06 - Cylinder Head - Valves

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    ITEM STA N D A R D SER VIC E LIM IT

    C ylinder com pression 1.350 kPa (13.5 kg/cm 2; 192 psi).

    C am lobe height IN . 31.579 - 31.739 (1.243-1.249) 31.30 (1.232)

    EX 31.419 - 31.579 (1.236-1.243) 31.20 (1.228)

    C ylinder head w arpage 0.10 (0.004)

    R ocker arm I.D . 12.000 - 12.018 (0.4724 - 0.4731) 12.05 (0.474)

    Shaft O .D . 11.977 - 11.995 (0.4715 - 0.4722) 11.93 (0.470)

    Arm -to-shaft clearance 0,005 - 0,041 (0.0002 - 0.0016) 0.08 (0.003)

    Valve spring free length IN N ER 39.2 (1.543) 38.0 (1.50)

    O U TER 44.85 (1.766) 43.5 (1.71)

    Valve stem O .D . IN 5.450 - 5.465 (0.2146 - 0.2152) 5.44 (0.214)

    EX 5.430 - 5.445 (0.2138 - 0.2144) 5.42 (0.213)

    Valve guide I.D . IN 5.475 - 5.485 (0.2156 - 0.2159) 5.50 (0.217)

    EX 5.475 - 5.485 (0.2156 - 0.2159) 5.50 (0.217)

    Stem -to-guide clearance IN 0.010 - 0.035 (0.0004 - 0.0014) 0.06 (0.002)

    EX 0.030 - 0.055 (0.0012 - 0.0022) 0.08 (0.003)

    Valve seat w idth 1.1 - 1.3 (0.043-0.051) 1.5 (0.06)

    XL200 6.

    SERVICE INFORMATION 6-1

    TROUBLESHOOTING 6-2

    CYLINDER HEAD COVER/CAMSHAFTREMOVAL 6-3

    CYLINDER HEAD REMOVAL 6-6

    CYLINDER HEAD DISASSEMBLY 6-7

    VALVE GUIDE REPLACEMENT 6-9

    VALVE SEAT INSPECTION/REFACING 6-10

    CYLINDER HEAD ASSEMBLY 6-13

    CYLINDER HEAD INSTALLATION 6-14

    CAMSHAFT/CYLINDER HEAD COVERINSTALLATION 6-15

    SERVICE INFORMATION

    GENERAL

    This section covers service proced ure for the cylind er head and valves.

    The eng ine m ust be rem oved to service the cam shaft, cylind er head , valves and rocker arm s.

    C am shaft and rocker arm lub rication oil is fed through an oil passage. B e sure the passage is not clog ged .

    C lean all disassem bled parts w ith clean solvent and dry them by blow ing them off w ith com pressed air before inspection.

    Pour clean engine oil into the oil pockets in the cylinder head during assem bly to lubricate the cam shaft lobes.

    SPECIFICATIONS

    UNIT: mm (in)

    CYLINDER

    HEAD/VALVES

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    XL200C YLIN D ER H EAD /VALVES

    6-0

    15 N.m (1.5 kg.m, 11ft-lb)

    12 N.m (1.2 kg.m, 9ft-lb)

    12 N.m (1.2 kg.m, 9ft-lb)

    10 N.m (1.0 kg.m, 7ft-lb)

    10 N.m (1.0 kg.m, 7ft-lb)

    4 N.m (0.4 kg.m, 3ft-lb)

    8 N.m (0.8 kg.m, 6ft-lb)

    6 N.m (0.6 kg.m, 4ft-lb)

    10 N.m (1.0 kg.m, 7ft-lb)

    14 N.m (1.4 kg.m, 10ft-lb)

    27 N.m (2.7 kg.m, 20ft-lb)

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    TORQUE VALUES

    Valve adjusting hole cap 15 N .m (1,5 kg.m , 11 ft-lb)

    V alve ad justing screw lock nut 14 N .m (1,4 kg .m , 10 ft-lb )

    C ylind er head cover 8 m m cap nut 27 N .m (2,7 kg .m , 20 ft-lb )

    C ylinder head cover 6 m m socket bolt 10 N .m (1,0 kg.m , 7 ft-lb)

    C am sprocket bolt 12 N .m (1,2 kg.m , 9 ft-lb)

    C am chain tensioner lifter m ounting bolt 12 N .m (1,2 kg.m , 9 ft-lb)C am chain tensioner lifter sealing screw 4 N .m (0,4 kg.m , 3 ft-lb)

    Tim ing hole cap 6 N .m (0,6 kg.m . 4 ft-lb)

    C rankshaft hole cap 8 N .m (0,8 kg.m , 6 ft-lb)

    TOOLS

    Valve guide ream er, 5.485 m m 07984-0980001

    Valve guide driver, 5,5 m m 07742-0010100B R

    Valve spring com pressor 07757-0010000B R

    TROUBLESHOOTING

    Engine top -end prob lem s usually affect engine perform ance. These can be diag nosed by a com pression or leak dow n test,or by tracing noises to the top -end w ith a sounding rod or stethoscop e.

    If the perform ance is poor at low speeds, check for white sm oke in the crankcase breather tub e. If the tub e is sm oky, check

    for a seized piston ring.

    Compression too low, hard starting or poor per- Excessive smokeformance at low speed W orn valve stem or valve g uideValves D am aged stem seal

    Incorrect valve adjustm ent Faulty cylinder or piston (Section 7)

    Burned or bent valves

    Incorrect valve tim ing Excessive noiseBroken valve spring Incorrect valve clearance

    W eak valve spring Sticking valve or broken valve spring

    C ylinder head W orn or dam aged push rod

    Leaking or dam aged cylinder head gasket Loose or worn cam chainW arped or cracked cylinder head W orn or dam aged cam chain tensioner

    Faulty cylind er/p iston (S ection 7) W orn cam sp rocket teeth

    W orn rocker arm and/or shaft

    Compression too high, overheating or knocking Faulty cylinder or piston (Section 7)

    Excessive carbon b uild-up in cylinder or on top of

    piston Rough idle

    Low cylind er com pression

    Intake air leak

    XL200

    6-2

    C YLIN D ER H EAD /VALVES

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    XL200 C YLIN D ER H EAD /VALVES

    6-3

    CYLINDER HEAD COVER/CAMSHAFT

    REMOVALR em ove the follow ing :

    starter m otor

    crankshaft/tim ing hole caps

    R em ove the bolts, cam chain tensioner lifter and gasket.

    A lign the Tm ark on the flyw heel w ith the index m ark on the left

    crankcase cover by turning the crankshaft counterclockw ise.

    R em ove the valve adjusting hole caps and m ake sure the piston

    is at T.D .C . on the com pression stroke b y checking for clearance

    at both rocker arm s.

    If the piston is not at T.D .C . on the com pression stroke, rotate thecrankshaft 360 deg rees counterclockw ise and recheck.

    R em ove the cam sprocket cover.

    R em ove the cam sprocket bolts by holding the crankshaft.

    R em ove the cam sprocket from the cam shaft flange, then rem ove

    the cam chain from the sprocket.

    N O T E

    Susp end the cam chain w ith a piece of w ire to prevent it

    from falling into the crankcase.

    CAM CHAIN TENSIONER

    BOLTS

    T MARK

    INDEX MARK

    CAM SPROCKET COVER

    CAM SPROCKET CAM CHAIN

    BOLTS

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    XL200

    6-4

    R em ove the eng ine hanger plate.

    R em ove the cylind er head cover cap nuts/sealing w ashers and

    flange bolts in a g radual, crisscross p attern.

    R em ove the cylind er head cover.

    R em ove the cam shaft.

    R em ove the d ow el pins.

    N O T E

    It is not necessary to force them out.

    R em ove the rub ber plug ; do not lose it.

    C lean off any sealant m aterial from the head cover and cylind er

    head m ating surface.

    CAMSHAFT INSPECTION

    Turn the outer races of cam shaft bearing s w ith your fing er.

    The bearing s should turn sm oothly and quietly.

    A lso check that the inner races fit tightly on the cam shaft.

    M easure the height of each cam lob e and insp ect it for w ear or

    dam age.

    SERVICE LIMIT:Intake: 31.30 mm (1.232 in)Exhaust: 31.20 mm (1.228 in)

    C YLIN D ER H EAD /VALVES

    HEAD COVER BOLTS

    CAP NUT/SEALING WASHER

    CAMSHAFT DOWEL PIN

    RUBBER PLUG

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    TENSIONER LIFTER

    SCREW

    PLATE

    6 mm BOLT

    ROCKER ARM SHAFT ROCKER ARM

    ROCKER ARM ROCKER ARM SHAFT

    XL200 C YLIN D ER H EAD /VALVES

    6-5

    TENSIONER LIFTER INSPECTION

    R em ove the cam chain tensioner lifter sealing bolt and O -ring .

    C heck the lifter operation:

    the tensioner shaft should not go into the body unless it is

    pushed.

    CYLINDER HEAD COVER DISASSEMBLY

    R em ove the rocker arm shaft plate by rem oving the setting

    screw .

    R em ove the rocker arm shafts by screw ing a 6 m m bolt into the

    threaded ends as show n.

    R em ove the rocker arm s.

    ROCKER ARM/SHAFT INSPECTION

    Inspect the rocker arm slipper surfaces for excessive w ear.

    Insp ect the rocker arm s and shafts for w ear or dam ag e.

    N O T E

    M easure the I.D . of each rocker arm .

    SERVICE LIMIT: 12.05 mm (0.474 in)

    M easure the O .D . of each rocker arm shaft.

    SERVICE LIMIT: 11.93 mm (0.470 in)

    C alculate the rocker arm -to-shaft clearance.

    SERVICE LIMIT: 0.08 mm (0.003 in)

    If the rocker arm s require servicing or replacem ent, inspect

    the cam lobes for scoring, chipping or flat spots.

    W hen it turned clockw ise w ith a screw driver, the tensioner

    shaft shoud be pulled into the bod y. The shaft should spring

    out of the bod y as soon as the screw driver is released.

    M ake a tensioner shaft stopper tool out of a thin p iece of steel

    (0.8 m m thick) using the diag ram .

    (0.8 mm thick)

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    XL200

    6-6

    CYLINDER HEAD REMOVAL

    R em ove the follow ing :

    cylind er head cover

    engine from the fram e

    cylind er head socket bolt/w asher

    cylinder head

    cam chain guide

    gasket

    dow el pins

    C lean off any gasket m aterial from the cylind er head and

    cylind er m ating surfaces.

    R em ove the cam chain tensioner.

    C heck the cam chain tensioner for excessive w ear or dam ag e.

    C heck the cam chain g uide for excessive w ear or dam age.

    C YLIN D ER H EAD /VALVES

    CYLINDER HEAD SOCKET BOLT/WASHER

    CAM CHAIN GUIDE

    GASKET DOWEL PIN

    CAM CHAIN TENSIONER

    CAM CHAIN GUIDE

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    XL200 C YLIN D ER H EAD /VALVES

    6-7

    CYLINDER HEAD DISASSEMBLY

    R em ove the cam chain tensioner pivot bolt, w asher and cam

    chain tensioner.

    R em ove the socket bolts and carburetor insulator.

    W hile com pressing the valve spring w ith a valve spring

    com pressor, rem ove the valve cotters.

    h

    TOOL:Valve spring compressor

    To prevent loss of tension, do not compress the valve springmore than necessary to remove the cotters.

    Loosen the valve spring com pressor and rem ove the follow ing :

    sp ring retainers

    outer and inner valve springs

    spring seatsinlet and exhaust valve

    N O T E

    R em ove the carbon d eposits from the com bustion cham ber.

    C lean off any gasket m aterials from the cylind er head surface.

    M ark all disassem bled parts to ensure correct reassem bly.

    INSPECTION

    C YLIN D ER HEA DC heck the spark plug hole and valve area for cracks.

    C heck the cylind er head for w arpag e w ith a straight ed ge and a

    feeler gaug e.

    SERVICE LIMIT: 0.10 mm (0.004 in)

    CAM CHAIN TENSIONER INSULATOR

    PIVOT BOLT/WASHER SOCKET BOLT

    SPRING COMPRESSOR

    STEM SEAL OUTER SPRING SPRING RETAINER

    VALVE SPRING SEAT INNER SPRING

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    XL200

    6-8

    VALVE

    Inspect the valve for trueness, burning , scratches or ab norm al

    stem w ear.

    M easure the valve stem O .D .

    SERVICE LIMIT:

    In: 5.44 mm (0.214 in)Ex: 5.42 mm (0.213 in)

    Insert each valve into the valve guide and check the valve

    m ovem ent in the guide.

    VALVE G U ID E

    N O T E

    R eam the valve g uide to rem ove the carbon build-up before

    checking the valve g uide.A lw ays rotate the ream er clockw ise, never couterclockw ise

    w hen installing , rem oving and ream ing .

    M easure and record each valve guide I.D . w ith a b all gauge or

    inside m icrom eter.

    SERVICE LIMIT: IN/EX: 5.50 mm (0.217 in)

    C alculate the stem -to-guide clearance.

    SERVICE LIMIT:

    IN: 0.06 mm (0.002 in)EX: 0.08 mm (0.003 in)

    N O T E

    If the stem -to-guide clearance exceeds the service lim it,

    determ ine if a new guide w ith standard dim ensions w ould

    bring the clearance w ithin tolerance. If so, replace the

    guides as necessary and ream to fit.

    If the stem -to-guide clearance still exceeds the service lim it

    w ith new guides, rep lace the valve g uide ream ers

    R eface the valve seat w henever new valve guides areinstalled.

    C YLIN D ER H EAD /VALVES

    VALVE GUIDE REAMER

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    XL200 C YLIN D ER H EAD /VALVES

    6-9

    VA LVE SPR IN G

    M easure the valve spring free length.

    SERVICE LIMIT:Inner: 38.0 mm (1.50 in)Outer: 43.5 mm (1.71 in)

    VALVE GUIDE REPLACEMENT

    C hill valve guides in the freezer section of a refrigerator for about

    an hour.

    H eat the cylind er head to 100C w ith a hot plate or oven.

    t

    To avoid burns, w ear heavy gloves w hen handling the

    heated cylinder head.

    h

    Sup port the cylind er head and drive out the valve g uide from the

    valve port w ith a valve guide driver.

    h

    TOOL:Valve guide driver, 5.5 mm

    Avoid damaging the cylinder head.

    Do not use a torch to heat the cylinder head; it may cause

    warping.

    Place a new O -ring on the new valve guide.

    Install a valve guide from the top of the cylinder head.

    h

    TOOL:Valve guide driver, 5,5 mm

    When installing a valve guide, take care not to damage thecylinder head.

    VALVE GUIDE DRIVER

    VALVE GUIDE DRIVER

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    XL200

    6-10

    A fter driving in the valve guide, ream it w ith a valve guide

    ream er.

    N O T E

    C lean the cylind er head thoroughly to rem ove any m etal particles.

    R eface the valve seat.

    U se cutting oil on the ream er during this operation.

    A lw ays rotate the ream er clockw ise, never

    counterclockw ise.

    VALVE SEAT INSPECTION/REFACING

    VALVE SEAT INSPECTION

    C lean the intake and exhaust valves thoroughly to rem ove the

    carbon d ep osits.

    A pply light coating if Prussian B lue to the valve seats.

    Lap the valves and seats using a rub ber hose or other hand

    lapping tool.

    R em ove the tool and insp ect the w idth of each valve seat.

    STANDARD: 1.1 - 1.3mm (0.04 - 0.05 in)

    SERVICE LIMIT: 1.5 mm (0.06 in)

    If the valve seat is too w ide, too narrow or has low spots, the seat

    m ust be g round .

    h

    The valve cannot be ground. If a valve face is burned orbadly worn or it contact the seat unevenly, replace the valve.

    C YLIN D ER H EAD /VALVES

    VALVE GUIDE REAMER

    (1) SEAT WIDTH

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    XL200 C YLIN D ER H EAD /VALVES

    6-11

    VALVE SEAT GRINDING

    H onda V alve Seat C utters, a g rind er or eq uivalent valve seat

    refacing eq uipam ent are recom m ended to correct a w orn valve

    seat.

    N O T E

    Follow the refacer m anufacturers operating instructions.

    U se a 45 deg ree cutter to rem ove ant roughness or irreg ularities

    from the seat.

    N O T E

    Reface the valve seat w ith a 45 deg ree cutter when a valve

    guide is rep laced .

    U sing 32 deg ree cutter, rem ove 1/4 of the exiting valve seat

    m aterial.

    VALVE GUIDE REAMER

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    XL200

    6-12

    U sing 60 d eg ree cutter, rem ove the bottom 1/4 of the oil seat.

    R em ove the cutter and inspect the area you have just rem oved.

    Install a 45 degree finish cutter and cut the seat to proper w idth.

    M ake sure that all pitting and irregularities are rem oved.

    R efinish if necessary.

    STANDARD SEAT WIDTH: 1.1 - 1.3 mm (0.04-0.05 in)

    A pply thin coat of Prussian B lue to the valve seat.

    Press the valve throug h the valve guide and onto the seat to

    m ake a clear pattern.

    N O T E

    If the contact area is too high on the valve, the seat m ust be

    low ered using a 32 deg ree flat cutter.

    The location of the valve seat in relation to the valve face is

    very im portant for good sealing .

    If the contact area is too low on the valve, the seat m ust be

    raised using a 60 deg ree inner cutter.

    C YLIN D ER H EAD /VALVES

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    XL200 C YLIN D ER H EAD /VALVES

    6-13

    R efinish the seat to sp ecifications, using a 45 d egree finish

    cutter.

    A fter cutting the seat, ap ply lap ping com pound to the valve face,

    and lap the valve using light pressure.

    A fter lap ping , w ash all residual com pound off the cylind er head

    and valve.

    CYLINDER HEAD ASSEMBLY

    Install the inner and outer valve spring seats and new valve stem

    seals.

    Lubricate each valve stem w ith engine oil.

    Insert the intake and exhaust valve into the valve guides.

    Install the valve sp ring seats, sp rings and retainers.

    N O T E

    Install the valve sp rings w ith the narrow pitch end facing the

    com bustion cham ber.

    C om press the valve spring and install the valve cotters.

    h

    TOOL:Valve spring compressor

    To prevent loss of tension, do not compress the valve spring

    more than necessary.

    STEM SEAL

    STEM SEAL OUTER SPRING SPRING RETAINER

    VALVE SPRING SEAT INNER SPRING

    SPRING COMPRESSOR

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    XL200

    6-14

    Tap the stem s gently w ith a plastic ham m er to firm ly seat the

    cotters.

    h

    Support the cylinder head above the work bench surface toprevent valve damage.

    C heck the insulator O -ring is in good condition, replace if

    necessary.

    Tighten the insulator socket bolt securely.

    Install the cam chain tensioner, w asher and pivot bolt.

    Tighten the pivot bolt to the sp ecified torque.

    TORQUE: 10 N.m (1.0 kg.m, 7 ft-lb)

    CYLINDER HEAD INSTALLATION

    Place the bottom end of the cam chain g uide into the groove in

    the left crankcase, and its bosses in the grooves in the cylinder

    up per surface.

    N O T E

    M ake sure that the cam chain is p rop erly installed on the

    tim ing sprocket as show n.

    C YLIN D ER H EAD /VALVES

    INSULATOR

    O-RING

    CAM CHAIN TENSIONER

    PIVOT BOLT/WASHER SOCKET BOLT

    ALIGN

    CAM CHAIN GUIDE

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    XL200 C YLIN D ER H EAD /VALVES

    6-15

    C lean the cylind er head gasket surface of any gasket m aterials.

    N O T E

    Install the dow el pins, new O -ring and new cylind er head gasket.

    D o not allow dust and dirt to enter the engine.

    Install the cylinder head

    Install a new sealing w asher and the tensioner pivot bolt through

    the tensioner hole.

    Tighten the bolt to the specified torque.

    TORQUE: 10 N.m (1.0 kg.m, 7 ft-lb)

    CAMSHAFT/CYLINDER HEAD COVER

    INSTALLATION

    CYLINDER HEAD COVER ASSEMBLY

    A pply oil to the rocker arm shafts.

    Install the rocker arm s and rocker arm shafts in the cylinder head

    cover.

    W ith the rocker arm shaft reliefs on the inside, install the rocker

    arm shaft plate.

    Tighten the setting screw securely.

    CAMSHAFT/CYLINDER HEAD COVER INSTALLATION

    Install the dow el pins and rub ber plug .

    DOWEL PIN GASKET

    SOCKET BOLT/WASHER

    CYLINDER HEAD

    SCREW PLATE

    ROCKER ARM ROCKER ARM SHAFT

    R U B B E R P LU G

    DO W EL PINS

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    XL200

    6-16

    A pply oil to the cam lob es and cam shaft bearing s.

    Install the cam shaft in the cylinder head, positioning the cam

    lobes dow n as show n.

    Pour fresh oil into the oil pocket in the cylinder head until the

    cam s are subm erged.

    A pply sealant to the m ating surface of the cylind er head cover.

    h

    Install the head cover onto the cylinder head.

    Do not apply sealant to the oil passage.

    A pply oil to the cap nut thread s.

    Install the new sealing w ashers/cap nuts and flange bolts.

    Tighten the cap nut in a crisscross p attern in 2-3 steps.

    TORQUE: 27 N.m (2.7 kg.m, 20 ft-lb)

    Tighten the flange bolts and setting bolt in a gradual crisscross

    pattern.

    TORQUE: 10 N.m (1.0 kg.m, 7 ft-lb)

    A lign the Tm ark on the flyw heel w ith the index m ark on the left

    crankcase cover by turning the crankshaft counterclockw ise.

    C YLIN D ER H EAD /VALVES

    CAMSHAFT

    SEALANT

    HEAD COVER

    (1) INDEX MARK

    (2) T MARK

    CA P NU T/W ASHER

    B O L T

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    XL200 C YLIN D ER H EAD /VALVES

    6-17

    Install the cam sprocket w ith its tim ing m arks facing out.

    Install the cam chain over the sprocket as show n.

    N O T E

    If it is difficult to install the chain over the sp rocket, m ake

    sure the chain is set properly on the tim ing sprocket.

    A lign the tim ing m arks on the cam sprocket w ith the m ating

    surface of the cylinder head and cover, w ithout rotating the

    crankshaft.

    A pply oil to the cam sprocket bolts and install them .

    Tighten the bolts to the specified torque.

    TORQUE: 12 N.m (1.2 kg.m, 9 ft-lb)

    Turn the tensioner shaft clockw ise w ith a sm all screw driver to

    retract the tensioner, and hold it in the fully retracted position.

    N O T E

    W ed ge the tensioner shaft w ith a piece of w ire to hold the

    tensioner.

    The tensioner w ill forced out by the spring w hen it is

    released.

    Install a new gasket on the cam chain tensioner lifter and install

    it.

    CAM SPROCKET

    CAM CHAIN

    TIMING MARKS

    BOLTS

    TENSIONER LIFTER SCREWDRIVER

    GASKET TENSIONER LIFTER

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    XL200

    6-18

    Tighten the cam chain tensioner lifter m ounting bolts.

    TORQUE: 12 N.m (1.2 kg.m, 9 ft-lb)

    R em ove the w ire holder piece from the tensioner lifter.

    Install and tighten the screw w ith a new O -ring .

    Tighten the screw to the specified torque.

    TORQUE: 4 N.m (0.4 kg.m, 3 ft-lb)

    R otate the crankshaft counterclockw ise a few tim es and recheck

    the valve tim ing.

    Install a new gasket and O -ring onto the sprocket cover.

    Install the sprocket cover w ith its oil pocket facing dow n as

    show n.

    Install and tighten the cover bolts securely.

    A pply clean engine oil to the O -ring s of the adjusting hole caps.

    Install and tighten the cap bolts.

    TORQUE: 15 N.m (1.5 kg.m, 11 ft-lb)

    Install and tighten the tim ing hole cap and crankshaft hole cap.

    TORQUE:Timing hole cap: 6 N.m (0.6 kg.m, 4 ft-lb)

    Crankshaft hole cap: 8 N.m (0.8 kg.m, 6 ft-lb)

    Install the follow ing:

    starter m otor

    engine

    C YLIN D ER H EAD /VALVES

    SOCKET BOLT SCREW

    CAM SPROCKET COVER

    O-RING

    BOLTS

    CRANKSHAFT HOLE CAP

    TIMING HOLE CAP

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    XL200 C YLIN D ER H EAD /VALVES

    6-19

    NOTAS

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    G ENERA L IN FO RM ATIO N

    HOW TO USE THIS MANUAL

    This service m anual describes the service

    proced ure for the XL200.

    Throughout the m anual, the follow ing

    abbreviations are used to identify individual

    m odels.

    Follow the M aintenance Sched ule (Section 3)

    recom m endations to ensure that the vehicle is in

    peak operation cond ition.

    Perform ing the first scheduled m aintenance is very

    im portant. It com pensates for the initial w ear that

    occurs during the break-in p eriod .

    Section 1 through 3 apply to the w hole m otorcycle,

    w hile section 4 throug h 18 describe parts of the

    m otorcycle, grouped according to location.

    Find the section you w ant on this p ag e, then turn to

    the tab le of contents on pag e 1 of that section.

    M ost sections start w ith an assem bly or system

    illustration, service inform ation and troubleshooting

    for the section, the subsequent pag es g ive detailed

    procedures.

    If you dont know the source of the trouble, go to

    section 20 TRO U BLES H O O TIN G .

    A ll inform ation, illustrations, directions and

    sp ecifications included in this publication are

    based on the latest product inform ation available

    at the tim e of approval for printing. M O TO

    H O N D A D A A M AZ N IA LTD A. Reserves the

    right to m ake chang es at any tim e w ithout notice

    and w ithout incurring any oblication w hatever.

    N ot part of this pub lication m ay be reprod uced

    w ithout w ritten perm ission.

    CONTENTS

    G ENERA L IN FO RM ATIO N 1

    LU BR IC A TIO N

    2M AIN TENAN C E 3

    FUEL SYSTEM 4

    EN G IN E RE M O VA L/IN STALLATIO N 5

    C YLIN D ER H EAD /VALVES 6

    C YLIN D ER /PISTO N 7

    C LUTC H /G EAR SH IFT LIN KA G E 8

    ALTERN ATO R/STARTER CLUTC H 9

    C RA N KSH AFT/KIC KSTAR TER/TRAN SM ISSIO N 10

    FRO N T W H EEL/SU SPEN SIO N /STEERIN G 11

    REA R W H EEL/SU SPENSIO N 12

    H YDR AU LIC BRA KE 13

    FAIR IN G /EXH A U ST SYS TEM 14

    C H ARG IN G SYSTEM 15

    IG N ITIO N SY STEM

    16ELEC TRIC STA RTER 17

    LIG H TS/M ETERS /SW ITC H ESELECTRIC

    ST

    ARTER

    FRAME

    ENGINE

    18

    W IRIN G D IAG RA M 19

    TRO U BLESHO O TIN G 20

    C ode A rea (type)

    D K G eneral Type

    2LA Latin A m erica

    http://informat.pdf/http://informat.pdf/http://lubricat.pdf/http://lubricat.pdf/http://mainten.pdf/http://mainten.pdf/http://fuel.pdf/http://fuel.pdf/http://engine.pdf/http://engine.pdf/http://head.pdf/http://head.pdf/http://cylinder.pdf/http://cylinder.pdf/http://clutch.pdf/http://clutch.pdf/http://alternat.pdf/http://alternat.pdf/http://transmis.pdf/http://transmis.pdf/http://transmis.pdf/http://suspens.pdf/http://suspens.pdf/http://rearwhee.pdf/http://rearwhee.pdf/http://brake.pdf/http://brake.pdf/http://fairing.pdf/http://fairing.pdf/http://battery.pdf/http://battery.pdf/http://ignition.pdf/http://ignition.pdf/http://starter.pdf/http://starter.pdf/http://lights.pdf/http://lights.pdf/http://diagram.pdf/http://diagram.pdf/http://troubles.pdf/http://troubles.pdf/http://troubles.pdf/http://diagram.pdf/http://lights.pdf/http://starter.pdf/http://ignition.pdf/http://battery.pdf/http://fairing.pdf/http://brake.pdf/http://rearwhee.pdf/http://suspens.pdf/http://transmis.pdf/http://alternat.pdf/http://clutch.pdf/http://cylinder.pdf/http://head.pdf/http://engine.pdf/http://fuel.pdf/http://mainten.pdf/http://lubricat.pdf/http://informat.pdf/