSEMBLY
Remove the washer.
Remove the snap ring and starter ratchet/spring.
RATCHET
•
11-12
CRANKSHAFT /TRANSMISSION/KICKSTARTER
Remove the snap ring, washer and starter pi nion

PINION GEAR
gear.
--SNAP RING
WASHER
INSPECTION
Check the kickstarter spindle for bending.
Check the friction spring fo r fatigue.
Check each part for wear or damage, replace if

necessary.
ASSEMBLY
Assembly is in the reverse order of disassembly.
.,,'o<n,mo SPINDLE
SNAP RING
PINION GEAR
FRICTION SPRING
SNAP RING
STARTER RATCHET
11-13
INSTALLATION KICKSTARTER
SPINDLE
Install the kickstarter spindle by aligning its friction
spring wi th the groove in the left crankcase as
shown.
Assemble the crankcase halves.
CRANKCASE ASSEMBLY DDINEL PINS
Clean the crankcase mating surfaces before assem~

bling.
NOTE:
Dress the surfaces with an oil stone jf necessary to

correct any minor roughness or irregularities.
Install the dowel pins and a new gasket onto the left
crankcase.
Make sura that the Install the right crankcase over the left crankcase.
gasket stays In
place. CRANKCASE
Install the seven bolts with the clamp and tighten

them in a crisscross panern in 2- 3 steps.
Apply engine oil to the cam chain and install it.

•
11-14
Install the washer and bolt to the shift drum, then

tighten the bott to the specified torque.
Insta ll the rubber cap.
Install the return spring and re tainer onto the

kickstarte r spindle.
Temporarily install the kickstarter pedal.
Install the spring ends onto the retainer and

crankcase lug as shown and press the retainer t o
set its edge against the stepped part of the
crankcase w hile turning the pedal counterclockwise.
Install the snap ring into the groove in the

kickstarter spindle securely.
11-15
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
74 N·m (7.5 54Ibf.ft)
N·m (2.0 kgf.m , 14Ibf·ft)
•
47 N·m (4.8 kgf.m ,35 Ibf·ft)
•
10 N·m (1,0 kgf·m, 7 Ibf·ft)
12-0
12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING
SERVICE INFORMATION 12-1 FRONT BRAKE 12-10
TROUBLESHOOTING 12-2 FORK 12-12
HANDLEBAR 12-3 STEERING STEM 12-15
FRONT WHEEL 12-5
SERVICE INFORMATION
GENERAL
R@*@'
A contaminated brake drum or shoe ,.duces stopping power. Discard contaminatBd shoes lind clelln II contaminated
drum with 8 high quality brake degrellsing IIgenf.
• When servicing the front wheet, brake, fork or steering stem, support the motorcycle using a safety stand or hoist.
SPECIFICATIONS
j:
runcut
i i
TORQUE VALUES
Handlebar mounting nut 20 N·m 12.0 kgf.m, 14Ibf·ft) U-nut

Engine stop switch holder screw 3 N·m (0.3 kgf.m , 2.2 Ibf·tt)
Brake lever pivot bolt 3 N·m (0.3 kgf.m ,2.2 Ibf·tt)
Brake lever pivot nut 3 N·m (0.3 kgf.m • 2.2 Ibf.ft)
Spoke nipple 2 N·m (0.2 kgf.m, 1.4Ibf·ft)
Front axle nut 47 N·m (4.8 kgf·m. 35Ibf·ft) U-nut
Front brake arm pinch bolt 6 N·m (0.6 kgf.m , 4.3 Ibf·ft) ALOe bolt
Fork protector bolt 10 N·m (1.0 kgf.m. 7 Ibf·ft)
Steering stem nut 74 N·m (7.5 kgf·m. 54lbf·ftl
Steering stem top thread See page 12-17
12-1
TOOLS
Spoke wrench, 4.1 X 4.5 mm 07701 - 0020100 Commercially available in U.S.A.
Bearing remover shaft 07746- 0050100 T Commercially available in U.S.A.
Bearing remover head, 12 mm 07746 - 0050300
Driver 07749 - 0010000
Attachment, 32 x 35 mm 07746 - 0010100
Pilot, 12 mm 07746 - 0040200
Pin spanner 07702 - 0020001
Ball race remover
Attachment, 37 x 40 mm
Steering stem driver
07944 - 1150001
07746- 0010200
07946 - GC40000 or Steering stem driver 07946-MBOOOOO with
•
Steering stem driver attachment
07946-GC4000A (U.S.A. only)
TROUBLESHOOTING
Hard steering Wheel turns hard
• Faulty or damaged steering head bearings • Faulty wheel bearing
• Insufficient tire pressure • Bent front axle
• Steering stem top thread too tight • Brake drag
Steers to one side or does not track straight Soft suspension

• Bent fork • Weak fork springs
• Bent axle • Tire pressure too low
• Wheel installed incorrectly
• Faulty steering head bearings Hard suspension
• Bentframe • Bent fork tubes
• Worn wheel bearing
• Worn swingarm pivot components Front suspension noisy
• Damaged or bent fork tubes
Front wheel wobbling • Loose fork fasteners
• Bent rim
• Worn front wheel bearings Improper brake performance
• Faulty tire • Incorrect adjustment of lever
• Unbalanced tire and wheel • Contaminated brake shoes
• Worn brake shoes
• Worn brake cam
• Worn brake drum
• Improperly engaged brake arm serrations
12-2
HANDLEBAR
REMOVAL
Remove the fuel tank breather tube from the
number plate and the number plate from the
steering stem nut.
Remove the wire bands.
Remove the two screws and engine slop switch!

throttle housing from the handlebar.
Disconnect the throttle cable and remove the

throttle grip.
Remove the left handlebar grip.

GRIP
12-3
Remove the two nuts and handlebar.
INSTALLATION
Install the handlebar into the fork top bridge and
tighten the mounting nuts.
Clean the inside surface of the left handlebar grip

and the outside surface oftha left handlebar. GRIP
Apply Honda Bond A or equivalent to the inside
surface of the left handlebar grip and to the out side
surface of the left handlebar. Wait 3 - 5 minutes
and install the grip.
Rotate the grip for even application of the adhesive.

NOTE:
Allowthe adhesive to dry for an hour before using.
Apply grease ,t o the throttle grip pipe flange and

install the throttle grip onto the right handlebar.
Connect the throttle cable to the throttle grip pipe

flange.
Install the engine stop switch/throttle housing onto

the handlebar, aligning the mating surface with the
punch mark on the handlebar.
Tighten the forward screw first, then the rear screw.
•
TORQUE: 3 N·m 10.3 kgf.m , 2.2 Ibf.ft)
12-4
Secure the engine stop switch wire with the wire

bands properly.
Install the number plate over the steering stem nut

end insert the breather tube into the hole in the
number plate.
Check the throttle grip operation and free play

(page 3-4).
FRONT WHEEL PROTECTOR

REMOVAL
A contaminated brake drum or shOll rsducfls

stopping power. Discard contaminated shoss and
c/tlBn a contaminated drum with 8 high quality
brake degre.sing 89ftnt.
Support the motorcycle securely using a safety

stand or a hoist.
Remove the brake cable from the cable holder on

the f ork protector.
Remove the two bolts and fork protector.
Disconnect the brake cable from the brake arm.

Remove the axle nut, axle and front wheel.
Remove the side collar and the brake panel from

the wheel hub.
12-5
INSPECTION
Axl.
Set the axle in V-blocks and measure the Tunout.
Actual runcut is 1/2 the total indicator reading.
SERVlCE LIMIT: 0.20 mm (0.008 in )
Wheel bearing
The bearings should turn smooth ly and quietl y.
Also check that the bearing outer race fits tightly in
the hub.
Always replaca Ifle Remove and discard the bearings if they do not
bearings in paJrs. turn smoothly, quietly, or if they fit loosely in the
hub.
Wheel rim runout

Check the rim runcut by placing the wheel in a turn-
ing stand.
Spin the w heel by hand, and read the runcut using
8 dial indicator.
Actual runcut is 1/2 1he total indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (O.OB in)
Axial: 2.0 mm (0.08 in)
DISASSEMBLY
Remove the dust seal.
•
12-6
Install the bearing remover head into the bearing.

From the opposite side, install the bearing remover
shah and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 12 mm 07746- 0050300
(Equivalent
commercially
available in U.S.A)
Bearing remover shaft 07746 - 0050100
(Equivalent
commercially
available in U.s.A)
ASSEMBLY
RIGHT WHEEL BEARING (6201U)
DISTANCE COLLAR
DUST SEAL
LEFT WHEEL BEARING (6201U)
CAUTION :
Never Insta" the old bearings. Once th" bearings

have been removed, the bearings must be replaced
with new ones.
Pack each wheel bearing cavities with grease.

Drive in a new left bearing squarely with its sealed
side facing out.
Install the distance collar and drive in a new right
bearing using the sama tools.
TOOLS:
Driver 07749 - 0010000
Attachment,32 x 35 mm 07746 - 0010100
Pilot, 12 mm 07746 - 0040200
12-7
Wheel center adjustment
~
Place the rim on the work bench.
Place the hub with the right side down and begin
lacing with new spokes.
Adjust the hub position so that the distance from 6.3 ± 1mm -
the hub left end surface to the side of rim is 6.3 ± ,
mm (0.25 ± 0.04 in) as shown. ,I \\
! I \
TOOL: 'W If)

~
Spoke wrench, 4.1 X 4.5 mm 07701 - 0020100
(Equ ivalent com-
merCially available
in U.S.A.)
- ~- _L"'-
TORQUE: 2 N·m (0.2 kgf.m. 1.4Ibf·ft)
Check the rim runout (page 12-81.
Apply grease to 8 new dust seal lips, then install it

into the right wheel hub.
INSTALLATION
Install the brake panel into the left wheel hub.
Install the side collar into the right wheel hub.
12-8
FRONT WHEEL/ BRAKE / SUSPENSION/ STEERING
Install the front wheel between the fork legs w h ile

aligning the brake panel groove with the boss on
the left fork tube.
Align
Apply a thin layer of grease to the front axle su rface.

Instal l the front axle from the right side.
Hold the axle and temporarily tighten the axle nut.
Install the spring and joint pin and connect the

brake cable.
Instal l the adjusting nut.
Adjust the front brake lever free play (page 3-14),
With the frol\t brake applied, pump the fork up and

down several times to seat the axle and check
brake operation.
n ghten the axle nut to the specified torque.
TORQUE: 47 N·m (4.8 kgf.m ,35 Ibf·tt)
Install the fork protector and tighten the bolts.
TORQUE: 10 N·m (1.0 kgf.m, 7 Ibf·tt)
InstaU the brake cable into the cable holder.
12-9
FRONT BRAKE
REMOVAL
Remove the brake panel from the front wheel (page
12-5),
INSPECTION
Measure the front brake drum 1.0.
Measure the brake lining thickness.
DISASSEM,BLV
SHOES
Remove the spring and brake shoes.
Remove the nut, bolt and brake arm.
Remove the wear indicator, dust seal and brake

cam. •
12-10
ASSEMBLY
WEAR INDICATOR
DUST BRAKEAAM
NUT
BRAKE SHOES
SPRING
Apply grease.to th e brake cam spindle.

Install the brake cam into the brake panel.
Apply oil to a new dust seal and install it onto the

brake panel.
Install the wear indicator onto the brake cam by

aligning its wide tooth with the wide groove in the
brake cam.
12-11
Install the brake arm by aligning the punch marks

on the arm and brake cam.
Install a new brake arm pinch bolt and nut as
shown and tighten it to the specified torque.
TORQUE: 6 N·m (0.6 kgf.m , 4.3 Ibf·ft)
Apply grease to the anchor pin and brake cam

sliding surfaces. SHOES
Install the brake shoes and spring as shown.
Wipe any excess grease of the brake cam and
anchor pin.
INSTALLATION
Install the front wheel (page 12-8).
FORK
DISASSEMBLY
Remove the front wheel (page 12-5),
l oosen the brake cable nut and remove the brake

cable from the fork slider.
Remove the dust seal from the fork outer tube by

sliding it down.
Remove the stopper ring.
Remove the fork t op bolt and washer and pull the

fork slider down to remove the f ork assembly.
•
12-12
Drive out the spring pin, using a 4 mm pin driver.
Remove the following from the fork slider:

PIN DRIVER
- fork spring/spring holders
- slider piston
- slider guide
- back up ring
- stopper ring
- dust seal
INSPECTION FORK SLIDER
Visually inspect each part for excessive wear or

damage.
DUST
SEAL
BACK-UP RING STOPPER RING
Measure the fork spring free length.
ASSEMBLY BACK-UP RING
STOPPER RING~
DUST SEAL ---r::J
FORK SUDER ----~
SPRING PIN SUDER GUIDE
12-13
Install the following onto the fork slider:

- new dust seal (apply grease to the seal lips) .~
- stopper ring (with the chamfered side facing up)
- back up ring
~(5 - 69)
- slider guide (apply 5- 6 9 of grease to the slider
guide sliding surface of the fork slider)
Install the slider piston and fork spring/holders as

shown.
Align the pin holes in the piston, fork slider and
SPR:lNG PIN
spring holder so that the locating pin on the upper
spring holder is facing inside of the fork slider and
drive the spring pin to secure them, using a 4 mm
pin driver.
Be sure that the spring pin do not project out of the

piston outer surface.
Narrow
Wide
PISTON
PISTON
Apply 5- 6 9 -of grease to the slider guide outer
groove.
Pack the fork spring with 14 9 of grease.
Install the fork assembly by aligning the locating

pin with the groove in the outer tube.
Install the fork top bolt and washer and tighten it.
Wipe any excess grease of the outer tube. •
12-14
Install the stopper r ing into the groove in the outer

tube properly.
Install the dust seal over the outer tube.
Wipe any excess grease of the fork slider.
Install the brake cable onto the fork slider and

secure it by tightening the cable nut.
Install the front wheel (page 12· 10).
STEERING STEM
REMOVAL
Remove the f ollowing:
- Number plate (page 2-3)
- Handlebar (page 12-3)
- Front wheel (page 12-5)
- Front fender (page 2-3)
- Steering stem nut and washer
- Fork top bolts and washers
- Top bridge
Remove the steering stem top thread using the spe-

cial tool.
TOOL:
Pin spanner 07702 - 0020001
Remove the following: INNER RACE ___ I

- Upper bearing inner race
-U pper bearing
- Steering stem
- Lower bearing
12-15
BEARING REPLACEMENT
Always rap/sea the Drive out the upper and lower bearing outer races
REMOVER
bearings and using the special tool.
races as a set.
TOOL:
8all race remover 07944 - 1150001
Drive new upper and lower bearing outer races into

the steering head pipe using the special lools as
shown.
TOOLS:
Driver 07749 - 0010000
Attachment, 37 X 40 mm 07746 - 0010200
Temporarily install the steering stem nut onto the INNER RACE, DUST SEAL AND WASHER
stem to prevent the threads from being damaged
when removing the lower bearing inner race from
the stem.
Remove the lower bearing inner ra ce with a chisel

or equivalent tool, being careful not to damage the
stem.
Remove the dust seal and washer.
Install the washer over the steering stem.

STEERING STEM
Apply grease to 8 new dust seal lips end install it DRIVER
over the steering stem.
Install a new lower bearing inner race using a spe-
cial tool and a hydraulic press.
TOOL:
Steering stem driver 07946 - GC40000
Steering stem driver 07946 - MBOOOOO with
Steering .tem driver attachment
07946-GC4000A
(U.S.A. only)
12-16
INSTALLATION
®--~ ___-- LOWER OUTER RACE

~.. LOWER BEARING
~ LOWER INNER RACE
LJ~ - - - - - - - DUST SEAL

WASHER
Apply grease to upper and lowe r bearings and

races.
Install the lower bearing onto the lower bearing
race.
Insert the steering slem into the steering head pipe.
Install upper bearing, inner race and top thread.
Hold the steering stem and tighten the stem top

thread to the initial torque. TOP THREAD
TORQUE: 25 N·m (2.5 kgf·m, 18Ibf·ft)
12-17
Move the steering stem right and left, lock-te-Iock

several times to seat the bearings.
Loosen the top thread.
Retighten the top thread to the specified torque.
TORQUE: 3 N·m 10.3 kgf.m ,2.2 Ibf·ft)
Install the top bridge.

TOP BRII)GE NUT AND
Install the stem nut and fork top bolts with the
washers and tighten them.
TORQUE: Stem nut: 74 N·m 0,5 kgf,m. 54Ibf·ft)
Make sure that the steering stem moves smoothlv,

without play or binding.

-Front fende r (page 2-3)
-Front wheel (page 12-8)
-Handlebar (page 12-4)
-Number plate (page 2-3)
12-18
MEMO
REAR WHEEL/BRAKE/SUSPENSION
34 N·m (3.5 kgf·m, 25 Ibf·ft)
34 N·m (3.5 kgf.m, 25Ibf·ft)
47 N·m (4.8 kgf·m ,

35lbf·ft) 39 N·m (4.0 kgf.m, 29Ibf·ft)
13-0
13. REAR WHEEL/BRAKE/SUSPENSION
SERVICE INFORMATION 13-1 SHOCK ABSORBER 13-10
TROUBLESHOOTING 13-2 SWINGARM 13-12
REAR WHEEL 13-3 BRAKE PEDAL 13-13
REAR BRAKE 13-8
SERVICE INFORMATION
GENERAL
A contaminated brake drum or shoe reduces stopping powsr. Discard contaminated shoes and clean 8 contamintlttKi
drum with. high quality brake degrellsing agent.
• When servicing the rea r wheel, support the motorcycle using a safety stand or hoist.
SPECIFICATIONS
(unout
TORQUE VALUES
Spoke nipple 2 N·m (0.2 kgf·m , 1.4 Ibf·tt)

Rear axle nut 47 N·m (4.B kgf.m . 35Ibf.ft) U·nut
Driven sprocket nut 32 N·m (3.3 kgf·m , 24Ibf·ft) U-nut
Rear brake arm pinch bolt 6 N·m (0.6 kgf.m , 4.3 Ibf·tt) ALOe bolt
Swingarm pivot nut 39 N·m (4.0 kgf·m . 29 fbf·tt) Apply grease to the seating surface/
U-nut
Shock absorber mounting nut 34 N·m (3.5 kgf.m. 25Ibf·ft) U-nut
Drive chain slider nut 12 N·m (1.2 kgf.m. 9Ibf·ft) U-nut
TOOLS
Spoke wrench, 4.1 x 4.5 mm 07701 - 0020100 Equivalent commercially available in U.S.A.
Bearing remover shaft 07746 - 0050100 T Equiva lent commercially available in U.S.A.
Bearing remover head, 12 mm 07746-0050300
Driver 07749 - 0010000
Attachment, 32 X 35 mm 07746 - 0010100
Pilot, 12 mm 077 46 - 0040200
13-1
TROUBLESHOOTING
Soft suspension Rear wheel wobbling
• Weak shock absorber spring • Bent rim
• Oil leakage from damper unit • Worn rear wheel bearings
• Tire pressure too low • Faulty tire
• Unbalanced tire and wheel
Hard suspension • Tire pressure too low
• Bent damper rod • Faulty swingarm pivot bushings
• Damaged swingarm pivot bushings
• Bent swingarm pivot
• Tire pressure too high
Steers to one side or does not track straight

• Bent rear axle
• Axle alignment/chain adjustment not equal on both sides
13-2
REAR WHEEL BRAKE ROD

REMOVAL
Support the motorcycle securely using a hoist or
equivalent and raise the rear wheel off the ground.
Remove the rear brake adjusting nut and discon-

nect the rear brake rod from the brake arm, and
remove the joint pin and sprin g.
l oosen the drive chain adjuster lock nuts and

adjusting nuts.
Remove the axle nut and left chain adjuster.
Push the fear w heel forward and derail the drive

chain from the driven sprocket.
Remove the axle from the left side and remove the
rear wheel.
Remove the left side collar from the left wheel hub.
Remove the brake panel from the right wheel hub.
13-3
•
INSPECTION
Axl.
Place the axle in V-blocks and measure the runout.
Actual runout is 1/ 2 the total indicator reading.
•
Wheel bearing
Bearings should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
hub.
Replace the wheel Remove and discard the bearings if the races do
bearings in pairs. not turn smoothly and quietly, or if they filloosely
in the hub.
Wheel rim runout

Check the rim runout by placing the wheel in a turn-
ing stand.
Spin the wheel slowly and read the runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading. •
SERVICE LIMITS: Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (O.OB in)
Driven sprocket
Check the condition of the final driven sprocket WEAR
teeth.
Replace the sprocket if worn or damaged.
NOTE:
• If the final driven sprocket requires replacement,

inspect the drive chain and drive sprocket.
• Never install a new drive chain on a worn sprock-
et or a worn chain on new sprockets. Both chain
•
and sprocket must be in good condition or the
replacement chain or sprocket will wear rapidly.
13-4 •
DISASSEMBLY
Remove the nuts, bolts and driven sprocket.
Remove the left dust seal.
Wheel bearing removal

Install the bearing rem over head into the bearing.
From the opposite side install the bearing remover
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing rem oYer head, 12 mm 07746 - 0050300
(Equivalent
commercially avail-
able in U.S.A.)
Bearing remover shaft 07746 - 0050100
(Equivalent
commercially avail-
able in U.S.A.)
ASSEMBLY
DISTANCE COLLAR
BEA.AINIG (S20lU)
BEARING (620 1U)
BOLTS
DRIVEN SPROCKET
13-5
I
REAR WHEEL/BRAKE/SUSPENSION •
Wheel bearing Installation
CAUTION:
Never install the old bearings, once the Narings

has b99n removed, the bearing must be replaced
•
with new ones.
Pack each wheel bearing cavity with grease.

Drive in a new right bearing squarely with the
sealed side facing up using the special tools as
shown.
TOOLS:
Driver 07749-0010000
Attachment, 32 X 35 mm 07746 - 00 10100
Pilot, 12 mm 077 46- 0040200
Install the distance collar and drive in a new left

bearing using the same tools.
Wheel center 8.djustment
~25 ± 'mm
Place the rim on the work bench.
Place the hub with the left side down and begin
lacing with new spokes.
Adjust the hub position so that the distance from
the hub right end surface to the side of rim is 25 ±
1 mm (1.0 ± 0.04 in) as shown.
/I \\
1/ \\
l-
TOOL: i l
~
Spoke wrench, 4.1 X 4.5 mm 07701 - 0020100
(Equivalent com-
mercially available
in U.S .A.)
~ -
TORQUE: 2 N·m 10.2 kgf.m, 1.4Ibf·ft)
Check the rim runout (page 13-4).
Apply grease to a new dust seal lips and install it

into the left wheel hub.
•
Install the driven sprocket, bolts and nuts and
tighten them.
TORQUE: 32 N·m (3.3 kgf.m , 24Ibf·ft)
13-6
INSTALLATION
Install the left side collar into the left wheel hub.
Instal l the brake panel into the right wheel hub.
Place the rear whee l into the swingarm by aligning

the brake panel groove with the swingarm boss.
Install the drive chain over the driven sprocket.

Apply thin layer of grease to the axle.
Install the axle with the right drive chain adjuster
from the right side.
Install the left drive chain adjuster and axle nut.
13-7
I
Install the spring onto the brake rod and the joint SPRING
pin into the brake arm.
Connect the brake rod and install the adjusting nut.
Adjust the drive chain slack (page 3-12).
JOINT PIN
ADJUSTING NUT
REAR BRAKE
REMOVAL
•
Remove the brake panel from the rear wheel (page
13-3),
INSPECTION
Measure the rear brake drum I.D.
Measure the br.ake lining thickness.
•
DISASSEMBLY
Remove the brake shoes and springs. •
13-8 •
Remove the brake arm cover if necessary.
Remove the nut. bolt and brake arm.
Remove the indicstor plate, dust seal and brake

cam.
COVER
• ASSEMBLY
BRAKE SHOES
BOLT
BRAKE CAM BRAKE ARM COVER
SPRING
Apply grease to the brake cam spindle.

Install the brake cam Into the brake panel.
13-9
Apply oil to a new dust seal and install it onto the

brake panel.
Install the w ear indicator onto the brake cam by

aligning its wide tooth with the wide groove in the
brake cam.
Install the brake arm by aligning the punch marks

on the arm and brake cam.
Install a new brake arm pinch bolt and nut as
shown and tighten it to the specified torque.
TOROUE: 6 N·m (0.6 kgf.m, 4.3 Ibf·tt)
Install the brake arm cover onto the arm.
Apply grease ..to the anchor pin and brake cam

sl iding surfaces.
Assemble the brake shoes and spring as shown
and install them onto the brake panel.
Wipe any excess grease off the brake cam and
anchor pin.
INSTALLATION
Install the rear wheel (page 13-7).
SHOCK ABSORBER
REMOVAL
Support the motorcycle securely using a hoist or
equivalent and raise the rear wheel off the ground.
Remove the seat (page 2-2).
Remove the shock. absorber lower mounting nut

and bolt.
13-10
Remove the upper mounting nut and bolt and the

shock absorber.
INSPECTION
Visually inspect the following:
-Spring for fatigue or damage
-Damper rod for bend or damage
-Damper unit for deformation or oil leaks
-Bump rubber fo r wear or damage
-Mounting bushings for damage
Replace the shock absorber assembly if necessary.
INSTALLATION
Install the shock absorber into the frame and
swingarm.
Install the upper and lower mounting bolts from the

left side.
Install the nuts and tighten them to the specified
torque.
TORQUE: 34 N·m (3.5 kgf.m , 25Ibf·ft)
13-11
•
SWINGARM
REMOVAL
-Rear wheel (page 13-3)
-Drive chain (page 3-12)
Remove the bolts and drive chain cover.

Remove the bolts, nuts and drive chain guard.
" " CHAIN GUARD
Remove the shock absorber lower mounting nut

and bolt.
SWINGARM
Remove the 5wingarm pivot nut, bolt and swing-
arm.
Remove the 0Vl and bolt and the drive chain slider.
INSPECTION
Inspect the swingerrn for wear or damage.
Inspect the pivot bushings for wear or damage.
BUSHINGS
13-12
I'
INSTALLATION
Install the drive chain slider and tighten the nut.
TORQUE: 12 N·m 0.2 kgf·m, 9Ibf·ft)
SLIDER
Install the swingarm over the frame, then install the

pivot bolt from the right side and the shock
absorber lower mounting bolt from the left side.
Apply grease to the seating surface of the

5wingarm pivot nut.
Instafl and tighten the nuts to the specified torque.
TORQUE: Swingarm: 39 N·m 14.0 kgf.m, 29 Ibf·tt)

Shock absorber:
34 N·m (3.5 kgf.m. 25 Ibf·tt)
Install the drivtt chain guard and tighten the bolts.

Install the drive chain cover and tighten the bolts.
Install the rear wheel (page 13-7).

Install the drive chain (page 3-12).
'-----
CHAIN GUARD
BRAKE PEDAL
REMOVAL
Remove the rear brake adjusting nut.
13-13
I
Remove the cotter pin, joint pin and brake rod.
Unhook the brake pedal return spring from the

spring holding pin.
Remove the cotter pin, washer and brake pedal.
INSTALLA,TION
Apply grease to the pivot groove and install the
brake pedal.
•
Install the washer and a new cotter pin to secure
the brake pedal.
Install the return spring as s hown.
13-14
Install the spring onto the brake rod and the joint
pin into the brake arm.
Install the rod to the brake arm with the adjusting
nut.
NUT JOINT PIN
Connect the brake rod to the pedal with the joint pin
and secure it with a new cotter pin.
Adjust the brake pedal free play (page 3-15),
13-15
IGNITION SYSTEM
•
SYSTEM DIAGRAM
ENGINE "rIP 'Wil-CH
IGNITION CONTROL MODULE (leM)
IGNITIC)N CDIL
IGNITION SWITCH
EXCITER COIL IGNITION PULSE GENERATOR
ENGINE STOP IGNmON

SWITCH SWITCH
~
8VW • 8VW •
I
U ~~G
'-_8 vw-cc:::J- BIfW
n OVY.
8VW
• 8VY • 8L 8
~ ~
8LIR
SWITCH CONTINUITY
ENGINE 'n:
T
STOP IGNITION 8"" 8
SW SW IGNITION
IGNITION
CONTROL COIL
IG E I"'- I. E MODULE
/1
'UN ON
OFF
""
81 : Black
. OFF
R: Red
Y : Yellow W : Whit.
• SPARK
PLUG
IGNITION
PULSE
GENERATOR
EXCITER
COIL
8u : 81u. G: Green
14-0
14. IGNITION SYSTEM
SYSTEM DIAGRAM 14-0 IGNITION CONTROL MODULE 14-6
SERVICE INFORMATION 14-1 ENGINE STOP SWITCH/
IGNITION SWITCH 14-7
TROUBLESHOOTING 14-2
IGNITION TIMING 14-7
IGNITION SYSTEM INSPECTION 14-3
IGNITION COIL 14-6
SERVICE INFORMATION
GENERAL
When the enginll must be running to do some worle, maks sur" the area is well-ventil.ted. Nev.r run the Bngine in an
,mcloud ar.". The exhaust contains poisonous CIIrbon monoxidtl gas that mllY cause loss of consciousness end Itll.d to
dSllth. Run the ,mgin. in an open area or with an exhaust evacuation systlfm in lin enclosed "re •.
• When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 14·3.
• The COl ignition system uses an electrically controlled ignition timing system. No adjustments can be made to the
ignition timing.
• The leM may be damaged jf dropped. Also if the connector is disconnected when current is flowing, the excessive
voltage may damage the module.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
• For alternator and ignition pulse generator removal and installation, see section 10.
SPECIFICATIONS
Spark plug Standard

ITEM
For cold climate/below 41 °F/5°C

For extended high seed ridin
CR6HSA (NGK)
CR5HSA (NGK)
CR7HSA (NGK)
SPECIFICATIONS
U20FSR-U (DENSO)
U16FSR-U (DENSO)
U22FSR-U DENSO)
1--
S ark I, , 0.60 0.70 mm (0.024-0.028 in )
Ignition coil peak voltage 100 V minimum
I nition ulse enerator ak volta e 0.7 V minimum
Alternator exciter coil eak volta e 100 V minimum
Ignition timing ("F" mark) 2JOBTOC at idle
TOROUE VALUES
Ignition coil mounting bolt 6 N·m (0.6 kgf·m, 4.3 Ibf·ft)
TOOLS
Peak vollage tester (U.S.A. only) or 07HGJ - 0020100 (not avai la ble in U.S.A.) w ith commercially
Peak voltage adaptor available digital multimeter (impedance 10 M Q/DCV minimum )
14-1
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap or spark plug w ire connections
-Water got into the spark plug cap (leaking the ignition coil secondary voltage)
No spark at spark plug
Unusual condition Probable cause (Check in numerical order)

Ignition coil low peak voltage 1. Incorrect peak voltage adaptor connections (System is normal if
primary measured voltage ;, over the specifications with raverse
voltage connections).
2. The multimeter impedance is too low; 10M Q/DCV.
3. Cranking speed is too low (operating force of the kickstarter is
weakJ.
4. The sampling timing of the tester and measured pulse were not
synchroni zed (System is normal if measured voltage is over the
standard voltage at least once).
5. Poorly connected connectors or an open circuit in ignition system.
6. Faulty exciter coil (Measure peak voltage).
7. Faulty ignition coil.
8. FaultY ICM (in case when above No. 1- 7 are normal).
No peak voltage 1. Incorrect peak voltage adaptor connections (System is normal if
measured voltage ;, over the specifications wi th reverse
connections).
2. Short circuit in ignition switch wire or engine stop switch wire
(black/white).
3. Faulty ignition switch or engine stop switch.
4. Loose or poorly connected ICM connectors.
5. Open circuit or poor connection in ground wire (green) of the ICM.
6. Faulty peak voltage adaptor.
. 7. Faulty exciter coil (Measure peak voltage) .
8. Faulty ignition pulse generator (Measure peak voltage).
9. FaultyJCMUn case when above No. 1- 8 are normal).
Peak voltage is normal, but 1.Faulty spark plug m leaking ignition coil secondary current
no spark jumps at plug ampere.
2. Faultv ionition coil.
Exciter coil Low peak voltage 1. The multi meter impedance is too low; 10 M C/DCV.
2. Cranking speed is too slow (operating force of the kickstarter is
weak).
synchronized (System is normal if measured voltage is over the
4. Faulty exciter coil (in case when above No. 1- 3 are normal).
No peak voltage 1. Faulty peak voltage adaptor.
2. FaultY ~xciter coil.
Ignition Low peak voltage 1. The multimeter impedance is too low; 10 M Q/OCV.
pulse 2. Cranking speed is too slow (operating force of the kickstarter is
generator weak).
synchronized (System is normal if measured voltage is over the
4. Faulty ignition pulse generator (in case w hen above No. 1- 3 are
normal).
No peak voltage 1. Faulty peak voltage adaptor.
2. FaultY ianition Dulse generator.
14-2
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION

NOTE:
-If there is no spark at plug, check all connections

for loose or poor contact before measuring each
peak voltage.
• Use recommended digital multimeter or commer-
cia lly available digita l multi meter with an
~~:;;[::::~~~.~.~.~
impedance of 10 M Q/DCV minimum. \"
• The display value differs depending upon the .." ....... _.... \ -_.. _._-
internal impedance aftha multimeter. '.
_If using peak voltag8 tester (U.S.A. only), follow
the manufacturer's instructions. PEAK VOLTAGE ADAPTOR
Connect the peak voltage adaptor to the digital

multi meter, or use the peak voltage tester (U.S.A.
only).
!, TOOLS:
Peak voltage tester (U.S.A. only) or
Peak voHage adaptor 07HGJ-0020100
(not available in U.S.A.) with commercially availa-
ble digital multimeter (impedance 10 M Q /DCV
minimum)
IGNITION. COIL PRIMARY PEAK VOL- GOOD KNOWN SPARK PLUG

TAGE
Avoid touching the spark plug and tester probes to

prevent electric shock.
NOTE:
• Check all system connections before inspection.

If the system is disconnected, incorrect peak
voltage might be measured.
• Check cylinder compression and check that the
spark plug is installed correctly.
Disconnect the spark plug cap from the spark plug.

Connect a known good spark pl ug to the spark plug
cap and ground the spark plug to the cylinder as
done in a spark test.
14-3
IGNITION SYSTEM
•
With the ignition coil primary wire connected, con-
IGNITION COIL
nect the peak voltage adaptor or peak voltage
tester probes to the ignition coil primary wi re
terminal and ground.
CONNEcnON:
BlackJ1'ellow terminal (- ) - Body ground (+)
Turn the ignition switch ON and engine stop switch

to "RUN",
Shift the transmission into neutral.

Crank the engine with the kickstarter and read
ignition coil primary peak voltage.
PEAK VOL lAGE: 100 V minimum
If the peak voltage is abnormal, fo llow the checks

described in the troubleshooting chart (page 14-21.
IGNITION PULSE GENERATOR PEAK

VOLTAGE
=
NOTE:
Check cylinder compression and check that the

spark plug is installed correctly.
Remove the seat assembly (page 2-2),
Disconnect the 4P connector from the leM.

Connect the peak voltage adaptor or peak voltage
tester probes to the connect or terminals of the wire
harness side. ICM CONNECTOR
•
TOOLS:
Peak voltage tester (U.S.A. only) or
Peak \/oltage adaptor 07HGJ - 0020100
(not available in U.S.A.) with commercially availa·
ble digital multlmeter (impedance 10 M Q /DCV
minimum)
CONNECTION:
BluelYeliowterminal (+) - Green (-)

Crank the engine with the kickstarter and re ad the
peak voltage.
PEAK VOLTAGE: 0.7 V minimum
14-4
IGNITION SYSTEM
If the peak voltage measured at reM connector is

IGNJTION PULSE GENERATOR CONNECTOR
abnormal, measure the peak voltage at the pulse
generator connector.
Disconnect the ignition pulse generator connector

(bluelyellow) and connect the peak voltage adaptor
or tester probes to the connector terminal of the
ignition pulse generator side and ground.
In the same manner as at the leM connector, meas-
ure the peak voltage and compare it to the voltage
measured at the leM connector.
• If the peak voltage measured at the leM is abnor-

mal and the one measured at the ignition pulse
generator is normal, the wire harness has an
open circuit or loose connection .
• If both peak voltages are abnormal, follow the
checks described in the troubleshooting chart
(page 14-2).
ALTERNATOR EXCITER COIL PEAK

VOLTAGE
Avoid touching the sp.rk plug .nd tester probes to

prevent electric shock.
NOTE :
Check. cylinder compression and check. that the

spark. plug is installed correctly.
Disconnect the 3P and 2P connectors from the ICM.

Connect the peak voltage adaptor or peak voltage
tester probes to the connector terminals of the wire ICM CONNECTORS
harness side.
TOOLS:
Peak vottage tester (U.S.A. only) or
Peak vottage adaptor 07HGJ - 0020100
(not availabte In U.S.A.! with commercially availa-
ble digital muttimeter (impedance 10M Q loeV
minimum)
CONNECTION: Black/Red terminal {+) - Green { - I

Crank the engine with kickstarter and read the peak
voltage.
PEAK VOLTAGE: l00V minimum
14-5
IGNITION SYSTEM
If the peak voltage measured at leM connector is EXCITER COIL CONNECTOR

abnormal, measure the peak voltage at the alterna-
tor exciter coil connector.
=
Disconnect the alternator exciter coil connector ~I\l'
(black/red) and connect the peak voltage adaptor or W
tester probes to the connector terminal of the ••
exciter coil side and ground.
In the same manner as at the leM connector,
measure the peak voltage and compare it to the
voltage measured at the leM connector.
• If the peak voltage measured at the leM is

abnormal and the one measured at the alternator
exciter coil is normal, the wire harness has an
open circuit or loose connection .
• If both peak voltages are abnormal, follow the
checks described in the troubleshooting chart
(page 14-2).
IGNITION COIL
Disconnect the spark plug cap from the plug.
Disconnect the wires from the ignition coil.
Remove the bolt and ignition coil.
Installation is in the reverse order of removal.
TORQUE: 6 N·m (0.6 kgf·m , 4.3 Ibf·ft)
IGNITION CONTROL MODULE

Disconnect the Ignition Control Module HCM) con-

nectors.
Remove the ICM from the frame.
Installation is in the reverse order of removal.
14-6
IGNITION SYSTEM
ENGINE STOP SWITCH!

IGNITION SWITCH
INSPECTION
Disconnect the switch connectors.
Check for continuity between the black/white and

green wire termina ls of the switch side connectors.
There sho uld be continuity w ith the switch OFF and

there should be no contin uity when the engine stop ENGINE STOP SWITCH
switch is RUN ar tha ignition switch is ON.
IGNITION TIMING
When the flogio. must be funning to do some

work, make sur. the area is well-ventilated. Never
run the flngintt in an enclosed area. The exhaust
contains poisonous carbon moncxidB glJs that may
CBuse loss of consciousness Bnd lead to death . Run
the engine In Itn open .rsa or with 8n exhaust
evacuation system in an enclosed af••.
Warm up the engine.

Stop the engine and rem ove the left crankcase
cover (page 10·2).
Read the Connect the timing light to the spa rk plug wire.
Ins/ructions for
timing light Start the engine and let it idle.
opera/ion.
IDLE SPEED: 1,700 ± 100 rpm
The ignition timing is correct if the "F" m ark alig ns

with tha index notch on the laft cran kcase.
Increase the engine speed by turning the throttle

stop screw and make sure the "F" mark begi ns to
move clockwise.
Install the left crankcase cover (page 10·8).
14-7
•
MEMO
•
•
•
•
ENGINE STOP IGNITION
SWITCH SWITCH
BIIW G
L..-_ BIIW -1>!=f- I.IIW·-i
G 8u/Y BVR
....a
~ ~
U1
•
SWITCH CONTINUITY
ENGINE
STOP
SW
IGNITION
SW
IGNITION IGNITION
BulY BIIA :E
-
RUN
IG E
ON
IG
f-'--'+-H
E
CONTROL
MODULE
COIL
-2:
lJ
OFF ...
EXCITER C)
COIL
BI : Black R : Red
Y : Yellow W : White
Bu: Blue G : Green
SPARK
PLUG
IGNITION
PULSE
GENERATOR
-C)
C
»
0030Z-G E L- 7000 lJ
... »
...•
U'1
S
•
MEMO
•
16. TROUBLESHOOTING
ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH
HARD TO START 16-1 SPEED 16-4
ENGINE LACKS POWER 16-2 POOR HANDLING 16-4
POOR PERFORMANCE AT LOW
AND IDLE SPEED 16-3
ENGINE DOES NOT START OR IS HARD TO START

Possible cause
Check the fuel flow to carburetor - - - - Not reaching carburetor --~••. Clogged fue l line and strainsr
) • Clogged fue l tank breather tube
Reaching carburetor
j
2. Perform a spark test - - - - - - - - Weak Dr no spark - - - - - - . . Faulty spark plug
I
Good spark
·
·
Fouled spark plug
Faulty ignition control module
· Broken or shorted spark plug wire
· faulty ignition pulse generator
· Faulty engine stop switch or ignition
switch
· Loose or disconnected ignition sys-
temwires
3. Remove and inspect spark plug - - - - Wet plug - - - - - - - - - . Flooded carburetor

I . · Choke valve closed
Good condition · Air cleaner dirty
j
4. Start by following normal procedure--- Engine starts but stops ---~••. Improper choke operation
I .
Carburetor incorrectly adjusted
Engine does not start . Intake pipe leaking
· Improper ignition timing (Faulty igni-
tion coil or ignition pulse generator)
· Fuel contaminated
5. Test cylinder compression - - - - - - low compression - - - - - - - . Valve clearance too small

· Valve stuck open
· Worn cylinder and piston ring
· Damaged cylinder head gasket
· Seized valve
· Improper valve timing
16-1
TROUBLESHOOTING
ENGINE LACKS POWER

Possible cause
1, Raise wheel off the ground and spin - - - Wheels do not spin freely---'~ . Brake dragging
by hand . Worn or damaged wheel bearing
I
Wheels spins freely
j
2. Check tire pressure - - - - - - - - - Pressure low - - - - - - -••- . Faulty tire valve
I · Punctured tire
Pressure normal
j
3. Accelerate rapidly from low 1 0 - - - Engine speed doesn't - ' Clutch slipping
second change accordingly . Worn clutch discS/plates
I · Warped clutch discs/plates
Engine speed reduced · Weak clutch spring
j · Additive in engine oil
4. Accelerate lightly - - - - - - - - - Engine speed does not --~.~ . Choke valve closed
I
'rn, ;n"""
increase . Clogged air cleaner
· Restricted fue l flow
,p"d
· Clogged muffler
· Pinched fuel tank breather tube
5. Check ignition t i m i n g l - - - - - - - - - Incorrect - - - - - - - - - - . . Faulty ignition control module

I · Faulty ignition pulse generator
Correct
j
6. Test cylinder compression - - , - - - - - - Incorrect - - - - - - - - - -
• . Valve clearance too small
I · Worn cylinder and piston rings
Normal · leaking head gasket
j · Improper valve timing
7. Check carburetor for clogging,----- Clogged - - - - - - - - - · Carburetor not serviced frequently

I enough
Not clogged
j
8. Remove spark plug - - - - - - - - - Fouled or discolored ----~.~ . Plug not serviced frequently enough
I · Spark plug are the incorrect heat range
Not fouled or discolored
j
9. Check oil level and condition - - - - - - Incorrect --------~.~ . Oil level too high
I~I---
Correct
. Contaminated oil
j
10. Remove cylinder head cover and - - - Valve train not lubricated --~.~ . Clogged oil passage
inspect lubrication properly . Clogged oil control orifice
I
Valve train lubricated properly
16-2
TROUBLESHOOTING
I Possible cause
11. Check for engine overheating - - - - - Overhe ating - - - - - - - -••. Excessive carbon build-up in combus-
1 tion chamber
Not overheating . Use of poor quality fuel
· Clutch s lipping
· Lean fuel mixture
· Wrong type of fuel
12.Accelerate or run at high speed - - - - - Engine knocks ------~.~ . Worn piston and cyl inder
.Wrong type of fuel
I • Excessive carbon build-up in combus-
9
En ine does not knock . :~On~t~~~m~~ing to advanced (faulty
j ignition control module)

· l ean fuel mixture
POOR PERFORMANCE AT LOW AND IDLE SPEED

Possible cause
,. Check carburetor air screw - - - - - - Incorrect - - - - - - - - - - . . See section 5

adjustment
I
Correct
I
2. Check for leaking intake pipe - -- - - - leaking ---------~.~ . loose carburetor mounting bolts
I . Damaged insulator
Not leak
I
3. Perform spark test - - - - - - - - - - Weak or intermittent ----~.~ . Faulty or foul ed spark plug
I spark • Faulty ignition control module
Good spark . Faulty ignition coi l
· Broken o r shorted spark plug wire
· Faulty engine st op switch or ignition
switch
· Faulty ignition pulse generator
· l oose or disconnected ignition system
wires
4. Check ignition timing-- - - - -- - - Incorrect - - - - - - - - --• . Improper ignition timing (faulty ignition
control module)
16-3
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED

Possible cause
1. Disconnect fuel tube and check the - - - Fuel flow restrictedj-----~••. Clogged fualline
fuel flow . Clogged fuel tank breather tube
I . Faulty fuel valve
Fuel flows freely . Clogged fuel strainer
j
2. Remove the carburetor and check - - - Cloggedl----------·· . Clean
for clogging
I
Not clogged
j
3. Check valve timing - - - ----:- - - - - Incorrect - - - - - - - - - . . . Cam sprocket not installed properly
I
Correct
j
4. Check ignition t i m i n g l - - - - - - - - - Incorrect - - - - - - - - - - - . Faulty ignition control module
I · Faulty ignition pulse generator
Correct
j
5. Check valve spring - - - - - - - - - - Weak ----------~.- . Faulty spring
j
Not weak
POOR HANDLING
Possible cause
1. If steering is heavy - - - - - - - - - - - - - - - - - - - - - - - - . Steering stem adjusting nut too tight

• Damaged steering head bearings
2.lf either wheel is wobbling -------------------~.- , Excessive wheel bearing play

· Bent rim
, Improper installed wheel hub
· Swingarm pivot bushing excessively
worn
· Bent frame
3.lf the motorcycle pulled to one side - - - - - - - - - - - - - - - - - - . Faulty shock absorber

· Front and rear wheel not aligned
· Bent fork
·
·
Bent swingarm
Bent axle •
16-4
17. INDEX
AIR CLEANER ...................................................... ·········3-5 REAR BRAKE· ........ ·· .. · .. ·........ ·........ · ...... ·........ ·........ 13-8
AlA CLEANER HOUSING ······· .. ·.. ····· .... ········· .... ···········5-3 REAR FENDER .......................................................... 2-4
AIR SCREW ADJUSTMENT ·········································5-10 REAR WHEE L· .. ·.......... ···· .. ·.. ····· .... ··· .. ·.. ···· .. ········ .... 13-3
BRAKE PEDAL ............................................................ 13-13 RIGHT CRANKCASE COVER INSTALLATION ........ · 9-17
BRAKE SHOEWEAA ...................... ,............................. 3-14 RIGHT CRANKCASE COVER REMOVAL .... .... ·9-3
BRAKE SYSTEM ................ ........................................... 3-14 SEAT······················ .. ···· ...... ···· .. ······ .. ····· .... · ................ 2-2
CABLE & HARNESS ROUTING···································· 1-14 SERVICE INFORMATION
CAM CHAIN TENSIONER .......................................... 10-4 ALTERNATOR/CAM CHAIN TENSIONER .......... 10-1
CAMSHAFT INSTALLATION ·······································7-15 ClUTCt-VGEARSHIFT LINKAGE ........................... 9- 1
CAMSHAFT REMOVAL····················.··········· ...... ······· .. · 7-3 CRANKSHAFT{TRANSMISSION/
CARBURETOR ASSEMBLy····· ...... ·· .. ··············· .... ···· .. · 5-6 KICKSTARTER·· .. ·.. ··· ........ ·...... ···· .. ····· ............ ··· .. ',-,
CARBURETOR DiSASSEMBLy .... ··· .......... ·........ ·.. ··· .. · 5-5 CYLINDER HEADNALVES ...... ··· .. ······· .... ·........ ··· .. 7-1
CARBURETOR INSTALLATION .... ··· .. ·.. ··· .. ··· .......... ·· .. · 5-8 CYLINDER/PISTON ............................................... 8· 1
CARB URETOR REMOVAL ........................................ ... 5-3 ENGINE REMOVAl/INSTALLATION· .... ·· ........ ··· .. 6-1
CLUTCH ················ .. ··· .. ······ .. ··· .. ·.... ··· .... ·.. ······ .. ·· .. ······ .. · 9-4 FRAME/BODY PANELS/EXHAUST SySTEM ...... · 2·1
CLUTCH SySTEM······ ........ ··· .. ········ .. ······ .. ·.... ··· .. ·...... ··· 3-16 FRONT WHEEl/BRAKE/SUSPENSION}
CRANKCASE ASSEMBLy·············· .. ······················ .. ·· 11 -14 STEERING ....... .................................................... 12-1
CRANKCASE BREATHER .. ··· .. ········ .. ········· .... ·········· .. ··· 5-11 FUEL SySTEM .. ··· .... ·· .... ·.. ·· .. ·.. ··········· ...... •.... · .. ····· 5-1
CRANKCASE SEPARATION··········· .. ·· .. ·· ...... ······ .... ···· 11-3 IGNITION SYSTEM .. ·· ...... ····· .. ····· .... ····· .... ·...... ·.. 14-1
CRANKSHAFT ·.. ·· .... · ...... ···· .. ······· .... ·· .............. ·...... ····11-4 LUBRICATION SYSTEM ...................................... 4-1
CYLINDER/PISTON INSPECTION·· .. ······· .... ········· .... ···· 8-4 MAINTENANCE.. · .... ··· ...... ···· .. ·.... ·.... ····· .... ·.. ·...... ·· 3-1
CYLINDER COMPRESSION ......................................... 7-3 REAR WHEEl/BRAKElSUSPENSION ................. 13-1
CYLINDER HEAD·· .... ·...... ·············· .. ·· .. ·· .... ·· .. ···· ........ ··· 7-4 SERVICE RULES ....................................................... 1-2
CYLINDER INSTALLATION .. ········· .... ·.......... ······· .. ·.... ·· 8-7 SHOCK ABSORBER ·· ...... · .. ·· .. ······ .... ·· .. ·.. ······ .. ··· .... · 13-10
CYLINDER REMOVAL .................................................. 8-3 SIDE STAND ............................................................. 2-5
DRIVE CHAIN ................................................................ 3-12 SIDE STAND .. ······ .... ·· ...... ····· .... ···· .... ··· .. ·.... ·· .. ··· ··· ··· .. 3-16
DRIVE CHAIN SLIDER ..... ................... ·3·1 4 SPARK ARRESTER· .. ·· .. ·.. ·· .. ·...... ··· .... ·............ · .. ······ ·· 3- 17
EMISSION CONTROL INFORMATION LABEL SPARK PLUG .... ........................................................ 3-6
(Except Canada type) ... ....................................... ·1 -18 SPECiFiCATIONS· .. ··· .... ··············· .... · .... ······ .. ···· .. ·..... 1-4
EMISSION CONTROL SYSTEMS .. ·· .. ············· .. ········ .. · 1-17 STATOA/FlYWHEELINSTALLATION ................... 10-6
ENGINE IDLE SPEED .... ····· .. ···· ...... ··· ........ ····· ...... ········· 3-11 STEERING HEAD BEARINGS .... · ................ ····· ·3-19
ENGINE INSTALLATION .... ·· .. ······································ 6-4 STEERING STEM ···· .. ··· ................ ········ ........ ·.... ······12-15
ENGINE OIL·· ...... ·········· .... ····· ...... ··· .. ,········ .. ·· .. ·············3-8 SUSPENSION ........................................................... 3-'6
ENGINE OIL CENTRIFUGAL FILTER ·· ........ ······· .. ·.. ······ 3- 10 SWINGARM -...... ·...... ···· ...... · ........ ·.... ····· ...... ·...... ·· .. 13-12
ENGINE OIL STRAINER SCREEN ................................ 3-10 SYSTEM DIAGRAM ......................................... ....... , 4-(1
ENGINE REMOVAL······· .... ···· .. ········ .. ···························6-2 THROTnE OPERATION······ .. ······ .. ·...... ··········· ........ · 3-4
ENGINE STOP SWITCH/IGNITION SWiTCH············· 14-7 TOOlS .. ·...... ·· .. ·.. ············ ...... ·...... ········· ...... ·· .... ···· ... .. '-12
EXHAUST SySTEM········ .. ····· .. ·.. ··································2-4 TORQUE VALUES ···· .. ····· .... · ...... ·········· .. ·.. ···· .. ········ .. 1-10
FLYWHEEl/STATOR REMOVAL ............................... 10-2 TRANSMiSSiON· .... ···· .... ····· .. ······ .... ··.... ...... ... 11 -6
FORK ····················· .... ·.. ······ .... ···· .... ······ .... ······ .... ·········12-12 TROUBLESHOOTING
FRONT BRAKE······· .. ·· .... ···· .... ···· .... ···· .. ·...... ···· .......... ·· 12-10 Al TERNATORlCAM CHAI N TENSIONER .......... , 0-'
FRONT FENDER ........................................................... 2-3 CLUTCH/GEARSHIFT LINKAGE ........................... 9-2
FRONT WHEEL ··· .... ·· .. ···· .............. ················· .. ·· .... ··· ·· 12-5 CRANKSHAFT{TRANSMISSION/
FUEL LINE··· .. ······· .. ············ .. ··· .... ················· ··· .. ········· .. ·3-4 KICKSTARTER ·.... ··· ................ ···· .. ····· .... ···· .. ····· .. · 11 -2
FUEL TANK .. ····· ........ ·.. ··· ...... ·........ ···· .. ·.. ·· .. ···· .... ···•••·· .. 2-3 CYLINDER/PISTON ............................................... 8-2
GEARSHIFT LINKAGE .... ··· .... ·· .. ·...... · ............ ·· ........ ·.... 9-14 CYLINDER HEADNALVES .... ··· .... · ...... · .. ··· .. ··· .. ·.... 7-2
GENERAL SAFETY······················································· 1-1 ENGINE DOES NOT START OR IS HARD TO
HANDLEBAR .......... .. ............................... ...... 12-3 START· .. ··· ............ ·· ...... · .. ··· .... ··· .... ·· ........ ·· .. ·· .. ·.... 16-1
IGNITION COIL··················· .. ······································ 14-6 ENGINE LACKS POWER·· .... ···· .... ·· .. ·.. · .. ···· .. ····· .. 16-2
IGNITION CONTROL MODULE ···················· .. ···· ·······14-6 FRAME/BODY PANELS/EXHAUST SySTEM .... ·.. 2-1
IGNITION SYSTEM INSPECTION .............................. 14-3 FRONT WHEEl/BRAKE/SUSPENSION/
IGNITION TIMING .. ······· ·.... ·· .. ·.. ································· 14-7 STEERING ............................................ .. ...... 12-2
KICKSTARTER······· .. ·· .. ·································.. ····· .. ····· 11-12 FUEL SySTEM·· .... ·...... ·.. ··· .. ····· .... ··· .... ····· ...... ·...... 5-2
LUBRICATION & SEAL POINTS .................................. 1-13 IGNITION SYSTEM ......... ·... ······· .. ····· .. ·.. ······ .. ·· .. · 14-2
LUBRICATION SYSTEM DIAGRAM ............................ 4-0 LUBRICATION SySTEM··· .. · .. ·· .. ·.. ···· .... ···· .. ····· .. ·.. 4-1
MAINTENANCE SCHEDULE·· ...... ······················ .... ···· .. 3·3 POOR HANDLING ·· .... ·· .. ··· .... ··· .. ·.. ··· ...... ··· .. ·· .. ···· 16-4
MODEL IDE NTIFICATION .... · ...... ······•· .. ········ .. ·············1-3 POOR PERFORMANCE AT HIGH SPEED ........... 16-4
NUMBER PLATE ······················· .. ··································2-4 POOR PERFORMANCE AT lOW AND IDLE SPEED· .. · 16-3
NUTS, BOLTS, FASTENERS ·· ...... ·· .. ·· .......................... 3-18 REAR WHEEl/BRAKE/SUSPENSiON ................. 13-2
Oil PUMP ......................................................... ············ 4-2 VALVE CLEARANCE ................................................. 3·7
PISTON INSTALLATION .... ........ .,......... ,...................... 8·7 WHEELS{TIRES .... ··· .. ···· .. ·.... · ........ ···· .. ······ .......... ·· .. ·· 3-18
PISTON REMOVAL· .. ·· ...... ····· ...... ·.. ·.. ·· .. ········ .. · .. ·.. ······· 8-3 WIRING DIAGRAM ........................... ....... ............... 15-1
17-1

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•

Follow the Maintenance Schedule (Section 3) recom-

If you do not know the source of the trouble, go to

Use molybdenum disulfide grease (containing more than 3 % molybdenum disulfide, Nl GI # 2 or

.lGl! Apply sealant.

Use fork or suspension fluid.

Run the engine in an open area or with an exhaust evacua-

FRAME SERIAL NUMBER

111 The frame serial number is stamped on the left side

ENGINE SERIAL NUMBER

CYLINDER HEAD/VALVES ---------,--------------------------;,---='-""''-''''1

Piston end gap

• Torque specifications listed below are for important fasteners .

NOTES: 1.Apply oil to the threads.

FRAME/BODY PANELS/EXHAUST SYSTEM:

LUBRICATION & SEAL POINTS

Cylinder bore surface Engine oil

Air cleaner housing cover mating groove MUlti-purpose grease

CABLE & HARNESS ROUTING

AIR CLEANER HOUSING

WIRE BANDS FUEL TUBE

ENGINE STOP SWITCH WIRE

CARBURETOR AIR VENT TUBE

IGNITION,--~~~§~-1--- ENGINE STOP SWITCH WIRE

CRANKCASE BREATHER TUBE CARBURETOR DRAIN TUBE

IGNITION CONTROL MODULE (leM)

MAIN WIRE HARNESS

EMISSION CONTROL SYSTEMS

EXHAUST EMISSION CONTROL SYSTEM

CRANKCASE EMISSION CONTROL SYSTEM

CRANKCASE BREATHER TUBE

EMISSION CONTROL INFORMATION

EMISSION CONTROL INFORMATION LABEL

Pull the seat assembly back and remove it.

TANK SHROUDS SCREWS

BOLT AND COLLAR ~+t-~

Remove the breather tube from the number plate.

Remove the two bolts, washer and collar.

FUEL TANK FUEL TUBE

NUMBER PLATE NUMBER PlATE

Remove the breather tube from the number plate.

Remove the number plate from the steering stem

Installation is in the reverse order of rem oval.

Instailation is in the reverse order of removal.

Serious burns may result if the exhaust system ;5

For spark REMOVAL

Tighten the joint nuts.

Tighten the mounting bolt.

TORQUE: 26 N-m (2.7 kgf-m, 20 Ibf·ft)

Install the seat assembly (page 2-2),

EXHAUST PIPE PROTECTOR

15 N ·m (1.5 kgf.m, 11 Ibf·ft)

EXHAUST PIPE COVER

Retract the side stand and remov e the following:

Tighten the pivot bott.

TORQUE: 10 N·m (1.0 kgf.m, 7Ibf·ft)

Loosen the pivot bolt 45 - 90 Q

Install the pivot nut and tighten it while holding the

Install the return spring as shown.

Check the side stand operation for freedom of