88-91NT650HAWKTMGT

HOW TO USE THIS MANUALFollow the Maintenance Schedule (Section 3)recommendations to ensure that the vehicle isin peak operating condition and the emissionlevels are within the standards set by the U.S.Environmental Protection Agency and Califor­nia Air Resources Board. Performing the firstscheduled maintenance is very important. Itcompensates for the initial wear that occursduring the break-in period.

Sections 1 through 3 apply to the wholemotorcycle, while sections 4 through 18describe parts of the motorcycle, grouped ac­cording to location.

Find the section you want on this page, thenturn to the table of contents on page 1 of thatsection.

Most sections start with an assembly orsystem illustration, service information andtroubleshooting for the section. The subse­quent pages give detailed procedures.

If you don't know the source of the trouble,go to section 20, Troubleshooting.

All information, illustrations, directions and speci­fications included in this publication are based onthe latest product information available at thetime of approval for printing. HONDA MOTORCO., LTD. reserves the right to make changes atany time without notice and without incurring anyobligation whatever. No part of this publicationmay be reproduced without written permission.

HONDA MOTOR CO., LTD.SERVICE PUBLICATIONS OFFICE

Date of Issue: September, 1988© HONDA MOTOR CO., LTD.

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CONTENTS

GENERAL INFORMATION

LUBRICATION

MAINTENANCE

FUEL SYSTEM

COOLING SYSTEM

ENGINE REMOVAL/INSTALLATION

CLUTCH/GEARSHIFT LINKAGE

ALTERNATOR/STARTER CLUTCH

CYLINDER HEADIVALVES

CYLINDER/PISTON

CRANKSHAFT/TRANSMISSION

FRONT WHEEl/SUSPENSION/STEERING

REAR WHEEl/SUSPENSION

HYDRAULIC BRAKES

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

ELECTRIC STARTER

LIGHTS/METERS/SWITCHES

WIRING DIAGRAM

TROUBLESHOOTING

INDEX

21. INDEXAir Cleaner 3-5

Case 4-4Air Vent Control Valve Inspection(California model only) .. 4-16Alternator/Starter Clutch 8-1Alternator 15-10Battery/Charging System 15-1Battery 15-4Bearing Replacement 13-9Brake Fluid 3-13

Replacement/Bleeding 14-3Brake Light Switch 3-14

Pad Wear 3-14Pads/Discs 14-5Pedal 14-17System 3-14

Cable & Harness Routing 1-9Camshaft Installation 9-17

Removal 9-3Carburetor Assembly........................................ 4-9

Choke 3-5Disassembly........................................... 4-5Idle Speed 3-9Installation 4-13Removal 4-5Separation/Assembly 4-12Synchronization 3-8

Charging System 15-7Clutch/Gearshift Linkage 7-1Clutch Diode 17-7

Installation 7-11Removal................................................ 7-4System 3-1 5

Control Cable Lubrication 2-10Coolant Replacement 5-3Cooling System 3-10, 5-1Crankcase 11-11

Assembly 11-16Breather 3-6Separation 11-3

Crankshaft/Transmission 11-1Crankshaft/Connecting Rod 11-4Cylinder HeadlValves 9-1Cylinder/Piston 10-1Cylinder. 10-2

Compression 3-10Cylinder Head Assembly 9-14

Cover Installation 9-20Cover Removal 9-3Installation 9-1 5

Cylinder Heads 9-7Installation 10-6

Drive Chain 3-12Eccentric Bearing Carrier Installation 13-12

Removal 13-6Electric Starter 17-1Emission Control Information Labels 1-18

Systems 1-16Engine Removal/Installation 6-1

Installation 6-5Oil Change 2-3Oil Level.... 2-3

Engine Removal ..Evaporative Emission Control System(California model only) .Flywheel Installation .

Removal .Fork .Front Wheel/Suspension/Steering .

Brake Caliper ..Master Cylinder .Wheel .

Fuel System ..Line ..

Fuel Pump .Relay .

Fuel Tank .Gearshift Linkage .General Information .

Safety .Handlebar Switches ..Handlebars .Headlight .

Aim ..Bracket .

High Altitude Adjustment (U.S.A. Only) ..Hydraulic Brakes .Ignition System .

Coil .Switch/Meter .System Inspection ..Timing .

Left Crankcase Cover Installation ..Removal .

Lights/Meters/Switches .Lubrication .

Points .Maintenance .

Schedule .Model Identification .Muffler/Exhaust Pipe .Neutral Switch .Nuts, Bolts, Fasteners ..Oil Filter Change ..Oil Pressure Check ..

Switch .Oil Pump/Relief Valve ..Pilot Screw Adjustment .Piston .

Installation ..Ring Installation .

Primary Drive Gear ..Pulse Generator .Purge Control Valve Inspection(California model only) ..Radiator Coolant .Radiator/Cooling Fan ..Rear Wheel/Suspension ..Rear Brake Caliper ..

Master Cylinder .Rear Cowling ..

Wheel ..Regulator/Rectifier ..Right Crankcase Cover Installation .

6-3

3-118-58-3

12-1212-1

14-1114-812-7

4-13-4

18-918-8

4-37-81-11-1

18-612-318-33-15

12-194-1414-116-116-318-416-316-4

8-68-2

18-12-1

2-103-13-31-2

13-2418-93-17

2-42-4

18-92-5

4-1410-310-510-57-1016-4

4-153-95-5

13-114-1514-1313-25

13-315-87-14

21-1

15-37-25-1

11-29-2

10-117-112-2

4-214-216-218-2

2-213-2

INDEX

Right Crankcase Cover Removal............... 7-3Seat 13-25Secondary Air Supply System(California model only) 3-11, 4-17Service Information

Alternator/Starter Clutch 8-1Battery/Charging System 15-1Clutch/Gearshift Linkage 7-1Cooling System 5-1Crankshaft/Transmission 11-1Cylinder HeadlValves 9-1Cylinder/Piston 10-1Electric Starter 17-1Engine Removal/Installation 6-2Front Wheel/Suspension/Steering 12-1Fuel System 4-1Hydraulic Brakes 14-1Ignition System .. 16-1Lights/Meters/Switches 18-1Lubrication 2-1Maintenance 3-1Rear Wheel/Suspension 13-1

Service Rules 1-1Shock Absorber : 13-14Side Stand 3-1 6Spark Plug 3-6Specifications 1-3Spindle 13-11Sprocket 13-6Starter Clutch 8-4

Motor 17-3Relay Switch 17-6

Steering Head Bearings 3-18Stem 12-20

Suspension 3-16Swingarm 13-19Switches Location .. 18-2System Testing 5-2Temperature Gauge 18-8

Sensor 18-7Thermostat 5-3Thermostatic Switch 18-7Throttle Operation 3-4Tools :......... 1-7Torque Values 1-5Transmission.............. 11-9

Assembly/Installation 11-15Troubleshooting

Battery/Charging System ..Clutch/Gearshift Linkage .Cooling System ..Crankshaft/Transmission .Cylinder HeadlValves ..Cylinder/Piston .Electric Starter ..Front Wheel/Suspension/Steering ..Fuel System .Hydraulic Brakes ..Ignition System ..Lights/Meters/Switches ..Lubrication .Rear Wheel/Suspension .

21-2

Turn Signal Relay ..Valve Clearance ..

Guide Replacement ..Seat Inspection/Refacing ..

Water Pump .Wheels/Tires .Wiring Diagram ..

18-103-7

9-119-12

5-73-1719-1

(282)

1. GENERAL INFORMATIONGENERAL SAFETY 1-1 TOOLS 1-7

SERVICE RULES 1-1 CABLE & HARNESS ROUTING 1-9 •MODELIDENTIFICATION 1-2 EMISSION CONTROL SYSTEMS 1-16

SPECIFICATIONS 1-3 EMISSION CONTROL INFORMATION

TORQUE VALUES 1-5 LABElS 1-18

GENERAL SAFETY-If the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an enclosedarea. The exhaust contains poisonous carbon monoxide gasthat may cause loss of consciousness and lead to death.

The battery generates hydrogen gas which can be highly explo­sive. Do not smoke or allow flames or sparks near the battery,especially while charging it.

Inhaled asbestos fibers have been found to cause respiratorydisease and cancer. Never use an air hose or dry brush to cleanbrake assemblies. Use an OSHA-approved vacuum cleaner oralternate method approved by OSHA designed to minimizethe hazard caused by airborne asbestos fibers.

The rear shock absorber contains nitrogen under high pres­sure. Do not allow fire or heat near the shock absorber.Before disposal of the shock absorber, release the nitrogen.

SERVICE RULES

Gasoline is extremely flammable and is explosive under cetainconditions work in a well ventilated area with the enginestopped. Do not smoke or allow flames or sparks in the workarea or where gasoline is stored.

The battery electrolyte contains sulfuric acid. Protect youreyes, skin and clothing. In case of contact, flush thoroughlywith water and call a doctor if electrolyte gets in your eyes.

Do not remove the radiator cap when the engine is hot. Thecoolant is under pressure and severe scalding could result. Theengine must be cool before servicing the cooling system.

CAUTION:Used engine oil may cause skin cancer if repeatedly left in con­tact with the skin for prolonged periods. Although this is un­likely unless you handle used oil on a daily basis, it is stilladviseable to thoroughly wash your hands with soap andwater as soon as possible after handling used oil.

1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA'sdesign specifications may damage to the vehicle.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.3. Use only metric tools when servicing the vehicle. Metric bolts, nuts, and screws are not interchangeable with English fas­

teners.4. Install new gaskets, a-rings, cotter pins, and lock plates when reassembling.5. When tightening bolts or nuts, begin with the larger-diameter or inner bolts first. Then tighten to the specified torque diag­

onally in 1-5 steps, unless a particular sequence is specified.6. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before re­

assembly.7. After reassembly, check all parts for proper installation and operation.8. Route all wires as shown on pages 1-9 through 1-14. Cable and Harness Routing.

1-1

GENERAL INFORMATION

MODEL IDENTIFICATION'SS SHOWN: After 'SS Similar:

The frame serial number is stamped on the right side of thesteering head.

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(4) CARBURETOR IDENTIFICATION NUMBER

The carburetor identification numbers are on the carbure­tor body intake side.

1-2

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/~ ~(1) VEHICLE IDENTIF·ICATION NUMBER

The vehicle identification number (VIN) is attached to theright side of the down tube.

The engine serial number is stamped on the right crank­case below the rear cylinder.

The color label is attached to the rear fender under theseat.When ordering a color coded part, always specify its desig­nated color code.

SPECIFICATIONS

ITEM

GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS

FRAME

Overall lengthOverall widthOverall heightWheelbaseSeat heightFoot peg heightGround clearanceDry weightCurb weight

TypeFront suspension, travelRear suspension, travelGross vehicle weight ratingMaximum weight capacityFront tire sizeRear tire size

2,085 mm (82.1 in)750 mm (29.5 in)

1,075 mm (42.3 in)1,430 mm (56.3 in)

778 mm (30.6 in)355 mm (14.0 in)155 mm (6.1 in)168 kg (370.3 Ib)184 kg (405.6 Ib)

Twin tube diamond, alminiumTelescopic fork 130 mm (5.12 in)Swingarm, 120 mm (4.72 in)291 kg (642 Ib)156 kg (345 Ib)110/80-17 57H Tubeless type150170 -17 69H Tubeless type

Cold tirepressure

Up to 90 kg(200 Ib) load

Up to maximumweight capacity

FrontRear

FrontRear

225 kPa (2.25 kg/em', 33 psi I225 kPa (2.25 kg/em', 33 psil

225 kPa (2.25 kg/em', 33 psi)250 kPa (2.50 kg/em', 36 psi)

Front brake, lining swept areaRear brake, lining swept areaFuel capacityFuel reserve capacityCaster angleTrail lengthFork oil capacity

Fork oil level

'88:After '88:

'88:After '88:

Hydraulic single disc, 262 x 2 em' (40.6 x 2 sq in)Hydraulic single disc, 200 x 2 em' (31.0 x 2 sq in)12.0 lit (3.18 US gal, 2.64 Imp gal)

2.0 lit (2.10 US qt, 1.76 Imp qt)27°111 mm (4.37 in)497 cc (16.8 US oz, 17.4 Imp oz)502 cc (16.9 US oz, 17.6 Imp oz)133 mm (5.2 in)128 mm (5.0 in)

TypeENGINE

Cylinder arrangementBore and strokeDisplacementCompression ratioValve trainOil capacity

Coolant capacity

Lubrication systemAir filtrationCylinder compressionIntake valve

Exhaust valve

Valve clearance (cold)

Engine weightIdle speed

: after disassembly: with oil filter: after draining

Coolant changeTotal system

: Opens: Closes: Opens: Closes: intake: exhaust

Water cooled twin, 4-stroke SOHC (Single Over HeadCamshaft) engine2 Cylinders 52° V79.0 x 66.0 mm (3.11 x 2.60 in)647 cc (39.4 cu-in)9.4 : 1Silent, multi-link chain drive and OHC with rocker arms2.8 lit (2.94 US qt, 2.46 Imp qt)2.3 lit (2.43 US qt, 2.02 Imp qt)2.2 lit (2.32 US qt, 1.94 Imp qtl1.6 lit 11.51 US qt, 1.41 Imp qtl2.2 lit (2.32 US qt, 1.94 Imp qt)Forced pressure and wet sumpPaper filter1,324 ± 196 kPa (13.5 ± 2 kg/em', 192 ± 28 psi)

10° BTDC3-40° ABDC .400 BBDC at 1 mm 11ft

10° ATDC0.15 ± 0.02 mm (0.006 ± 0.0008 in)0.20 ± 0.02 mm (0.008 ± 0.0008 in)80 kg (176 Ib)1,200 ± 100 rpm

Revised: June. 1991© 1991 American Honda Motor Co.. Inc.. All Rights ReservedMSV 5511 (9106) ·SS··91 NT650

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GENERAL INFORMATION

[ I: California model

ITEM SPECIFICATIONS

CARBURE- Carburetor type Constant Velocity dual carburetorTION Identification number VDGKA [VDGLAI

Pilot screw initial setting See page 4-1 4Float level 9.2 mm (0.36 in)

DRIVE TRAIN Clutch Cable operating, multi-plate, wetTransmission 5-speedPrimary reduction 1.888 (36/68)Final reduction 2.750 (16/44)Gear ratio I 2.769 (13/36)Gear ratio II 1.882 (17/32)Gear ratio III 1.450 (20/29)Gear ratio IV 1.'174 (23/27)Gear ratio V 0.965 (29/28)Gear shift pattern Left foot operated return system, 1-N-2-3-4-5

ELECTRICAL Ignition Digitalized full transistor ignitionIgnition timing "F" mark 10° BTDC at idleFull advance 31 ° BTDC at 7,000 ± 200 rpmStarting system Starter motorAlternator 240 W/5,OOO rpmBattery capacity 12 V 8 Ah MF BatterySpark plug NGK ND

Standard DPR8EA-9 X24EPR-U9

For cold climateDPR7EA-9 X22EPR-U9

(Below 5°C, 41°F)

For extended high speedDPR9EA-9 X27EPR-U9

riding

Spark plug gap 0.80-0.90 mm (0.031-0.035 in)Firing order Front - (232 0) - Rear- (488 0) - FrontFuse/Main fuse 10 A x 6, 15 A x 1/30 A

LIGHTS Headlight (highllow beam) 12 V-60/55 WTail/brakelight . 12 V-2/32 cp x 2 SAE No. 1157Front turn signal/running light 12 V-32/3 cp SAE No. 1034Rear turn signal light 12V-32cp SAE No. 1073Instrument light 12 V-3.4 W x 1, 1.7 W x 2Oil pressure warning light 12 V-3.0 WHigh beam indicator 12 V-3.0 WTurn signal indicator 12V-3.0Wx2Neutral indicator 12 V-3.0 W

1-4

GENERAL INFORMATION

TORQUE VALUESThe torque specifications listed under "Engine" and "Frame" are for specific tightening points. If a specification is not listed,follow the standard torque values below.

STANDARD TORQUE VALUES

TYPE TORQUE N'm (kg-m, ft-Ib) TYPE TORQUE N'm (kg-m, ft-Ib)

5 mm bolt, nut 5 (0.50, 3.6) 5 mm screw 4 (0.40, 2.9)6 mm bolt, nut 10 (1.0, 7.2) 6 mm screw, 6 mm8 mm bolt, nut 22 (2.2, 16) bolt with 8 mm head 9 (0.9, 6.5)

10 mm bolt, nut 35 (3.5, 25) 6 mm flange bolt, nut 12 (1.2,"9)12 mm bolt, nut 55 (5.5,40) 8 mm flange bolt, nut 27 (2.7, 20)

10 mm flange bolt, nut 40 (4.0,29)

ENGINE

Item Q'tyThread dia. Torque

Remark(mm) N'm (kg-m, ft-Ib)

Spark plug 4 12 14(1.4,10)Cylinder head cover bolt 4 6 10 (1.0, 7.2) Special boltCamshaft holder bolt 6 8 23 (2.3, 17)

nut 2 8 23 (2.3, 17)6 mm bolt 4 6 10(1.0,7.2)

Cylinder head nut 8 10 48 (4.8, 35)bolt 4 8 23 (2.3, 17)8 mm nut 4 8 23 (2.3, 17)6 mm bolt 2 6 10(1.0,7.2) Socket bolt

Camshaft sprocket bolt 4 7 23 (2.3, 17) NOTE 1Clutch lock nut 1 18 130 (13.0, 94) Staked nut.Right crankcase cover bolt 15 6 10(1.0,7.2)Left crankcase cover bolt 9 6 10(1.0,7.2)Oil filter cartridge 1 20 10(1.0,7.2) Apply clean engine oil to the

. O-ringOil drain bolt 1 14 35 (3.5, 25)Neutral switch 1 10 12(1.2,9)Oil pressure switch 1 -- 12 (1.2, 9) NOTE 4Primary drive gear bolt 1 12 90 (9.0, 65) UBS bolt, NOTE 2Flywheel bolt 1 12 130 (13.0, 94) Left hand threads, NOTE 2Starter one way clutch 6 8 30 (3.0,22) Torx bolt, NOTE 1Oil control bolt 1 10 23 (2.3, 17)Oil pipe bolt 2 7 10(1.0,7.2) Special boltConnecting rod cap nut 4 8 34 (3.4,25)Crankcase bolt 14 8 27 (2.7, 20) NOTE 2

6 6 12 (1.2, 9) NOTE 2Shift drum stopper plate bolt 1 6 26 (2.6, 19) NOTE 1Insulator band screw 4 5 4 (0.4,2.9) NOTE 2Timing hole cap 1 14 10 (1.0, 7.2) NOTE 3Crankshaft hole cap 14 30 15(1.5,11) NOTE 3Oil pump driven sprocket bolt 1 6 15(1.5,11) NOTE 1Valve adjusting screw lock nut 6 7 23 (2.3, 17)Cylinder stud bolt 8mm 2 8 20-30 (2.0-3.0, NOTE 1, Refer section 10.

14-22)10 mm 8 10 30- 50 (3.0- 5.0, NOTE 1, Refer section 10.

22-36) .NOTE 1: Apply a locking agent to the threads.NOTE 2: Apply clean engine oil to the threads.NOTE 3: Apply molybdenum disulfide grease to the threads.NOTE 4: Apply sealant to the threads.

1-5

GENERAL INFORMATION

FRAME

Item Q'tyThread dia. Torque

Remark(mm) N'm (kg-m, ft-Ib)

Front engine bracket bolt 4 8 28 (2.8, 20)Front engine mounting bolt 1 10 40 (4.0,29)Rear upper engine mounting bolt 1 10 40 (4.0,29) NOTE 2-mounting bolt lock nut 1 22 55 (5.5,40)-mounting bolt adjusting bolt 1 22 11(1.1,8)Gearshift arm bolt 1 6 12 (1.2, 9)Thermostatic switch 1 16 18 (1.8, 13) NOTE 3Exhaust pipe joint nut 4 8 27 (2.7, 20)Muffler band bolt 1 8 27 (2.7, 20)Muffler mounting bolt 2 8 27 (2.7, 20)Fuel tank mounting bolt : Front 1 6 12(1.2,9)

: Rear 1 8 22 (2.2, 16)Fuel filter bracket bolt 1 6 22 (2.2, 16)Front brake master cylinder holder 2 6 12(1.2,9)Brake oil bolt 4 10 30 (3.0, 22)Brake reservoir screw 4 4 1.5 (0.2, 1.4)Bleed valve 2 7 6 (0.6, 4.3)Front caliper mounting bolt 2 8 27 (2.7, 20) Flange boltFront caliper pin bolt 2 10 28 (2.8, 20)Pad pin 2 10 17 (1.7,12)Pad pin plug 2 10 2.5 (0.25, 1.8)Front brake disc retaining bolt 6 8 40 (4.0, 29) NOTE 1Rear brake reservoir mounting screw 1 6 9 (0.9, 6.5)Rear brake disc retaining bolt 4 8 35 (3.5, 25)-retaining bolt lock nut 1 8 9 (0.9, 7)Rear caliper mounting bolt 2 8 27 (2.7, 20)Rear caliper pivot bolt 1 8 22 (2.2, 16)Brake torque rod bolt 2 10 35 (3.5, 25)Handlebar pinch bolt 2 8 27 (2.7, 20)Ignition switch mounting bolt 2 8 25 (2.5, 18)Fork pinch bolt (upper) 2 7 11 (1.1,8)Fork pinch bolt (lower) 2 10 50 (5.0, 36) NOTE 2Fork tube cap 2 -- 23 (2.3, 17)Fork socket bolt 2 8 17 (1.7,12) NOTE 1Steering bearing adjustment nut 1 26 20 (2.0,14) NOTE 2Steering stem nut 1 24 105 (10.5, 76) Flange nutFront axle bolt 1 14 60 (6.0, 43)Front axle pinch bolt 4 8 22 (2.2, 16)Rear wheel nut 1 18 120 (12.0, 87)Eccentric bearing carrier lock nut 1 35 165 (16.5,120) Staked nutShock absorber upper mounting bolt 1 12 65 (6.5, 47) Flange boltShock absorber lower mounting bolt 1 10 45 (4.5, 33) Cap nutShock absorber damper rod lock nut 1 14 62 (6.2, 45) NOTE 1Swingarm adjusting bolt 1 26 15(1.5,11)Swingarm adjusting bolt lock nut 1 26 65 (6.5, 47)Swingarm pivot nut 1 14 65 (6.5, 47)Eccentric bearing carrier pinch bolt 1 16 75 (7.5, 54)Sprocket mounting bolt 6 8 43 (4.3, 31)Foot peg bracket bolt 4 8 27 (2.7, 20)Sub-frame mounting bolt 4 10 40 (4.0, 29)Side stand pivot bolt 1 10 38 (3.8, 27)Side stand bracket bolt 2 8 28 (2.8, 20)Center stand mounting bolt 2 10 55 (5.5, 40) Using a box wrench.Ignition switch mounting bolt 2 6 25 (2.5,18) Torx bolt

NOTE 1: Apply a locking agent to the threads.NOTE 3: Apply sealant to the threads.

1-6

NOTE 2: Apply clean engine oil to the threads.

TOOLSSPECIAL

GENERAL INFORMATION

Description Tool number Alternate tool Tool numberRefer tosection

Oil pressure gauge 07506-3000000 p-NOTE 1 2Oil pressure gauge attachment 07510-4220100 2Oil filter wrench 07HAA-PJ70100 2Vacuum gauge 07404-0030000 I--Vacuum gauge M937B-021-XXXXX 3Valve adjusting wrench 07908- KE90000 07908- KE901 00Vacuum/Pressure pump A937X-041-XXXXX lT~acuum pump ST-AH-260-MC7 4

Pressure pump ST-AH-255-MC7 4Snap ring pliers 07914-3230001 I--NOTE 1 2, 13,

14Steering stem socket 07916-3710100 12Clutch center holder 07923-KE10000 07HGB-001000A 7Bearing remover set 07936-3710001 11- remover handle 07936-3710100- bearing remover set 07936-3710600- remover weight 07741-0010201 1Remover

weight 07936-3710200Valve guide driver attachment(IN) 07943- MF501 00 9Valve guide driver attachment(EX) 07943-MF50200 9Valve guide reamer, 5.5 mm 07984- 200000B(IN) 07984- 2000001 (U.S.A. only) 9Valve guide reamer, 6.6 mm 07984-ZE2000B(EX) 07984-ZE20001 9Steering stem driver 07946 - MBOOOOO 12Lock nut wrench 07908-KE90000 12Bearing remover set 07946-MJOOOOO 13-driver head 07946 - MJ00200- driver shaft 07946- MJ001 00 - Driver handle 07949-3710001Spherical bearing driver 07946 - KA30200 -NOTE 2 13Ball race remover set 07946-KM90001 * L ~djUstable bear 07736-A01000A 12-driver attachment A 07946-KM90100 ing puller (U.S.A. only)-driver attachment B 07946-KM90200-driver shaft assembly 07946-KM90300-bearing remover A 07946-KM90401 *-bearing remover B 07946-KM90500-assembly base 07946 - KM90600Fork seal driver 07947-KA50100-driver attachment 07947-KF00100Shock absorber compressor 07967-KE10000 13Main bearing driver attachment 07HMF-MM90400 11Oil seal driver 07965-KE80100 13Digital multitester KS-AHM-32-003 ~U.S.A. only 15Christie battery charger MC-1012/2Honda battery tester 07GMJ-0010000

*: New for this model.NOTE 1: Equivalent commercially available in U.S.A.NOTE 2: Not available in U.S.A.

1-7

GENERAL INFORMATION

COMMON

Description Tool number Alternate tool Tool numberRefer tosection

Float level gauge 07401-0010000 trNOTE 1 4Lock nut wrench, 17 x 27 mm 07716-0020300 7Gear holder 07724-0010100 f-NOTE 2 7Flywheel holder 07725 - 0040000 p-NOTE 1 8Torx bit 07703-0010100 8, 18Rotor puller 07733-0020001 07933-3290001 8Valve guide remover, 5.5 mm 07742-0010100 9Valve guide remover, 6.6 mm 07742-0010200 9Attachment, 24 x 26 mm 07746-0010700 13Attachment, 32 x 35 mm 07746-0010100 13Attachment, 42 x 47 mm 07746-0010300 11, 12,

13Attachment, 52 x 55 mm 07746-0010400 11, 12Attachment, 62 x 68 mm 07746-0010500 13Pilot, 15 mm 07746-0040300 13Pilot, 17 mm 07746-0040400 13Pilot, 20 mm 07746-0040500 11, 12Pilot, 25 mm 07746-0040600 11Extension bar 07716-0020500 rNOTE 1 12Lock nut wrench, 30 x 32 mm 07716-0020400 12Pilot, 35 mm 07746-0040800 13Pilot, 40 mm 07746-0040900 13Pilot, 22 mm 07746-0041000 11, 13Bearing remover shaft 07746-0050100 13Bearing remover head, 20 mm 07746-0050600 12Driver 07749-0010000 11, 12,

13Valve spring compressor 07757 -0010000 Valve spring 07957-3290001 9

compressor

NOTE 1: Equivalent commercially available in U.S.A.NOTE 2: Not available in U.S.A.

VALVE SEAT CUTTERS (NOT AVAILABLE IN U.S.A.)

Description Tool number Remarks

Valve seat cutter, 27.5 mm 07780-0010200 45° INValve seat cutter, 35 mm 07780-0010400 45° EXValve seat cutter, 28 mm 07780-0012100 32° INValve seat cutter, 35 mm 07780-0012300 32° EXValve seat cutter, 30 mm 07780-0014000 60° INValve seat cutter, 37.5 mm 07780-0014100 60° EXCutter holder, 5.5 mm 07781-0010101 Valve guide INCutter holder, 6.6 mm 07781-0010201 Valve guide EX

1-8

GENERAL INFORMATION

CABLE &HARNESS ROUTINGNote the following when routing cables and wire harnesses:

• A loose wire. harness or cable can be a safety hazard. Afterclamping, check each wire to be sure it is secure.

• Do not squeeze wires against welds or clamps.

• Secure wires and wire harnesses to the frame with their re­spective wire bands at the designated locations. Tightenthe bands so that only the insulated surfaces contact thewires or wire harnesses.

o XQ

• Route harnesses so they are neither pulled taut nor have ex­cessive slack.

• Protect wires and harnesses with electrical tape or a tubingif they contact a sharp edge or corner. Clean the attachingsurface thoroughly before applying tape.

o~

• Do not use a wire or harness with broken insulation. Repairby wrapping them with protective tape or replace them.

• Route wire harnesses to avoid sharp edges or corners. Alsoavoid the projected ends of bolts and screws.

• Keep wire harnesses away from the exhaust pipes andother hot parts.

• Be sure grommets are seated in their grooves properly.

• After clamping, check each harness to be certain that itdoes not interfere with any moving or sliding parts.

• After routing, check that the wire harnesses are not twistedor kinked.

• Wire harnesses routed along the handlebars should not bepulled taut, have excessive slack, be pinched by or interferewith adjacent or surrounding parts~n all steering positions.

• Do not bend or twist the control cables.Damaged control cables will not operate smoothly and maystick or bind.

0: CORRECTx: INCORRECT

1-9

GENERAL INFORMATION

(1) SUB-FUSE BOXCONNECTOR (9P)

(4) METER WIRECONNECTOR

(3) SUB-FUSE BOX ~::::""'-..fL-1~~~~~~CONNECTOR (3P)

.~~

(2) HEADLIGHTCONNECTOR

1-10

GENERAL INFORMATION

(1) THROTTLECABLES ---::""=~~t1 (4) CRANKCASE BREATHER

TUBE

(5) FUEL TUBEINLET LINE

(6) FUEL TANKDRAIN CUP

(7) ALTERNATORWIRE

(2) FRONT IGNITION COIL

(3) PULSEGENERATORWIRE

11*--\..,....:::....,4---- (1) CLUTCH CABLE

(4) RIGHT HANDLEBAR SWITCH9P RED CONNECTOR

(5) TURN SIGNAL6P WHITE CONNECTOR

(6) PULSE GENERATOR4P WHITE CONNECTOR

1-11

GENERAL INFORMATION

(7) FUEL PUMP -­RELAY

(6) FUEL PUMP WIRE (5) REAR IGNITION COIL

(12) FUEL TUBE

(11) COOLANT RESERVETANK OVERFLOW TUBE

(10) AIR CLEANER CASE (8) SHOCK ABSORBERDRAIN TUBE/PLUG DRAIN TUBE

(9) FUEL TANKDRAIN TUBE

(1) REAR IGNITION COILCONNECTOR (2P) (3) FUEL TUBE

(2) FUEL PUMP RELAY

(7) REGULATOR/RECTIFIER4P BLACK CONNECTOR

1-12

GENERAL INFORMATION

(8) AIR CLEANER (7) FUEL PUMPCASE DRAINTUBE

(11) RESERVE TANKOVER FLOW TUBE

(12) AIR CLEANER CASEDRAIN TUBE

(13) FUEL TANK DRAINTUBE

1-13

GENERAL INFORMATION

CALIFORNIA MODEL ONLY:

NOTE

The hoses shown below are numbered as they appear on the Vacuum Hose Routing Diagram Label (page 1-19).

(4)@TUBE

(3) FUEL TUBE

(2) (J) TUBE

(6) TO CARBURETOR.-

VIEWZ VIEWY

(10) PURGE CONTROL VALVE (PCV)

(11) AIR VENT CONTROL VALVE (AVCV)

(17)AIR SUCTION VALVE (ASV)

(8) ® TUBE

(7)@TUBE

(14) AIR CLEANER CASEDRAIN TUBE

(19) FUEL TANK DRAIN TUBE

SECTION AA

(20) CD TUBE

1-14

CALIFORNIA MODEL ONLY:

(12) FUEL TANK DRAIN TUBETO FUEL TANK

~::::.-:=--'--(11) CANISTER

GENERAL INFORMATION

(2) AIR VENTCONTROL VALVE (AVCV)

(4) GROUND CABLE

1-15

GENERAL INFORMATION

EMISSION CONTROL SYSTEMSThe U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify thattheir motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintainedaccording to the instructions provided, and the E.P.A. requires that motorcycles built after January 1, 1983 comply with ap­plicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser,when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's LimitedWarranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in ef­fect.

SOURCE OF EMISSIONS

The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because,under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does notreact in the same way, but it is toxic.

Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro­carbons.

EXHAUST EMISSION CONTROL SYSTEM

Except for California:The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made exceptidle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcaseemission control system.

California only:The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaustgases in the exhaust port. No adjustments to this system should be made, although periodic inspection of the components isrecommended. The secondary air supply system helps improve emission performance.

(1) AIR CLEANER

(4) INTAKEMANIFOLD

(3) CARBURETOR

(2) AIR SUC!TI:O:N~[:~~~~~=~~~~:jVALVE

1-16

GENERAL INFORMATION

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into thecombustion chamber.

(1) AIR CLEANER

(2) CARBURETOR

<>: FRESH AIR_. BLOW-BY GAS

EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)

This model complies with California Air Resources Board evaporative emission requirements.Fuel vapor from the fuel tank and carburetor is directed into the charcoal canister where it is adsorbed and stored while theengine is stopped. When the engine is running and the purge control diaphragm valve is open, fuel vapor in the charcoal canis-ter is drawn into the engine through the carburetor. (3) FUEL TANK

(7) AIR VENT CONTROLVALVE(ENGINE STOP)

(6) AIR VENTCONTROL VALVE

III..

(8) TO OPENAIRCo: FRESH AIR

_. FUEL VAPOR

(2) PURGE CONTROLVALVE

1-17

GENERAL INFORMATION

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causingthereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replace­ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale ordelivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design hasbeen removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.

2. Removal of, or puncturing of any part of the intake system.

3. Lack of proper maintenance.

4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specifiedby the manufacturer.

EMISSION CONTROL INFORMATION LABELSAn Emission Control Information Label is located on the rear fender as shown. It contains basic tune-up specifications.

A.I v~

VEHIClE EMISSION CONTROl. INFORMATION ~AT£

~IlDA MOTOR CO., LTD.THIS VEHICU HAS II((Jl ADJUSTED TOIMPROVE EMISS. CONTROL PERFORIlANCEWHEN OPERATED AT HIGII ALTITIIlE.ALTITI& PERfORMANCE ADJUSTMEIIT INSTRUCTIONSARE AVAILABLE AT 'lUI AUTHORIZED HONDA DEALER..~.

-(1) EMISSION CONTROL~ INFORMATION~ UPDATE LABEL---- ....... ./

EMISSION CONTROL INFORMATION UPDATE LABELAfter making a high altitude carburetor adjustment (Page 4-151. attach an update label on the left sub-frame upper pipe.Instructions for obtaining the update label are given in Service Letter No. 132.

.----::::

1-18

GENERAL INFORMATION

VACUUM HOSE ROUTING DIAGRAM LABEL (California model only)The Vacuum Hose Routing Diagram Label is on the air cleaner case cover. Route the vacuum hoses as shown on this label.

VACUUM HOSE ROUTING DIAGRAMENGlhE FAMI.Y-JI*I064742G9 TO AIRIC tEVAPORATIVE FAMlY-88ZD IJWCVCAUFORNIA VEHiClE

~.-,"-

(1) VACUUM HOSE ROUTINGDIAGRAM LABEL

1-19

LUBRICATION

(1) ROCKER ARM

(13) CAMSHAFT--~~---;.@~~~~~~~~

(12) PISTON

2-0

2. LUBRICATIONSERVICE INFORMATION

TROUBLESHOOTING

ENGINE OIL LEVEL

ENGINE OIL CHANGE

OIL FILTER CHANGE

2-1

2-2

2-3

2-3

2-4

OIL PRESSURE CHECK

OIL PUMP/RELIEF VALVE

CONTROL CABLE LUBRICATION

LUBRICATION POINTS

2-4

2-5

2-10

2-10

SERVICE INFORMATION_l-- _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.The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

CAUTION

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikelyunless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possi­ble after handling used oil.

GENERAL• The oil pump can be serviced after removing the engine from the frame.

SPECIFICATIONSEngine oil

Oil capacity 2.8 lit (2.94 US qt, 2.46 Imp qt) after disassembly.2.3 lit (2.43 US qt, 2.02 Imp qt) at oil filter and oil change.2.2 lit (2.32 US qt, 1.94 Imp qt) after draining.

Oil recommendation HONDA 4 stroke oil or equivalent APIservice classification: SE or SFVISCOSITY: SAE 10W-40

Other viscosities shown in the chart maybe used when the average temperaturein your riding area is within the indicatedrange.

OIL VISCOSITIES

Oil pump

-20 -10 0 10 20 30 40'C

ITEM STANDARD SERVICE LIMIT

Rotor tip clearance 0.15 mm (0.006 in) 0.20 mm (0.008 in)

Pump body clearance 0.15-0.22 mm (0.006-0.009 in) 0.35 mm (0.014 in)

Pump end clearance 0.02-0.07 mm (0.001 -0.003 in) 0.10 mm (0.004 in)

Oil pressure 441 kPa (4.5 kg/cm2 , 64 psi) at 6,000 rpm (80oC/176°F) --

TORQUE VALUESOil pressure switchEngine oil drain boltOil filter

12 N'm (1.2 kg-m, 9 ft-Ib) Apply sealant to the threads35 N'm (3.5 kg-m, 25 ft-Ib)10 N'm (1.0 kg-m, 7.2 ft-Ib)

2-1

TROUBLESHOOTING

ENGINE IS HARD TO START OR SOON STOPSPOSSIBLE CAUSE

1. Drain and check fuel flow to carbure­tor

IREACHING CARBURETOR

2. Try to start with choke ON

IDOES NOT START

3. c~eck spark plug

INO PROBLEM

NOT REACHING CARBURETOR----1..... Clogged fuel line or fuel filter/strainer

• Clogged fuel tank breather holeLoose or disconnected fuel pumpand relay wireFaulty fuel pump relayFaulty fuel pumpFaulty floatClogged carburetor body

ENGINE STARTS----------t....,· Clogged carburetor jets

WET PLUG-----------....-. Dirty air cleanerLoose spark plugMixture too richCarburetor flooded

• Choke valve stuck openDirty air cleaner elementCylinder floodedImproper spark plug

WEAK OR NO SPARK-------.. ,· Refer to page 16-2(ONE CYLINDER)

LOW COMPRESSION-------.....~,· Improper valve and seat contactDamaged cylinder head gasketValve stuck openWorn cylinder and piston rings

4. Spark test both cylinders

INO PROBLEM

5. J, ,,1'0'" com"","o "'09compression gauge

INO PROBLEM

6. c~eck valve train NO GOOD------------.....• Valve clearance too smallI Improper valve timing

COMPRESSION NORMAL Worn camshaftI . Loose valve adjuster and lock nut

------------------------------... Improper ignition timing(Faulty pulse rotor or generator withferrous burrs)Clogged carburetor passage or jets

20-2

LUBRICATION

ENGINE Oil lEVELPlace the motorcycle on its center stand and shift into neutral.

Start the engine and let it idle for a few minutes.

Stop the engine, remove the oil filler cap/dipstick and wipe itclean.Check the oil level with the oil filler cap/dipstick by inserting itwithout screwing it in.

NOTE

• Do not screw the cap in when making this check.

(2) UPPER--.j.

(3) LOWER

If the oil level is below the lower level mark on the dipstick, fillto the upper level mark with the recommended oil.Check the O-ring for damage.

ENGINE Oil CHANGENOTE

Change the engine oil with the engine warm and the motor­cycle on its side stand to assure complete and rapid drain­ing.

Remove the oil filler cap/dipstick and drain bolt.With the engine stop switch OFF, start the starter motor forfew seconds to drain any oil which may be left in the engine.

NOTE

• Do not operate the motor for more than few seconds.

After the oil has drained, check that the drain bolt sealingwasher is in good condition. and install the bolt.

TORQUE: 35 N'm (3.5 kg-m, 25 ft-Ibl

Fill the crankcase with the correct quantity of the recommend­ed oil.

OIL CAPACITY:2.8 lit 12.94 US qt, 2.46 Imp qt) after disassembly2.3 lit 12.43 US qt, 2.02 Imp qt) at oil filter and oil change2.2 lit (2.32 US qt, 1.94 Imp qt) after draining

RECOMMENDED OIL: Honda 4-stroke oil or qeuivalentAPI service classification: SE or SFVISCOSITY: SAE 10W-40

Install the oil filler cap/dipstick.Start the engine and let it idle for 2 - 3 minutes.

Stop the engine and wait a few minutes. then check that theoil level is at the upper level mark.

Check that there are no oil leaks.

(1) DRAIN BOLT

\

\(2) SEALING WASHER

2-3

LUBRICATION

OIL FILTER CHANGEDrain the engine oil (page 2-31.

CAUTION

• Do not replace the oil filter when the exhaust system is hot.

Remove the drive sprocket cover (page 8-21.Remove the oil filter with a filter wrench.TOOL:Oil filter wrench 07HAA-PJ70100

Apply oil to the new oil filter O-ring and install the new oil filter.Tighten the oil filter with a filter wrench.

TORQUE: 10 N'm (1.0 kg-m. 7.2 ft-Ibl

Fill the engine with recommended oil (page 2-3).

OIL PRESSURE CHECK

Remove the oil pressure switch cover and disconnect theswitch wire.

07510-4220100 orequivalent commerciallyavailable in U.S.A.07506-3000000 orequivalent commerciallyavailable in U.S.A.

Oil pressure gauge

Warm the engine up to normal operating temperature (approxi­mately 80 o C/176°F).Stop the engine.

If the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss of consciousness and lead to death.

Remove the oil pressure switch and connect an oil pressuregauge attachment and gauge to the pressure switch hole.Check the oil level.TOOLS:Oil pressure gauge attachment

-'-----------

Start the engine and check the oil pressure at 6.000 rpm.Oil PRESSURE:

441 kPa (4.5 kg/cm 2 • 64 psi) at 6.000 rpm (80 0 C/176°Fl

Stop the engine.

Apply 3-BOND@ sealant or equivalent to the pressure switchthreads and install.TORQUE: 12 N'm (1.2 kg-m. 9 ft-Ibl

Connect the oil pressure switch wire and start the engine.Check that the oil pressure warning indicator goes out afterone or two seconds. If the oil pressure warning indicator stayson. stop the engine immediately and determine the cause.

(2) OILPRESSUREGAUGE

~~.....,~

2-4

OIL PUMP/RELIEF VALVEREMOVAL

Separate the crankcase (Section 11).

Remove the bolt and pressure relief valve cover.Remove the pressure relief valve from the oil pump.

LUBRICATION

(3) PRESSURE RELIEF VALVE

DISASSEMBLY

Remove the snap ring and disassemble the relief valve.

TOOL:Snap ring pliers 07914-3230001

(1) SNAP RING

INSPECTION

Check the spring, O-ring and valve for fatigue, wear or dam­age.Check the body for clogging or damage.

Clean all the parts and assemble them in the reverse order ofdisassembly.

Replace the relief valve, if necessary, as an assembly.

OIL PUMP REMOVALIDISASSEMBLY

Remove the oil pump by removing two mounting bolts.

Remove the dowel pins and a-rings.

(1) a-RING

~ (2) BODY

o (3) VALVE

~(5) SNAP RING

(1) BOLTS

2-5

LUBRICATION

Remove the oil strainer and oil pipe from the oil pump. (1) OIL STRAINER

Check the a-rings and oil seal for fatigue or damage.

Clean the oil strainer and oil pipe with non-flammable or highflash point solvent.

(1) OIL SEAL

Remove the three cover bolts.Disassemble the parts and clean them with non-flammable orhigh flash point solvent.

INSPECTION

Install the outer and inner rotors to the pump body.

Measure the outer rotor-to-pump body clearance.

SERVICE LIMIT: 0.35 mm (0.014 in)

2-6

(1) COVER SaLTS

Remove the oil pump shaft from the oil pump and measure thepump end clearance.

SERVICE LIMIT: 0.10 mm (0.004 in)

Temporarily install the shaft in the pump body.

Measure the inner rotor tip clearance.

SERVICE LIMIT: 0.20 mm (0.008 in)

Replace the oil pump, if necessary as an assembly.

ASSEMBLY

(1) PUMP BODY

(2) OUTER ROTOR

LUBRICATION

(10) O-RING

(11) OIL STRAINER

2-7

LUBRICATION

Install the outer rotor in the pump body with the punch markfacing the cover, then install the inner rotor.Install the drive pin and spacer on the shaft.

Install the shaft in the body, aligning the drive pin with theinner rotor groove.

Install the dowel pin and a new gasket on the pump body, theninstall the cover.

Tighten the cover bolts securely.

(1) OUTER ROTOR

(2) PUNCH MARK

(6)INNER ROTOR

(1) OIL PUMP BODY

(2) OIL PUMP COVER

(1) COVER BOLTS

Install the O-rings, oil seal, oil strainer and oil pipe on the oilpump.

CAUTION

Install the O-rings on the oil pipe with the tapered side facingout as shown, or the engine will be damaged... ..

2-8

(1) OIL STRAINER

(5)OIL'SEAL

,'(2) O-RING

INSTALLATION

Install the dowel pins and new a-rings.

Install the oil pump as an assembly.

Assemble the pressure relief valve and install it in the oil pump.

Install the pressure relief valve cover with the bolt.Assemble the crankcase (Section 11).

LUBRICATION

(2) DOWEL PIN

2-9

LUBRICATION

CONTROL CABLE LUBRICATIONPeriodically disconnect the throttle and choke cable at theirupper ends. Thoroughly lubricate the cables and their pivotpoints with a commercially available cable lubricant or a lightweight oil.

LUBRICATION POINTSUse general purpose grease when not otherwise specifiedhere.Apply oil or grease to the other sliding surfaces and cables notshown here .

(5) DRIVE CHAIN(GEAR OIL SAE #80-90)

-~(4) FOOT PEG PIVOTS AND

SEAT LOCK STRIKER & LATCH\\

-~(6) SIDE STAND & MAIN STAND

PIVOT

(3) SWINGARMPIVOT BALLAND NEEDLEBEARINGS

(2) THROTTLEPIPE

JI

J

" -~JI

II

JJ

JJ

JJ

J,

,III_--.:

(7) BRAKE PEDALPIVOT

(8) BRAKECALIPER PIVOTS(SILICON GREASE)

-~(9) SPEEDOMETER

DRIVE GEAR

.,(1) CLUTCH AND BRAKE

LEVER PIVOTS

iii or equivalent

(10) FORK

-~(11) STEERING

HEAD BEARINGS ----'-----1

2-10

3. MAINTENANCESERVICE INFORMATION

MAINTENANCE SCHEDULE

<ENGINE>

FUEL LINE

THROTTLE OPERATION

CARBURETOR CHOKE

AIR CLEANER

CRANKCASE BREATHER

SPARK PLUG

VALVE CLEARANCE

CARBURETOR SYNCHRONIZATION

CARBURETOR IDLE SPEED

RADIATOR COOLANT

COOLING SYSTEM

CYLINDER COMPRESSION

SECONDARY AIR SUPPLY SYSTEM(California model only)

SERVICE INFORMATION

3-1

3-3

3-4

3-4

3-5

3-5

3-6

3-6

3-7

3-8

3-9

3-9

3-10

3-10

3-11

EVAPORATIVE EMISSIONCONTROL SYSTEM(California model only)

<CHASSIS>

DRIVE CHAIN

BRAKE FLUID

BRAKE PAD WEAR

BRAKE SYSTEM

BRAKE LIGHT SWITCH

HEADLIGHT AIM

CLUTCH SYSTEM

SIDE STAND

SUSPENSION

NUTS, BOLTS, FASTENERS

WHEELS/TIRES

STEERING HEAD BEARINGS

3-11

3-12

3-13 D3-14

3-14

3-14

3-15

3-15

3-16

3-16

3-17

3-17

3-18

-'-----------------------Support the motorcycle on the center stand on a level surface before starting any work.If the engine must be running to do some work. make sure tlte area is well-ventilated. Never run the engine in an enclosed area.The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.Do not smoke or allow flames or sparks in the work area or where gasoline is stored.

GENERAL

• Engine oil• Engine oil filter change

See page 2-3See page 2-4

SPECIFICATIONS

~ENGINE~

Ignition timing

Spark plug

InitialFull advance

100 BTDC at idle31 0 BTDC at 7,000 ± 200 rpm

NGK NOStandard DPR8EA-9 X24EPR-U9

For cold climate Ibelow 50 C/41 0F) DPR7EA-9 X22EPR-U9

For extended high speed riding DPR9EA-9 X27EPR-U9

Spark plug gapValve clearance IN

(COLD) EXIdle speedCylinder compressionThrottle grip free play

0.8-0.9 mm (0.031 -0.035 in)0.15 ± 0.02 mm (0.006 ± 0.0008 in)0.20 ± 0.02 mm (0.008 ± 00008 in)1,200 ± 100 rpm1,324 ± 196 kPa 113.5 ± 2.0 kg/em', 192 ± 28 psi)2-6 mm (1/16-1/4 inl

Revised: June, 1991© 1991 American Honda Motor Co.. Inc.. All Rights ReservedMSV 5511 (9106) '88-'91 NT650

3-1

MAINTENANCE

~CHASSIS~

Clutch lever free playDrive chain slack

Tires

10-20 mm (3/8-3/4 in)20-30 mm (3/4-1-3/16 in) Refer to page 3-12

Front Rear

Tire size (Tubeless type) 110/80-17 57H 150/70-1 7 69H

Cold tire pressures Up to 90 kg (200 Ibs) 225 (2.25, 33) 225 (2.25, 33)kPa (kg/cm 2 , psi) Up to maximum weight

capacity225 (2.25, 33) 250 (2.50, 36)

Tire brand Bridgestone G547G G548Dunlop K505G K505

Wheel balance weight 60g Maximum 60g Maximum

TORQUE VALUES

Eccentric bearing carrier pinch boltValve adjusting screw lock nutTiming hole capCrankshaft hole capSpark plug

TOOLS

SpecialValve adjusting wrenchVacuum gauge

3-2

75 Nom (7.5 kg-m, 54 ft-Ib)23 Nom (2.3 kg-m, 17 ft-Ib)10 Nom (1.0 kg-m, 7.2 ft-lb)TApply molybdenum disulfide grease to the15 Nom (1.5 kg-m, 11 ft-Ib)-.J threads14 Nom (1.4 kg-m, 10 ft-Ibl

07908-KE9000007404-0030000 or M937B-021-XXXXX Vacuum gauge set

MAINTENANCE

MAl NTENANCE SCHEDULEThe following items require some mechanical knowledge. Certain items (particularly those marked * and * *) may requiremore technical information and tools. Owners should consult their authorized Honda dealer.Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.C: CLEAN R: REPLACE L: LUBRICATE

3-8

ODOMETER READING (NOTE 1)

x 1,000 mi 0.6 4 8 12 16 20 24 REFER TOf-x-1-0-0-k-m-+-10---1-

6-4

-+--1

2-8-+-1-92-+--2-5-6-+-3-2-0-+-3-8-4-1 PAGE

NOTE

I

I

I

(NOTE 2) R R

(NOTE 3) C C C C C C

R R R R R R

I I I I

R R R R

R R R R

FREQUENCY

ITEM

*

*

*

*

~ SPARK PLUG 3-6Lfjl--+------------j----t-----j--t--+---t--t--+---t--t-----j!::: VALVE CLEARANCE 3-6ol---+------------t----+------t--+----+----+--+----+----+--+------t

ENGINE OIL 2-3~I__-+------------t----+------t--+---+----+--+----+---+--+------t<l: ENGINE OIL FILTER 2-4uJl--+------------j----t-----j--t--+---t--t--+---t--t-----j0:: * CARBURETOR-Z SYNCHRONIZATION

(/)Q I--+------------j----t-----j--t--+---t--t--+---t--t-----j

CARBURETOR-IDLE SPEED 3-9~f---t------------+----t-----+---+---1f---+--+--+--+--j------+"" RADIATOR COOLANT (NOTE 5) *R 3-9wl--+------------j--'-----:....t-----j--t--+---t--t--+---t--t-----j

COOLING SYSTEM 3-10

SECONDARY AIR SUPPLYSYSTEM

(NOTE 5) 3-11

* EVAPORATIVE EMISSIONCONTROL SYSTEM

(NOTE 4) 3-11

DRIVE CHAIN

(/) BRAKE FLUID

~ BRAKE PAD WEAR!:::I--j------------o BRAKE SYSTEMw~ * BRAKE LIGHT SWITCH

uJ * HEADLIGHT AIM0::1--+------ _Z CLUTCH SYSTEMa f___t_-----------Ui SIDE STAND(/)1__-+------------~ * SUSPENSIONwZ * NUTS, BOLTS, FASTENERSaZ * * WHEELS/TIRES

* * STEERING HEAD BEARINGS

3-12

3-13

3-14

3-14

3-14

3-15

3-15

3-16

3-16

3-17

3-17

3-18

* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanicallyqualified.

* * In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.NOTES: 1. At higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in unusually wet or dusty areas.3. Service more frequently when riding in rain or at full throttle.4. California model only.5. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechani­

cal skill.

3-3

MAINTENANCE

FUEL LINERemove the seat (page 13-25).

Check the fuel lines for deterioration, damage or leakage.Replace the fuel lines if necessary.

THROTTLE OPERATIONCheck for smooth throttle grip full opening and automatic fullclosing in all steering positions.Check the throttle cables and replace them if they are deterio­rated, kinked or damaged.

Lubricate the throttle cables, if throttle operation is notsmooth.

Measure the free play at the throttle grip flange.

FREE PLAY: 2-6 mm (1/16-1/4 in)

_ i vI \(1) 2-6 mm

(1/16-1/14 in)

(2) FUEL FILTER

Throttle grip free play can be adjusted at either end of thethrottle cable. Minor adjustments are made with the upper ad­juster.

Major adjustments are made with the lower adjuster.

Adjust the free play by loosening the lock nut and turning theadjusting nut. Tighten the lock nuts.

Recheck throttle operation. Replace any damaged parts, ifnecessary.

3-4

CARBURETOR CHOKEThis model's choke system uses a fuel enrichening circuit con­trolled by a choke valve. The choke valve opens theenrichening circuit via a cable when the choke lever on thehandlebar is pulled back.

Check for smooth upper choke lever operation. Lubricate thechoke cable if the operation is not smooth.

Remove the left and right choke cable boots from the chokevalve nuts.

Loosen each choke valve nut and remove the choke valve fromthe carburetor.

Push the choke lever on the handlebar all the way up to fullyclosed and measure the distance between the ends of thechoke valve and nut.It should be 10-11 mm (0.39-0.43 in).

Adjust the distance to within specifications by loosening thelock nut and turning the cable's elbow at the left handlebarswitch housing.Tighten the lock nut securely and recheck the distance.

Thread the choke valve in by hand and then tighten the chokevalve nut 1/4 turn with a 14 mm wrench.

AIR CLEANERRemove the fuel tank (page 4-3).Remove the air cleaner case cover screws and cover.

MAINTENANCE

(1) CHOKE LEVER

3-5

MAINTENANCE

Remove the air cleaner element.Replace the element in accordance with the maintenanceschedule.Also, replace the element any time it is excessively dirty ordamaged.

CRANKCASE BREATHERThe crankcase breather drain; air cleaner case drain tube isbehind the side stand.

Remove the drain plug from the tube to empty any deposits.Reinstall the plug securely.

NOTE

Service more frequently when the motorcycle has beenridden in rain, at full throttle, or after it is washed or over­turned. Service if the deposit level can be seen in the trans­parent section of the drain tube.

SPARK PLUGDisconnect the spark plug caps and remove the spark plugs.

RECOMMENDED SPARK PLUG:

NGK ND

Standard DPR8EA-9 X24EPR-U9

For cold climateDPR7EA-9 X22EPR-U9

(below 5°C/41°F)

For extended high speedDPR9EA-9 X27EPR-U9

riding

Measure the new spark plug gap with a wire-type feeler gauge.

SPARK PLUG GAP: 0.8-0.9 mm 10.031-0.035 inl

Adjust the gap if necessary, by bending the side electrodecarefully. With the plug washer attached, thread each sparkplug in by hand to prevent crossthreading. Continue tighteningby hand until the spark plug bottoms.Then, tighten the spark plugs another 1/2 turn with a sparkplug wrench to compress the plug washer.

TORQUE: 14 N'm (1.4 kg-m. 10 ft-Ibl

Connect the spark plug caps.

Install the removed parts in the reverse order of removal.

3-6

(1) DEPOSITS

0.8-0.9 mm(0.031-0.035 in)

(2) CENTERELECTRODE

I~ (31 CLIP

~121 DRAINa

PLUG"

(1) SIDEELECTRODE

(1) SPARK PLUG

MAINTENANCE

VALVE CLEARANCENOTE

Inspect and adjust valve clearance while the engine is cold(below 35°C/95°F).

Remove the following parts:- seat (page 13-25)- fuel tank (page 4-3)- air cleaner case (page 4-4)- thermostat housing mounting bolt and radiator mounting

bolts to releasing tension of water hoses- crankshaft and timing hole caps- cylinder head cover

Remove the cylinder head covers. (3) INDEX NOTCH

FRONT CYLINDER

Rotate the flywheel counterclockwise to align the" FT" markwith the index notch on the left crankcase cover. Make surethe piston is at TDC (Top Dead Center) on the compressionstroke and the cam lobes are all facing down as shown.

(2) "FT" MARK

Inspect the clearance of all three valves by inserting a feelergauge between the adjusting screw and the valve.

VALVE CLEARANCES: (COLD)Intake: 0.15 ± 0.02 mm (0.006 ± 0.0008 in)Exhaust: 0.20 ± 0.02 mm (0.008 ± 0.0008 in)

Apply oil to the nut and screw threads.

TORQUE: 23 N'm (2.3 kg-m. 17 ft-Ib)

Hold the adjusting screw and tighten the lock nut.

07908 - KE90000

Adjust by loosening the lock nut and turning the adjustingscrew until there is a slight drag on the feeler gauge.

TOOL:Valve adjusting wrench

3-7

MAINTENANCE

REAR CYLINDER

Rotate the flywheel counterclockwise to align the "RT" markwith the index notch on the left crankcase cover. Make surethe piston is at TDC on the compression stroke and the camlobes are all facing down.

Inspect and adjust the valve clearance using the same methodas for the front cylinder.Install the front and rear cylinder head covers.

Apply molybdenum disulfide grease to the threads of thetiming and crankcase hole caps, then install and tighten them. (1) CAM LOBES

(2) "RT" MARK

NOTE

IDLE SPEED: 1,200 ± 100 rpm

(1) VACUUM GAUGE

~) JOINT PLUG (PIN: 16124-MBO-000). ~:---...........

07404-0030000 orM937B-021-XXXXX

TOOL:Vacuum gaugeVacuum gauge set

Warm up the engine and adjust the idle speed with the throttlestop screw.

Connect the vacuum gauge tube and vacuum gauge.

FRONT CYLINDER:Remove the plug from the front cylinder intake port and installthe vacuum gauge adaptor.

TORQUE:Timing hole cap:

10 N'm (1.0 kg-m, 7.2 ft-IblCrankshaft hole cap:

15 N'm (1.5 kg-m. 11 ft-Ibl

Perform this maintenance with the engine at normal operat­ing temperature. the transmission in neutral. and the motor­cycle on its center stand.

REAR CYLINDER:Remove the plug from the rear cylinder intake port and installthe joint plug (PIN: 16124- MBO-OOO).

If the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss of consciousness and lead to death.

CARBURETOR SYNCHRONIZATION

Remove the rear fuel tank mounting bolt first. then remove thefront side (page 4-3). Carefully raise the tank and support it inthe frame using a suitable base.

-'-------------

3-8

Check that the difference in vacuum readings is 40 mm (1.6in) Hg or less.

NOTE

• The rear cylinder carburefor is the base carburetor.

If necessary, synchronize to the specification by turning thesynchronization adjusting screw.

Recheck the idle speed and synchronization.Disconnect the gauge and adaptors and install the removedparts.

CARBURETOR IDLE SPEEDNOTE

Inspect and adjust idle speed after all other engine adjust­ments are within specifications.The engine must be warm for accurate adjustment. Tenminutes of stop-and-go riding is sufficient.

Warm up the engine, shift to NEUTRAL, and place the motor­cycle on its center stand.

-'--------------Ij the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss oj consciousness and lead to death.

Turn the throttle stop screw as required to obtain the specifiedidle speed.

IDLE SPEED: 1,200 ± 100 rpm

RADIATOR COOLANTCheck the coolant level of the reserve tank with the enginerunning at normal operating temperature.-'--------------Ij the engine must be running to do some work, make sure the

area is well-ventilated. Never run the engine in an enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss oj consciousness and lead to death.

The level should be between the '''UPPER'' and "LOWER"level lines.

If necessary, remove the reserve tank cap.Fill up to the upper level line with 50/50 mixture of distilledwater and antifreeze.

Reinstall the reserve tank cap.

MAINTENANCE

/ /7(2) LOWER LEVEL

3-9

MAINTENANCE

COOLING SYSTEMRemove the radiator shroud and check the radiator air pas­sages for clogging or damage.Straighten bent fins or collapsed core tubes with a small flatblade screwdriver as shown and remove insects, mud or anyobstructions with compressed air or low pressure water.Replace the radiator if the air flow is restricted over more than30% of the radiator's surface.For radiator replacement, refer to page 5-5.

Make sure the hoses are in good condition.Replace any hose that shows any sign of deterioration.Check that all hose clamps are tight.

CYLINDER COMPRESSIONWarm up the engine to normal operating temperature.

-'-----------If the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss of consciousness and lead to death.

Stop the engine, disconnect both spark plug caps and removeone spark plug.

NOTE

To measure the cylinder compression of each individual cyl­inder and remove only one plug at a time.

Turn the engine stop switch OFF.

Insert the compression gauge. Open the throttle all the wayand crank the engine with the starter motor. Crank the engineuntil the gauge reading stops rising. The maximum reading isusually reached within 4- 7 seconds.

COMPRESSION PRESSURE:1,324 ± 196 kPa (13.5 ± 2.0 kg/cm2 , 192 ± 28 psi)

If compression is high, it indicates that carbon deposits haveaccumulated on the combustion chamber and/or the pistoncrown.

If compression is low, pour 3-5 cc (0.1-0.2 US. oz) of cleanengine oil into the cylinder through the spark plug hole and re­check the compression.If the compression increases from the previous value, checkthe cylinder, piston and piston rings.If the compression is the same as the previous value, checkthe valves for leakage.

3-10

~~ .(1) SCREWDRIVER

MAINTENANCE

SECONDARY AIR SUPPLY SYSTEM(California model only)Check the air and vacuum hoses and tubes for bending ortwisting and straighten if necessary.

Check the system hoses and tubes for damage, deterioration.clogging or loose connections.Check the air suction valve for damage (page 4-17l.Refer to the vacuum hose routing diagram label for hose con­nections as shown below.

EVAPORATIVE EMISSION CONTROLSYSTEM (California model only)Check the hoses between the fuel tank, canister, purge controlvalve (PCV), air vent control valve (AVCVl, and carburetor fordeterioration, damage or loose connections.

(2) PURGE CONTROLVALVE

(1) CARBURETORS

[~

ro!JE:?~ill'l(4) DRAIN

(5) CHARCOALCANISTER

\':=~~~~=~~~;U'1"'----(6)AIR VENTI • CONTROL VALVE

~ (7) AIR VENT CONTROL(8) TO OPEN VALVE

AIR (ENGINE STOP)<>: FRESH AIR.....: FUEL VAPOR

(3) FUEL TANK

Also check the tubes for bending or twisting and straighten ifnecessary.Check the canister for cracks deterioration. or other damage.Refer to the vacuum hose routing diagram label for connec­tions as shown right.

VACUUM HOSE ROUTING DIAGRAMENGltoE FAMLY-AiN064742G9 TO AIRIC tEVAPORATIVE FAMlLY-88Z0 NCVCALIFORNIA VEHICLE

3-11

MAINTENANCE

DRIVE CHAINCHAIN SLACK INSPECTION-'--------------Never inspect or adjust the drive chain while the engine is run­

ning.

Turn the ignition switch OFF. support the motorcycle on itscenter stand and shift the transmission into neutral.Place the chain slack gauge against the reference arrow onlower edge of the swingarm as shown. 9~ _

(1) DRIVE CHAIN SLACK GAUGE (EQUIPMENT TOOL)

Pull the lower run of the drive chain down with your finger andcheck slack using the gauge.

xUP

xUP

...£...1

(2) DRIVE CHAIN

oUP

(1) DRIVE CHAIN SLACK GAUGE (EQUIPMENT TOOL)

NOTE

The chain slack gauge and eccentric bearing carrier wrenchare supplied with this motorcycle.The chain slack gauge is using the "UP" mark facing theswingarm without fail.Make sure the upper edge of the chain is between lines Aand B on the gauge.

A-B: Good.Above A: Too tight.Below C: Too loose.

CHAIN ADJUSTMENT

Loosen the eccentric bearing carrier pinch bolt.Turn the eccentric bearing carrier clockwise or counter­clockwise by the bearing carrier wrench to obtain the drivechain slack as necessary.

Tighten the eccentric bearing carrier pinch bolt.

TORQUE: 75 N'm (7.5 kg-m. 54 ft-Ibl

Recheck chain slack.Lubricate the drive chain with SAE #80 or 90 gear oil.

111 ECCENTRIC BEARING CARRIER WRENCH~(EQUIPMENT TOOL) . ;/

Check the chain wear label on the swingarm. If the red zone onthe label aligns with the driven sprocket teeth after chain hasbeen adjusted. the chain must be replaced.

REPLACEMENT CHAIN: RK525 5M3 or 010525 V7 (112 LE)LINK: 112 Links

o-====10

3-12

LUBRICATION AND CLEANING

When the drive chain becomes extremely dirty, it should becleaned prior to lubrication.Clean the drive chain with a non-flammable or high flash pointand wipe dry.

The drive chain on this motorcycle is equipped with small 0­rings between the link plates. The a-rings can be damaged bysteam cleaners, high pressure washers and certain solvents.

Lubricate only with SAE #80 or 90 gear oil.Commercial chain lubricants may contain solvents whichcould damage the rubber a-rings.

DRIVE AND DRIVEN SPROCKET

Inspect the sprocket teeth for excessive wear or damage. Re­place if necessary.

NOTE

Never install a new drive chain on worn sprockets or a wornchain on new sprockets. Both chain and sprockets must bein good condition, or the new replacement chain or sprock­ets will wear repidly.

BRAKE FLUIDFRONT

Check the front brake fluid level with the handlebar turned sothat the reservoir is level.Check the front brake fluid through the sight glass. If the levelis visible, check pad wear first; replace the pads if necessary.Then remove the cover, set plate and diaphragm. Fill the reser­voir to the upper level with DOT 4 fluid from a sealed contain­er. Check the system for leaks.

CAUTION

Do not remove the reservoir cover until the handlebar has beenturned so that the reservoir is level.Do not mix different types offluid, as they are not compatiblewith each other.

• Do not allow foreign material to enter the system when fillingthe reservoir.A void spilling the fluid on painted, plastic or rubber parts.Place a rag over these parts whenever the system is serviced.

Refer to section 14 for brake bleeding procedures.

REAR

Check the rear brake fluid level after supporting the motor­cycle upright on level ground.Check the rear brake fluid level; if it is near the lower line,check pad wear first; replace the pads if necessary. Thenremove the cover, set plate and diaphragm. Fill the reservoir tothe upper level with DOT 4 fluid from a sealed container.Check the system for leaks.

(1) WIPE DRY

(2) LUBRICATE~ SAE #80 or #90

. iii GEAR OIL

(1) COVER

MAINTENANCE

(2) NORMALI

(2) UPPERLEVEL

3-13

MAINTENANCE

BRAKE PAD WEARFRONT

Check the front brake pads for wear, through from the lowerend of the caliper.

REAR

Check the rear brake pads for wear, through from the rear ofthe caliper.

CAUTION

Always replace the brake pads as a sello assure even disc pres­sure.

See section 14 for brake pad replacement.

BRAKE SYSTEMInspect the brake hoses and fittings for deterioration, cracksand signs of leakage. Tighten any loose fittings.Replace hoses and fittings as required.

REAR BRAKE PEDAL

Check the rear brake pedal height.To adjust the brake pedal height, loosen the lock nut and turnthe master cylinder push rod. Tighten the lock nut.

NOTE

Adjust the brake light switch after adjusting the brake pedalheight.

BRAKE LIGHT SWITCHNOTE

Perform the rear brake light switch adjustment after adjust­ing the brake height.The front brake light switch does not require adjustment.

Adjust the brake light switch so that the brake light will comeon when brake engagement begins.Adjust by turning the adjuster while holding the switch body.Tighten the adjuster lock nut and recheck the brake lightswitch operation.

NOTE

• Do not turn the switch body.

3-14

HEADLIGHT AIMAdjust vertically by loosing the headlight mounting bolts.Adjust horizontally by turning the horizontal adjusting screw.

NOTE

Adjust the headlight beam as specified by local laws andregulations.

-'-----------An improperly adjusted headlight may blind oncoming dril-eYs,or it may fail 10 light the road for a safe distance.

CLUTCH SYSTEMMeasure the clutch lever free play at the lever end.

FREE PLAY: 10-20 mm (3/8-3/4 in)

Minor adjustments are made with the upper adjuster.

Pull the lever cover back, loosen the lock nut and turn the ad­juster to obtain the specified free play.

Tighten the lock nut and install the cover.

Check clutch operation.

Major adjustments are made with the lower adjuster.Loosen the lock nut and turn the adjusting nut to obtain thespecified free play.

Tighten the lock nut and check the clutch operation.

Revised: June. 1991© 1991 American Honda Motor Co.. Inc.. All Rights ReservedMSV 551 1 (9106) ·SS··91 NT650

MAINTENANCE

3-15

MAINTENANCE

SIDE STANDPlace the motorcycle on its center stand.Check the rubber pad on the side stand for deterioJation andwear.Replace the rubber pad if wear extends to the wear line.

Check the side stand operation:When lowerd, the stand should move easily to the first stop,then lock forward to support the motorcycle when the padtouches the ground and the weight of the motorcycle is sup­ported.

When the motorcycle is raised, the stand should automaticallymove to the first stop, then retract easily when kicked.

U(2) SIDE STAND RUBBER

(3) FIRST CLICK

If the side stand does not operate smoothly, disassemble andcheck the side stand assembly as following procedure:

Remove the return spring at the retracted position.Remove the pivot bolt and side stand.Check the following parts:- inside of the pivot and pivot collar for wear or damage.- pivot dust seal for damage.

Lubricate the pivot area with clean grease and reassemble theside stand.

TORQUE:Side stand pivot bolt: 38 N'm (3.8 kg-m, 27 ft-Ibl

CAUTION

Install the dust seal lip spring is facing out.Make sure that the dust seal lip spring is seated securely.

Check the side stand operation as indicated above.

SUSPENSIONFRONT

Check the suspension action by compressing it several times.

Check the entire fork leg assembly for signs of leaks or dam­age.Replace any components which are unrepairable.Tighten all nuts and bolts to the specified torque value._L- _

Do not ride a vehicle with faulty suspension. Loose. worn, ordamaged suspension parts may affect stability and rider con­trol.

3-16

REAR

Check the action of the rear suspension components by com­pressing the suspension several times.Check the entire suspension assembly, being sure it is securelymounted and not damaged or distored.

Place the motorcycle on its center stand.Check for worn swingarm bearings by grabbing the swingarm,and attempting to move the swingarm side to side. Replacethe bearings if any looseness is noted (page 13-19).

Tighten all nuts and bolts.

NUTS, BOLTS,FASTENERSTighten the bolts, nuts and fasteners at the intervals shown inthe Maintenance Schedule (page 3-3).Check that all chassis nuts and bolts are tightened to their cor­rect torque values (page 1-5 and 6).Check all cotter pins and safety clips.

WHEELS/TI RESTIRE PRESSURE

NOTE

• Tire pressure should be checked when the tires are COLD.

MAINTENANCE

Front Rear

Tire size (Tubeless) 11 0/80-1 7 57H 150170-1769H

Cold tire Up topressures maximum

225 (2.25, 33) 250 (2.50, 36)kPa weight(kg/cm2 , capacitypsi) Up to 90 kg

(200Ibs) 225 (2.25, 33) 225 (2.25, 33)load

Tire Bridgestone G547G G548brand Dunlop K505G K505

3-17

MAINTENANCE

Check the tires for cuts, imbedded nails, or other sharp ob­jects.

Check the front and rear wheels for trueness (Section 12 and13).Measure the tread depth at the center of the tires.Replace the tires if the tread depth reaches the following limit:

MINIMUM TREAD DEPTH:Front: 1.5 mm (0.06 in)Rear: 2.0 mm (0.08 in)

STEERING HEAD BEARINGSNOTE

Check that the control cables do not interfere with handle­bar rotation.

Raise the front wheel off the ground.Check that the fork pivots freely from side to side. If the forkpivots unevenly, binds, or has vertical movement, inspect thesteering head bearings (Section 12).

3-18

FUEL SYSTEM

'88 Shown:

4-0

k m 9 ft-Ibl12 N'm (1.2 g- ,

16 ft-Ibl( 2 kg-m,22 N'm .

SERVICE INFORMATION

TROUBLESHOOTING

FUEL TANK

AIR CLEANER CASE

CARBURETOR REMOVAL

CARBURETOR DISASSEMBLY

CARBURETOR ASSEMBLY

CARBURETORSEPARATION/ASSEMBLY

4. FUEL SYSTEM4-1 CARBURETOR INSTALLATION 4-13

4-2 PILOT SCREW ADJUSTMENT 4-14

4-3 HIGH ALTITUDE ADJUSTMENT

4-4 (U.S.A. ONLY) 4-14

4-5PURGE CONTROL VALVEINSPECTION (California model only) 4-15

4-5AIR VENT CONTROL VALVE III4-9 INSPECTION (California model only) 4-16

SECONDARY AIR SUPPLY4-12 SYSTEM (California model only) 4-17

SERVICE INFORMATION

-"-------------------------Gasoline is extremely flammable and is explosive under certain conditions work in a well ventilated area with the engine stopped.Do not smoke or allow flames or sparks in the work area or where gasoline is stored.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.The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

GENERAL

• Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments.• When disassembling fuel system parts, note the locations of the a-rings; replace them with new ones on reassembly.• The carburetor float chambers have drain screws that can be loosened to drain residual gasoline.• For fuel pump inspection refer to section 18.• All hoses used in the evaporative emission control system are numbered for identification. When connecting one of these

hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4-15 (California model only), forits routi ng.

CAUTION

• Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.

NOTE

If the vehicle is to be stored for more than one month, drain the float chambers. Fuel left in the float chambers may causeclogged jets resulting in hard starting or poor driveability.

SPECIFICATIONS

'88 After '88

Item 49 St. model I California model 49 St. model I California model

Type Constant Velocity dual carburetor

Throttle bore 36.5 mm (1.4 in)

Identification No. VDGKA I VDGLA VDGKA I VDGLA

Float level 9.2 mm (0.36 in) 9.2 mm (0.36 in)

Main jet Front: #138, Rear: #132 Front: #138, Rear: #132

Slow jet #42 #42

Idle speed 1,200 ± 100 rpm

Throttle grip free play 2-6 mm (1/8-1/4 in)

Pilot screw initial opening 2-1/8 I 2-1/2 Front: 1-1/2, Rear: 1 I 1-3/8

4-1

FUEl SYSTEM

TORQUE VALUES

Fuel tank mounting bolt

TOOLS

SpecialVacuum/Pressure pump

Pressure pumpVacuum pump

CommonFloat level gauge

: Front: Rear

12 N'm (1.2 kg-m. 9 ft-Ib)22 N'm (2.2 kg-m. 16 ft-Ib)

A937X-041-XXXXX orST-AH-255-MC7 (U.S.A. only)ST-AH-260-MC7 (U.S.A. only)

07401-0010000

TROUBLESHOOTINGEngine cranks but won't start

No fuel to carburetorEngine flooded with fuelNo spark at plug (ignition system faulty)Clogged air cleanerIntake air leakImproper choke operationImproper throttle operation

Hard starting or stalling after startingImproper choke operationIgnition malfunctionFaulty carburetorFuel contaminatedIntake air leakIncorrect idle speedIncorrect valve clearance (Section 3)Incorrect carburetor synchronization (Section 3)Improper choke valve operation. •

Rough idleFaulty ignition systemIncorrect idle speedIncorrect valve clearance (Section 3)Incorrect carburetor synchronizationFaulty carburetorFuel contaminatedFaulty air cut off valve(California model only:): Faulty purge control valve: Faulty air vent control valve: Worn/damaged emission system hoses

Afterburning during decelerationFaulty ignition systemFaulty air cut off valveLean mixture(California model only:): Worn/damaged emission system hoses

4-2

Misfiring during acceleration• Faulty ignition system

BackfiringFaulty ignition system

• Faulty carburetor

Poor performance ldriveability) and poor fuel economy• Clogged fuel system

Faulty ignition systemDirty air cleaner(California model only:): Faulty air vent control valve: Worn/damaged emission system hoses

Lean mixtureClogged fuel jetsStuck vacuum pistonFaulty float valveLow float levelClogged fuel tank breatherClogged fuel strainerRestricted fuel lineIntake air leakRestricted or faulty fuel pump

Rich mixtureClogged air jetsFaulty float valveFloat level too highDirty air cleaner

FUEL TANKREMOVAL

-'----------Gasoline is extremely flammable and is explosive under certainconditions. Work in a well ventilated area with the enginestopped. Do not smoke or allow flames or sparks in the workarea or where gasoline is stored.

Remove the seat (page 13-25) and turn the fuel valve OFF.Disconnect the fuel tube from the fuel tank.

OFF

FUEL SYSTEM

'88 Only:California model only:Disconnect the No.1 fuel breather tube (to canister) from thefuel tank.

All models:Remove the rear fuel tank mounting bolt first, then the frontbolt and remove the tank from the frame.

CAUTION

Ifyou remove thefronl mounting bolt first, it may damage thefront mounting collar.

Check that fuel flows out of the fuel valve freely.If flow is restricted. clean the fuel startiner.

After '88:Remove the rear fuel tank mounting bolt first, then the frontbolt.

Screw the rear mounting bolt in the front mounting collar.Remove the rear mounting bolt and the collar as a set.

California model only:Disconnect the No.1 fuel breather tube (to canister) from thefuel tank.

All models:Remove the fuel tank from the frame.

INSTALLATION

'88, After '88:Install the fuel tank in the frame.Install the front mounting collar and the bolt first, then the rearmounting bolt.

TORQUE:Front: 12 N'm 11.2 kg-m, 9 ft-IblRear: 22 N'm 12.2 kg-m, 16 ft-Ibl

Connect the removed tubes securely.

Revised: June. 1991© 1991 American Honda Motor Co.. Inc.. All Rights ReservedMSV 551 1 (9106) '88·'91 NT650

4-3

FUEL SYSTEM

AIR CLEANER CASEREMOVAL

NOTE

The air cleaner case can be removed without removing thecase cover removal.

Remove the seat and fuel tank.Remove the air cleaner case mounting bolt.

Loosen the air cleaner connecting tube band screws and dis­connect the crankcase breather and air cleaner case draintube.Remove the air cleaner case.

Install the air cleaner case in the reverse order of removal.

Disconnect the air hoses (carburetors-to-sub-air cleaner cov­er).Remove the sub-air cleaner mounting bolt and cover andremove the element.

SUB-AIR CLEANER ELEMENT

Remove the following:- seat (page 13-25) and fuel tank (page 4-3)- air cleaner case

, .

Wash the element in non-flammable or high flash point sol­vent, squeeze out the solvent thoroughly. and allow the ele­ment to dry.Soak the element in gear oil (SAE #80-90) and squeeze outthe excess.Reinstall the element and cover, and tighten the bolt.Reconnect the air tubes from the carburetors.

4-4

(1 )

WASH INSOLVENT

<>(i<>i j

(2)

SQUEEZE OUTSOLVENTTHOROUGHLY

(3)

DRY

(4) (5)GEAR OIL SQUEEZE OUT(SAE #80-90) EXCESS OIL

CARBURETOR REMOVAL_L--- _Gasoline is extremely flammable and is explosive under certainconditions. Work in a well ventilated area with the enginestopped. Do not smoke or allow flames or sparks in the workarea or where gasoline is stored.

Loosen the drain screws and drain the fuel into a container.Remove the air cleaner case.Disconnect the throttle cables from the carburetor.

NOTE

Turn the choke lever fully in to avoid losing the chokevalves.

Remove the choke valves from the carburetor and loosen thecarburetor insulator bands.

California model only:Disconnect the purge control valve No. 5 tubes and air ventcontrol valve No.6 and 11 tubes from the carburetor.

Pull the carburetors upward and away from the engine.

CARBURETOR DISASSEMBLYNOTE

The carburetors can be disassembled without being sepa­rated.

Remove the fuel tube from the carburetor.

VACUUM CHAMBER

Remove the four screws and vacuum chamber cover.

FUEL SYSTEM

(3) THROTTE CABLES

4-5

FUEL SYSTEM

Remove the spring, piston/diaphragm.Inspect the vacuum piston for wear, nicks, scratches or otherdamage.

Make sure the piston moves up and down freely in the cham­ber.

Push the jet needle holder in and turn it in 90 degrees counter­clockwise.

Then remove the needle holder, spring, jet needle and from thepiston.Inspect the needle for excessive wear at the tip, bending orother damge.Inspect the diaphragm for damage, fatigue or pin holes.Inspect the vacuum piston for wear or damage.

(1) DIAPHRAGM/PISTON

FLOAT CHAMBER, FLOAT AND JETS

Remove the four screws and float chamber.

4-6

Remove the float pin, float and float valves.

Check the float valve and valve seat for scratches, clogging ordamage.

Inspect the operation of the float valve.

FUEL SYSTEM

Remove the main jet, needle jet, slow jet and valve seat/filter.

Check each part for wear or damage.Blow open all jets with compressed air.

Clean each jet with non-flammable or high flash point solvent.

Inspect the float valve seat and filter for grooves, nicks or de­posits.

Clean the filter with low-pressure compressed air. o(5) FILTER-

(4) VALVE SEAT--

(2) MAINJET

/'", (3) SLOW JET

PILOT SCREW REMOVAL

NOTE

The pilot screws are factory pre-set and should not be re­moved unless the carburetors are overhauled.The pilot screw plugs are factory installed to prevent pilotscrew misadjustment. Do not remove the plugs unless thepilot screws are being removed.Cover all openings with tape to keep metal particles outwhen the plugs are drilled.

4-7

FUEL SYSTEM

Center punch the pilot screw plug to center the drill point.Drill through the plug with a 4 mm (5/32 in) drill bit. Attach adrill stop to the bit 3 mm (1/8 in) from the end to prevent drill­ing into the pilot screw.

CAUTION

Be careful not to drill into the pilot screw.Both pilot screws must be replaced even if only one requires it,for proper pilot screw adjustment (page 4-/4).

(1) CARBURETOR (2) DRILL BIT

Force a self-tapping 4 mm screw, PIN 93903-35410) intothe drilled plug and continue turning the screwdriver until theplug rotates with the screw.

Pull on the screw head with pliers to remove the plug.

Use compressed air to clean the pilot screw area and removemetal shavings.

(1) SELF TAPPING SCREW

7"'NGo

/(4) WASHER

(3) PILOT SCREW - )

Remove the pilot screws and inspect them. Replace them ifthey are worn or damaged.

CAUTION

Turn each pilot screw in and carefully count the number ofturns until it seats lightly. Make a note of this to use as a refer­ence when reinstalling the pilot screws.

• Damage to the pilot screw seat will occur if the pilot screw istightened against the seat.

AIR CUT OFF VALVE

Remove the two screws, the set plate and the air cut off valvecover.

NOTE

The air cut off valve cover is under spring pressure. Do notloose the spring and screws.

4-8

Visually check the following:- diaphragm for deterioration, pin hole or other damage.- spring for deterioration or other damage.- diaphragm needle for excessive wear at the tip or other

damage.- orifice of air vent for clogging.- a-ring for damage.

Replace the air cut off valve as an assembly, if necessary.

CARBURETOR CLEANING

Separate the carburetors (page 4-12).Remove the float valve, all jets, and the pilot screws.Blow open all carburetor body openings with compressed air.

CARBURETOR ASSEMBLY

FUEL SYSTEM

(3) DIAPHRAGM

/I

(4) SPRING

,(1) CARBURETOR BODY--

(16) NEEDLE JET

(13) FLOATCHAMBER

(11) SLOW JET

(12) MAIN JET

(6) VACUUMCHAMBERCOVER

4-9

FUEL SYSTEM

INSTALLATION

If the air tube joint was removed, install a new a-ring onto theair tube joint.

Install the air cut off valve cover with the joint set plate andtighten the screws securely.Be sure the diaphragm and spring are properly seated.

Install the pilot screws and return them to their original posi­tion as noted during removal.Perform pilot screw adjustment if new pilot screws are in­stalled (page 4-1 4).

NOTE

Do not install new plugs on new pilot screw holes until afteradjustment has been made.If you replace the pilot screw in one carburetor, you mustreplace the pilot screw in the other carburetor for properpilot screw adjustment.

FLOAT CHAMBER, FLOAT AND JETS

Install the pilot screw and turn it in until it seats lightly.Turn the pilot screw out the number of turns recorded duringremoval.

CAUTION

Damage to the pilot screw seat will occur if the pilot screw istightened against the seat.

Install the valve seat, slow jet, needle jet and main jet.

Install the float with float valve in the carburetor body, then in­stall the float arm pin through the body and the float.

4-10

O. '70TSCREW

/(3) SPRING

FLOAT LEVEL

Measure the float level with the float tang just contacting thefloat valve.

FLOAT LEVEL: 9.2 mm 10.36 in)

Adjust the float level by carefully bending the tang.

Install the new a-ring in the float chamber groove.

Install the float chamber and tighten the screws securely.

NOTE

• Install the fuel tube clamps.

VACUUM CHAMBER

Install the washer, jet needle, spring and jet needle holder inthe vacuum piston.Push the jet needle holder in and turn it in 90 degrees cloc­kwise.

Hold the vacuum piston up to almost full open to avoid pinch­ing the diaphragm with the chamber cover.

FUEL SYSTEM

(1) JET NEEDLE HOLDER (4) FINGER

4-11

FUEL SYSTEM

Install the vacuum piston, aligning the tab of the diaphragmwith the groove of the carburetor.

Install the chamber cover with the spring, aligning the coverwith the hole in the carburetor, and secure with at least twoscrews before releasing the vacuum piston.

Install the fuel tubes as shown.

CARBURETORSEPARATION/ASSEMBLYSEPARATION

Loosen the synchronization adjusting screw.

NOTE

When separating the carburetors, be careful not to lose thethrust spring and synchronization adjusting spring.

Separate the carburetors by removing the two attachingscrews.

Remove the synchronization spring.

4-12

(1) CHAMBER COVER

j

ASSEMBLY

Loosen the synchronization adjusting screw until there is nospring tension.

Install the thrust spring between the throttle links.

Secure the carburetors together with the two screws.

Install the synchronization spring and synchronization adjust­ing screw.

Inspect throttle operation as described below:Open the throttle slightly by rotating the throttle valve, thenrelease the throttle. Make sure that there is no drag whenopening and closing the throttle.

Turn the throttle stop screw to align the rear cylinder carbure­tor throttle valve with the edge of the by-pass hole.

Align the front cylinder carburetor throttle valve with the by­pass hole edge by turning the synchronization adjustingscrew.

Make sure the throttle returns smoothly to the fully closed po­sition.

FUEL SYSTEM

4-13

FUEL SYSTEM

CARBURETOR INSTALLATION(1) CARBURETOR

Install the carburetors onto the cylinder heads and tighten theinsulator bands securely.

Install the following parts- air cleaner case- fuel tank- throttle cables- choke cablesAdjust as follows:- pilot screw- carburetor synchronization (page 3-8)- throttle grip free play (page 3-4)- carburetor idle speed (page 3-9)- carburetor choke (page 3-5)

PILOT SCREW ADJUSTMENTIDLE DROP PROCEDURE (U.S.A. ONLY)

NOTE

(4) THROTTLE CABLES

• The pilot screws are factory pre-set and no adjustment isnecessary unless the pilot screws are replaced.Use a tachometer with graduations of 50 rpm or smallerthat will accurately indicate a 50 rpm change.

1. Turn each pilot screw clockwise until it seats lightly andback it out to the specification given.This is an initial setting prior to the final pilot screw adjust­ment.

INITIAL OPENING:

49 st, model Carifornia model

'88 2-1/8 turns out 2-1/2 turns out

After Front: 1-1/21-3/8 turns out

'88 Rear:1 turns out

CAUTION

Damage to the pilot screw seat will occur if the pilot screw istightened against the seat.

2. Warm up the engine to operating temperature.Stop and go riding for 10 minutes is sufficient.

3. Attach a tachometer according to the manufacturer's in­structions.

4. Adjust the idle speed with the throttle stop screw.

4-14

5. Turn each pilot screw 1/2 turn out from the initial setting.6. If the engine speed increases by 50 rpm or more, turn

each pilot screw out by an additional 1/2 turn until enginespeed drops by 50 rpm or less.

7. Adjust the idle speed with the throttle stop screw.8. Turn the rear cylinder carburetor pilot screw in until the

engine speed drops 50 rpm.9. Turn the rear cylinder carburetor pilot screw 1 turn out

from the position obtained in step 8.10. Adjust the idle speed with the throttle stop screw.11. Perform steps 8, 9 and 10 for the front cylinder carburetor

pilot screw.12. Drive new pilot screw plugs into the pilot screw bores

with a 7 mm valve guide driver (PIN 07942-8230000).When fully seated the plug surfaces will be recessed1 mm.

HIGH ALTITUDE ADJUSTMENT(U.S.A. only)When the vehicle is to be operated continuously above 2,000m (6,500 feet) the carburetors must be readjusted as followsto improve driveability and decrease exhaust emissions.Remove each pilot screw plug (page 4-7).Warm up the engine to operating temperature. Stop and goriding for 10 minutes is sufficient.Turn each pilot screw clockwise 1/2 turn.Adjust the idle speed to specification with the throttle stopscrew.

IDLE SPEED: 1,200 ± 100 rpm

NOTE

This adjustment must be made at high altitude to ensureproper high altitude operation.

Drive new pilot screw plugs into the pilot screw bores (page4-7).Attach a Vehicle Emission Control Information Update label onthe left sub-frame upper pipe as shown. See SL#132 for infor­mation on obtaining the label.

NOTE

Do not attach the label to any part that can be easily re­moved from the vehicle.

-----------Operation at an altitude lower than 1.500 m (5.000 feet) withthe carburetors adjusted for high altitudes may cause the engineto idle roughly and stall.

When the vehicle is to be operated continuously below 1,500m (5,000 feet), turn each pilot screw counterclockwise 1/2turn to its original position after removing each pilot screwplug and adjust the idle speed to specification (page 4-1).Drive new pilot screw plugs into the pilot screw bores (page4- 7). Be sure to do these adjustments at low altitude with theengine at normal ?perating temperature.

FUEL SYSTEM

(1) VEHICLE EMISSION CONTROLINFORMATION UPDATE LABEL

I(1) UPDATE LABEL

4-15

FUEL SYSTEM

PURGE CONTROL VALVE INSPECTION(California model only)NOTE

• The purge control valve should be inspected if hot restart isdifficult.

Check all fuel tank, Purge Control Valve (PCV), and charcoalcanister hoses to be sure they are not kinked and are securelyconnected. Replace any hose that shows signs of damage ordeterioration.

NOTE

(1) PURGE CONTROL VALVE

"(5) TO CHARCOALCANISTER

(4) TO CARBURETOR (2) VACUUM PUMPBODY

• The PCV is located under the fuel tank.

SPECIFIED VACUUM: 250 mm (9.8 in) Hg

SPECIFIED VACUUM: 250 mm (9.8 in) Hg

/(2) VACUUM PUMP

A937X-041-XXXXX orST-AH-260-MC7(U.S.A. only)

A937X-041-XXXXX orST-AH-260-MC7(U.S.A. only)

The specified vacuum should be maintained.Replace the PCV if vacuum is not maintained.TOOL:Vacuum/Pressure pumpVacuum pump

The specified vacuum should be maintained.Replace the PCV if vacuum is not maintained.TOOL:Vacuum/Pressure pumpVacuum pump

Connect a pressure pump to the 8 mm (0.31 in.) 1.0. hose No.4 that goes to the charcoal canister. While applying the speci­fied vacuum to the PCV hose that goes to the 3-way jointpump air through the canister hose. Air shoud flow through thePCV and out of the hose that goes to the 3-way joint.Replace the PCV if air does not flow out.

Remove the vacuum pump and connect it to the vacuum hoseNo. 11 that goes to the left carburetor body.Apply the specified vacuum to the PCV.

Connect a vacuum pump to the 8 mm (0.31 in.) 1.0. hose No.5 that goes to the 3-way joint. Apply the specified vacuum tothe PCV.

Disconnect the PCV hoses from their connections and removethe PCV from its mount. Refer to the routing label on the aircleaner case cover for hose connections.

CAUTION

• To prevent damage to the purge control valve, do not use highpressure air sources. Use a hand operated air pump only.

TOOL:Vacuum/Pressure pumpVacuum pumpPressure pump

A937X-041-XXXXX orST -AH-260-MC7ST-AH-255-MC7(U.S.A. onlyl

Remove the pumps, install the PCV on its mount, route and re­connect the hoses according to the routing label (page 4-18).

4-16

A937X-041-XXXXX orST-AH-260-MC7(U.S.A. only)

(1)TOAIRJOINT PIPE

----

CAUTION

A937X - 041 - XXXXX orST-AH-260-MC7(U.S.A. only)

AIR VENT CONTROL VALVE INSPECTION(California model only)Disconnect the Air Vent Control Valve (AVCV) hoses fromtheir connections and remove the AVCV from its mount. Referto the routing label on the air cleaner case cover for hose con­nections.Connect a vacuum pump to the No.1 0 hose that goes to theright carburetor body.Apply the specified vacuum to the AVCV.

SPECIFIED VACUUM: 250 mm (9.8 in) HgTOOL:Vacuum/Pressure pumpVacuum pump

The specified vacuum should be maintained.Replace the AVCV if vacuum is not maintained.

• To prevent damage to the air vent control valve, do not usehigh pressure air sources. Use a hand operated air pump only.

Connect the vacuum pump to the air vent port of the AVCV.Apply vacuum to the AVCV. The vacuum should hold steady.Replace the AVCV if vacuum leaks.TOOL:Vacuum/Pressure pumpVacuum pump

FUEL SYSTEM

(2) TO OPEN AIR• (3) AIR VENT CONTROLI VALVE

(4) TO CHARCOALCANISTER /1

(5) TO /' \CYLINDERINTAKE PORT

(6) VACUUM PUMP

(1) VACUUM PUMP

Connect the vacuum pump to the No.1 0 hose that goes to theright carburetor body.Connect the pressure pump to the air vent port of the AVCV.While applying the vacuum to the AVCV No. 10 hose thatgoes to the right carburetor body, pump air through the airvent port.Air should flow through the AVCV and out of the hose thatgoes to the carburetor air joint pipe.

Replace the AVCV if pressure is not retained.Remove the pumps, install the AVCV on its mount, route andreconnect the hoses according to the routing label.

Plug the hose that goes to the carburetor air joint pipe.While applying vacuum to the AVCV No.1 0 hose that goes tothe 3-way joint, apply air pressure. It should hold steady.

TOOL:Vacuum/Pressure pumpVacuum pumpPressure pump

TOOL:Vacuum/Pressure pumpVacuum pumpPressure pump

A937X-041-XXXXX orST-AH-260-MC7ST-AH-255-MC7(U.S.A. only)

A937X-041-XXXXX orST-AH-260-MC7ST-AH-255-MC7(U.S.A. only)

4-17

FUEL SYSTEM

SECONDARY AIR SUPPLY SYSTEM(California model only)SYSTEM INSPECTION

Start the engine and warm it up to normal operating tempera­ture.Disconnect the secondary air intake hose from the air cleanercase.

NOTE

• Do not disconnect the fuel tubes from the tank.

(2) AIR INTAKE HOSE (3) AIR CLEANER

Check that the secondary air intake ports are clean and free ofcarbon deposits.

Check the secondary air intake hose for clogging, deteriorationor damage and replace if necessary.Check the reed valves in the air suction valve (ASV) if theintake hose or supply hose is damaged by exhaust gas.Disconnect the vacuum tube (No.1 0) from the ASV and installa plug in the vacuum tube to keep air from entering.Connect the vacuum pump to the ASV.

TOOL:Vacuum/Pressure pumpVacuum pump

A937X - 041 - XXXXX orST-AH-260-MC7(U.S.A. only)

Start the engine and open the throttle slightly to be certain thatair is sucked in through the intake hose.If air is not drawn in, check the air supply hoses and vacuumtube for clogging. • ,With the engine running, gradually apply vacuum to the ASV.Check that the air intake hose stops drawing air, and that thevacuum does not bleed off.

SPECIFIED VACUUM:300-370 mm (11.8-14.6 in) Hg

If air is still drawn in, or if the specified vacuum is not main­tained, install a new ASV.If afterburn occurs on deceleration, even when the secondaryair supply system is normal, check the air cut-off valve for cor­rect vacuum operation.

4-18

VACUUM HOSE ROUTING DIAGRAMENGINE FAMIlY-JHN064742G9 TO AIRIC tEVAPORATIVE FAMLY-88Z0 CVCALIFORNIA VEHiClE

REED VALVE INSPECTION

Disconnect the air supply hoses from the reed valve covers ofthe ASV.Disconnect the vacuum tube and air intake hose from theASV.Remove the ASV mounting bolts and ASV.

Remove the two screws, the reed valve cover and the reedvalve from the ASV.

Check the reed valve for damage or fatigue, and replace if nec­essary.

Install a new reed valve if the seat rubber is cracked or dam­aged, or if there is clearance between the reed valve and seat.

CAUTION

Do not disassemble the reed valve assembly or bend the reedstopper.

• If the stopper, reed or seat is faulty, replace the valve as an as­sembly.

Assemble and install the ASV in the reverse order of disassem­blylremoval.

NOTE

• After installing, make sure the air and vacuum tubes arecorrectly connected (page 1-10 to 15.).

FUEL SYSTEM

(2) REED VALVE

(3) REED

(4) REED STOPPER

4-19

5. COOLI NG SYSTEMSERVICE INFORMATION

TROUBLESHOOTING

SYSTEM TESTING

COOLANT REPLACEMENT

SERVICE INFORMATION

5-1

5-1

5-2

5-3

THERMOSTAT

RADIATOR/COOLING FAN

WATER PUMP

5-3

5-5

5-7

GENERAL ~_L-- _Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The enginemust be cool before servicing the cooling system.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.The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

• Use only distilled water and ethylene glycol in the cooling system. A 50- 50 mixture is recommended for maximum corro­sion protection. Do not use alcohol-based antifreeze.

• Add coolant at the reserve tank. Do not remove the radiator cap except to refill. or drain the system. or to test the coolantmixture.

• Avoid spilling coolant on painted surfaces.• After servicing the system, check for leaks with a cooling system tester.• For temperature sensor and thermostatic switch inspection, refer to section 18.

SPECIFICATIONS

ITEM SPECIFICATIONS

Radiator cap relief pressure 88-127 kPa (0.9-1.3 kg/cm 2, 13-18 psi)

Freezing point (Hydrometer test): 55% Distilled water + 45% ethylene glycol: -32°C (-25°F)50% Distilled water + 50% ethylene glycol: -37°C (-34°F)45% Distilled water + 55% ethylene glycol: -44.5°C (-48°F)

Coolant capacity: Coolant change: 1.60 lit (1.51 US qt, 1.28 Imp qt)Total system: 2.20 lit (2.32 US qt, 1.94 Imp qt)

Thermostat Begins to open: 80° to 84°C (176° to 183°F)Valve lift: Minimum of 8 mm at 95°C (0.3 in at 203°F)

Boiling point (with 50- 50 mixture): Unpressurized: 107.7°C (226°F)Cap on, pressurized: 125.6°C (258°F)

TROUBLESHOOTI NGEngine temperature too high

Faulty temperature gauge or sensorThermostat stuck closedFaulty radiator capInsufficient coolant or coolant level too lowPassages blocked in radiator, hoses or water jacketCooling fan motor does not turn- Burned or loose sub-fuse- Faulty fan motor- Faulty thermostatic switch- Poor connector contact or open circuit in harnessFaulty water pump

Engine temperature too low• Thermostat stuck open

Coolant leaksFaulty pump mechanical seal

• Deteriorated a-rings

5-1

COOLING SYSTEM

SYSTEM TESTI NGCOOLANT MIXTURE

Remove the reserve tank cap.Test the coolant mixture with an antifreeze tester.For maximum corrosion protection, a 50-50% solution ofethylene glycol and distilled water is recommended.

Remove the fuel tank (page 4-3).Remove the radiator cap.

-'------------Be sure the engine is cool before removing the cap or you maybe severely scalded.

RADIATOR CAP

Wet the radiator cap sealing surface, install the cap on thetester, and apply pressure.

Replace the radiator cap if it does not hold pressure. or if it'srelief pressure is too high or too low. It must hold specifiedpressure for at least six seconds.

RADIATOR CAP RELIEF PRESSURE:88-127 kPa (0.9-1.3 kg/em', 13-18 psi)

SYSTEM PRESSURE TEST

Remove the fuel tank and radiator cap.

Attach the tester to the radiator and apply enough pressure totest the radiator, engine and hoses. check for leaks.

CAUTION

Excessive pressure can damage the radiator. Do not exceed /25kPa (1.25 kglcm1, /8 psi)

Repair or replace components if the system will not hold speci­fied pressure for at least six seconds.

5-2

(1) COOLING SYSTEM TESTERCOMMERCIALLY AVAILABLE

COOLANT REPLACEMENT_L- _The engine must be cool before replacing the coolant or severescalding may result.If the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss of consciousness and lead to death. .

Remove the radiator cap (page 5-21.

Drain the coolant from the system by removing the drain bolton the water pump cover.Reinstall the drain bolt.

Fill the system with 50- 50 mixture of distilled water and eth­ylene glycol.Bleed air from the cooling system.

Support the motorcycle on its center stand and shift thetransmission into neutral.Start the engine and snap the throttle grip, 3-4 times at4,000- 5,000 rpm. Then add coolant up to the radiatorfiller neck.Reinstall the radiator cap.Check the level of coolant in the reserve tank and fill to thecorrect level if the level is low.

THERMOSTATREMOVAL

Remove the following:- fuel tank (page 4-3)- air cleaner case (page 4-3)

Remove the thermostat housing mounting bolts.

Disconnect the siphon tube from the filler neck.Disconnect the upper radiator hose at the filler neck and thewater hoses at the thermostat housing.

cover attaching bolts and separate the

Remove the thermostat from the housing case.

COOLING SYSTEM

(1) HOUSING MOUNTING BOLT

18) COVER 80~ ~

IJ Y /' /

'\---fY"'.,."..... -eJ~ 011+--="'"

(5) WATER HOSES

5-3

COOLING SYSTEM

INSPECTION

Inspect the thermostat visually for damage.Suspend the thermostat in heated water to check its opera­tion.

NOTE

If the thermostat or thermometer touches the pan, you'llget a false reading.

Replace thermostat if valve stays open at room temperature,or if it responds at temperatures other than those specified.

Data:

Start to open 80° to 84°C (176-183°F)

Valve lift 8 mm (0.3 in) minimum whenheated to 95°C (203°F) for fiveminutes.

INSTALLATION

Install the following:- the thermostat into the housing case.- the new O-ring into the case groove.- the cover onto the case, with the bolts.

Assemble the case and filler neck with the new O-ring.Tighten the bolts.

Install the thermostat housing case and filler neck onto theframe.

Connect the removed hoses and tube securely.

Install the removed parts in the reverse order of removal.

Fill the system with coolant and air bleed it.

(6) HOUSING CASE

5-4

\(2) THERMOMETER

(1) HOUSING MOUNTING BOLT

(4) UPPER HOSE

(5) WATER HOSES

RADIATOR/COOLING FANREMOVAL

Drain the coolant (page 5-3l.Disconnect the cooling fan motor connector.

Disconnect the lower radiator hose at the radiator.

Remove the radiator side covers by removing mountingscrews.

Remove the radiator lower mounting bolts.

Disconnect the upper radiator hose at the radiator.Remove the radiator upper pivot bolt and radiator from theframe.

COOLING SYSTEM

5-5

COOLING SYSTEM

DISASSEMBLY

Disconnect the cooling fan motor wire connector from thethermostatic switch and remove the wire from the clamp.Remove the ground wire terminal bolt.

Remove the cooling fan motor mounting bolts and cooling fanmotor.

RADIATOR INSPECTION

NOTE

• See section 18 for thermostatic switch inspection.

Inspect the radiator soldered joints and seams for leaks.

Slow dirt out from between core fins with compressed air. Ifinsects, etc., are clogging the radiator, wash them off withlow pressure water.

Carefully straighten any bent fins.

(2) MOUNTING SOLTS

(3) GROUND TERMINAL/SOLT(1) COOLING FAN MOTOR

(3) PIVOT SOLT (1) RADIATOR

01'(4) LOWER MOUNT SOLTS

5-6

ASSEMBLY/INSTALLATION

Install the cooling fan motor.

Connect the ground terminal and thermostatic switch wireconnector.

Install the mounting bolts.

If the thermostatic switch was removed, install a new O-ringand tighten to the specified torque.

THERMOSTATIC SWITCH:TORQUE: 18 N'm (1.8 kg-m, 13 ft-Ib)

Install the radiator in the reverse order of removal.

WATER PUMPMECHANICAL SEAL INSPECTION

Inspect the telltale hole for signs of mechanical seal coolantleakage.Replace the water pump as an assembly if the mechanical sealis leaking.

REMOVAL

Drain the engine oil (page 2-3).Remove the water pump cover mounting bolts and cover.

Remove the O-ring and dowel pins from the water pump as­sembly and disconnect the water hose.

Remove the water pump from the crankcase.

COOLING SYSTEM

(4) WIRE (2) MOUNTING BOLTSCONNECTOR

(3) GROUND TERMINAL/BOLT(1) COOLING FAN MOTOR

(3) DOWEL PINS

5-7

COOLING SYSTEM

INSPECTION

Check the water pump for mechanical seal leakage and bear­ing deterioration. Replace the water pump as an assembly ifnecessary.

(4) a-RING

(2) WATER PUMP ASSEMBLY

INSTALLATION

Connect the water hose with the clamp.Apply a coat of clean engine oil to a new a-ring and install it inthe water pump shaft housing groove.

Align the water pump shaft groove with the oil pump shaft andinsert the water pump into the crankcase.

Apply a coat of engine oil to a new a-ring and install it aroundthe impeller housing.

Install the two dowel pins.

Install the water pump cover and tighten the cover mountingbolts.

Fill the system with coolant (page 5-3).Fill the engine with the recommended engine oil (page 2-3).Check the cooling system for leakage.

5-8

6. ENGINE REMOVAL/INSTALLATIONSERVICE INFORMATION

ENGINE REMOVAL

6-2 ENGINE INSTALLATION

6-3

65 N'm (6.5 kg-m, 47 ft-Ibl

6-5

40 N'm (4.0 kg-m, 29 ft-Ibl

10 N'm (1.0 kg-m, 7.2 ft-Ibl

6-1

ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATIONGENERAL

• Support the motorcycle using a hoist, a floor jack or other adjustable support.• The following parts can be serviced with the engine installed in the frame:

Clutch AlternatorGearshift linkage Starter motorCamshafts CarburetorsCylinder head Water pump

• To service the crankshaft/transmission, oil pump, and cylinder the engine must be removed from the frame.• When using the lock nut wrench, use a 20 inche long deflecting beam type torque wrench. The lock nut wrench increases

the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut.

SPECIFICATIONS

Engine dry weightOil capacityCoolant capacity

TORQUE VALUES

Muffler mounting boltExhaust pipe joint nutGearshift arm boltDrive sprocket boltSwingarm pivot nutSwingarm pivot lock nutSwingarm pivot adjusting boltFront engine bracket boltFront engine mouning boltRear upper engine mouning bolt- mounting bolt lock nut- mounting bolt adjusting boltFuel tank mounting bolt: Front

: Rear

TOOL

SpecialLock nut wrench

6-2

61 kg (1341bl2.8 lit (2.94 US qt, 2.46 Imp qt) at disassembly2.0 lit (1.89 US qt, 2.27 Imp qt) total

27 N·m (2.7 kg-m, 20 ft-Ibl27 N'm (2.7 kg-m, 20 ft-Ib)12 N'm (1.2 kg-m, 9 ft-Ibl10 N'm (1.0 kg-m, 7.2 ft-Ib)65 N'm (6.5 kg-m, 47 ft-Ibl65 N'm (6.5 kg-m, 47 ft-Ibl15 N'm (1.5 kg-m, 11 ft-Ibl28 N'm (2.8 kg-m, 20 ft-Ibl40 N'm (4.0 kg-m, 29 ft-Ibl40 N'm (4.0 kg-m, 29 ft-Ibl55 N'm (5.5 kg-m, 40 ft-Ibl11 N'm (1.1 kg-m, 8 ft-Ib)12 N'm (1.2 kg-m, 9 ft-Ib)22 N'm (2.2 kg-m, 13 ft-Ibl, .

07908 - ME90000

ENGINE REMOVALPlace the motorcycle on its center stand.Drain the engine oil (page 2-3).Drain the coolant (page 5-3).Disconnect the battery negative cable from the battery termi­nal.

Remove the following:- fuel tank (page 4-3l.- air cleaner case (page 4-4).- carburetor (page 4-5l.- radiator (page 5-5).- exhaust pipe and muffler (page 13-24).

Remove the gearshift arm from the gearshift spindle.

Loosen the drive chain (page 3-12).Remove the drive sprocket cover (page 8-2), then remove thesprocket from the drive chain by removing two sprocket boltsand the plate.

Disconnect the following electrical connections:- oil pressure switch wire.- neutral switch wire.- pulse generator wire.- alternator wire.- starter moter cable and ground cable.

Disconnect the following cooling system connections:- water hoses to thermostat housing at the engine.- siphon tube at the filler neck.

Remove the thermostat housing with water hoses attached:

Disconnect the clutch cable from the clutch lifter arm by re­moving the holder bolt.

Remove the swingarm pivot nut.

ENGINE REMOVAL/INSTALLATION

.-- ~---.. ' (1) EXHAUST PIPE AND MUFFLER

~ -

6-3

ENGINE REMOVAl/INSTALLATION

Place a floor jack or other adjustable support under the engine.

CAUTION

The jack heigh1 muSI be conlinually adjusled 10 relieve Slressfor ease of boll removal.Do nol jack up the engine al lhe oil filler.

Remove the engine upper bracket bolts and bracket.

Remove the swingarm pivot adjusting bolt lock nut.

Remove the front engine lower mounting bolt.Loosen the rear engine upper mounting bolt lock nut andremove the rear engine upper mounting and adjusting bolts.

TOOL:Lock Nut wrench 07908-ME90000

Turn the pivot bolt with the adjusting bolt counterclockwise torelease the engine mounting frame.

Pull the swingarm pivot bolt out to clear the engine mountinghole, but do not remove it.

Remove the engine from the frame.

6-4Revised: June. 1991© 1991 American Honda Motor Co.. Inc. - All Rights ReservedMSV 5511 (9106) '88- '91 NT650

ENGINE INSTALLATIONInstall the engine into the frame correctly.

Engine installation is essentially the reverse order of removal.Use a floor jack or other adjustable support to carefullymanuever the engine into place.

CAUTION

Carefully align the mounting points with the jack to prevent •damage to mounting bolt threads and wire harness and cables.

Insert the swingarm pivot bolt while aligning the serrations ofthe pivot bolt and adjusting bolt.

ENGINE REMOVAL/INSTALLATION

(2) ADJUSTING BOLT~ - \

Turn the pivot bolt with the adjusting bolt clockwise fully toseat the swingarm left pivot collar.Tighten the bolt to the specified torque.

TORQUE: 15 N'm (1 .5 kg-m, 11 ft-Ibl..

(1) PIVOTIADJUSTING BOLT

\

TORQUE:Actual: 65 N'm (6.5 kg-m, 47 ft-Ib)Indicated: 59 N'm 15.9 kg-m, 43 ft-Ibl

Install the lock nut onto the adjusting bolt.Tighten the lock nut to the specified torque while holding thepivot bolt and adjusting bolt together.

TOOL:Lock nut wrench 07908-ME90000

6-5

ENGINE REMOVAL/INSTALLATION

Install the swingarm pivot nut and tighten it to the specifiedtorque.

TORQUE: 65 N'm (6.5 kg-m. 47 ft-Ibl

Install the rear engine upper mounting adjusting bolt.Turn the mounting adjust bolt clockwise fully to seat theengine mount.Tighten to the specified torque.

TORQUE: 11 N'm (1.1 kg-m. 8 ft-Ibl

Install the lock nut onto the adjusting bolt.

TORQUE: 55 N'm (5.5 kg-m. 40 ft-Ibl

Install the rear engine upper mounting bolt and tighten it to thespecified torque.

TORQUE: 40 N'm (4.0 kg-m. 29 ft-Ibl

Tighten all the fasteners to the torques given on page 6-1 and2.

NOTE

Route the wires and cables properly (Section 1).Fill the crankcase to the proper level with the recommendedoil (page 2-1).Fill the cooling system (page 5-3l.Perform the following inspection and adjustments:Throttle operation (page 3-4l.Clutch (page 3-15).

6-6

CLUTCH/GEARSHIFT LINKAGE

'SS Shown:

15 N·m (1.5 kg-m11 ft-Ibl

7-0

7. CLUTCH/GEARSHIFT LINKAGESERVICE INFORMATION

TROUBLESHOOTING

RIGHT CRANKCASE COVER REMOVAL

CLUTCH REMOVAL

GEARSHIFT LINKAGE

SERVICE INFORMATIONGENERAL

7-1

7-2

7-3

7-4

7-8

PRIMARY DRIVE GEAR

CLUTCH INSTALLATION

RIGHT CRANKCASE COVERINSTALLATION

7-10

7-11

7-14

• This section covers the removal and installation of the clutch, oil pump drive chain, gearshift linkage and primary drivegear. All these operations can be done with the engine installed in the frame.

• If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 11).

• Coat the new clutch discs with clean engine oil before reassembly.

SPECIFICATIONSUnit: mm (in)

ITEM STANDARD SERVICE LIMIT

Clutch Spring free length 44.4 (1.75) 42.8 (1.69)

Spring preloadllength 22.75/26.2 kg/mm --(50.15/1.031 Ib/in)

Disc thickness Disc A 2.92-3.08 (0.115-0.121) 2.60 (0.102)

Disc B 2.62-2.78 (0.103-0.109) 2.30 (0.091)

Plate warpage -- 0.30 (0.012)

Outer guide 1.0. 21.991-22.016 (0.8658-0.8668) 22.09 (0.870)

0.0. ~1.959-31.975 (1.2582-1.2589) 31.92 (1.257)

Outer 1.0. 32.000-32.025 (1.2598-1.2608) 32.10 (1.264)

Oil pump drive sprocket 1.0. 32.000-32.025 (1.2598-1.2608) 32.10 (1.264)

Mainshaft 0.0. at clutch outer guide 21.967 -21.980 (0.8648-0.8654) 21.92 (0.863)

TORQUE VALUES

Shift drum stopper plate boltPrimary drive gear boltOil pump driven sprocket boltClutch lock nutOil pass pipe bolt (8 mm)

(7 mm)

TOOLS

SpecialClutch center holderGear holder

CommonLock nut wrench, 17 x 27 mm

26 N'm (2.6 kg-m, 19 ft-Ib) Apply locking agent to the threads90 N'm (9.0 kg-m, 65 ft-Ib)15 N'm (1.5 kg-m, 11 ft-Ib) Apply locking agent to the threads130 N'm (13.0 kg-m, 94 ft-Ibl Staked nut23 N'm (2.3 kg-m, 17 ft-Ib)10 N'm (1.0 kg-m, 7.2 ft-Ib)

07923-KE10000 or 07HGB-001000A (U.S.A. only)07724-0010100 Not available in U.S.A.

07716-0020300 Equivalent commercially available in U.S.A.

7-1

CLUTCH/GEARSHIFT LINKAGE

TROUBLESHOOTI NGFaulty clutch operation can usually be corrected by adjusting the clutch lever free play.

Clutch slips when acceleratingNo free playDiscs wornSprings weak

Clutch will not disengageToo much free play

• Plates warped

Motorcycle creeps with clutch disengagedToo much free play

• Plates warped

Excessive lever pressureClutch cable kinked, damaged or dirty

• Lifter mechanism damaged

Clutch operation feels roughClutch outer slots rough

• Dirty clutch cable

7-2

RIGHT CRANKCASE COVER REMOVALDrain the engine oil (page 2-3).Remove the exhaust pipe.Remove the clutch cable holder and disconnect the clutchcable from the clutch lifter arm.Loosen the oil pipe holder and remove the oil pipe bolt and seal­ing washers from the right crankcase cover.

Remove the right crankcase cover bolts and cover.

NOTE

R. crankcase cover can be serviced with rear exhaust piperemoval only.

Remove the dowel pins and gasket.

Remove the oil orifice.

CLUTCH LIFTER

Remove the clutch lifter piece. and remove the snap ring andreturn spring from the right crankcase cover.

Remove the clutch lifter shaft.

Check the clutch lifter piece and shaft for damage or excessivescratching.Check the return spring for fatigue or damage.

CLUTCH/GEARSHIFT LINKAGE

(2) L1FTER/SHAFT

7-3

CLUTCH/GEARSHIFT LINKAGE

Check the needle bearings for wear or damage or a loose fit inthe cover.Check the dust seal for fatigue or damage.

Apply grease to the dust seal and needle bearing.

Install the clutch lifter shah, snap ring and return spring.Hook the spring end in the cover tab securely, and turn theshaft.

Install the clutch lifter piece, aligning the piece end with thegroove in the clutch lifter shaft.

CLUTCH REMOVALRemove the following:- clutch bolts- clutch lifter plate- springs

NOTE

• Remove the bolts in a crisscross pattern in 2 or 3 steps.

• Be careful not to damage the shah threads.

Unstake the clutch lock nut with a drill or grinder.

7-4

•NOTE

Hold the clutch center with the special tool and loosen theclutch lock nut. Remove the tools and the lock nut.

If you will remove the oil pump driven sprocket, loosen thedriven sprocket mounting bolt at this time.

TOOLS:Clutch center holder

Lock nut wrench, 17 x 27 mm

NOTE

07923-KE10000 or07HGB-001000A(U.S.A. only)07716 - 0020300 Equiva­lent commercially availablein U.S.A.

CLUTCH/GEARSHIFT LINKAGE

Remove the following:- washer- clutch center, judder spring and spring seat- discs and plates- pressure plate

Remove the thrust washer and clutch outer.

Remove the oil pump driven sprocket mounting bolt, drivensprocket and oil pump drive chain.

7-5

CLUTCH/GEARSHIFT LINKAGE

Remove the drive sprocket and clutch outer guide from themainshaft.

INSPECTION

Check the lifter plate bearing for damage.Turn the bearing inner race with your finger.The bearing should turn smoothly and quietly.Also check that the bearing outer race fits tightly in the clutchlifter plate.Replace the bearing if necessary.

Measure the spring free length.

SERVICE LIMIT: 42.8 mm (1.69 in)

Replace the clutch discs if they show signs of scoring or dis­coloration.

Measure the thickness of discs A and B.

SERVICE LIMITS:Disc A: 2.60 mm (0.102 in)Disc B: 2.30 mm (0.091 in)

NOTE

Replace the discs and plates as a set if anyone is beyondthe service limit.

7-6

(1) BEARING

(2) CLUTCH LIFTER PLATE

\(1) CLUTCH DISC

Check the plate warpage on a surface plate using a thicknessgauge.

SERVICE LIMIT: 0.30 mm (0.012 in)

NOTE

Replace the discs and plates as a set if anyone is beyondthe service limit.

Check the clutch center for nicks or indentations made by theclutch plates.

Check the spring seat and judder spring for distortion, wear ordamage.Replace them if necessary.

..

Check the slots in the clutch outer for nicks or indentationsmade by the clutch discs.

Measure the 1.0. of the clutch outer.

SERVICE LIMIT:Clutch outer 1.0. 32.10 mm (1.264 in)

CLUTCH/GEARSHIFT LINKAGE

(1) JUOOER SPRING

•

7-7

CLUTCH/GEARSHIFT LINKAGE

Check the oil pump drive sprocket for damage.

Measure 1.0 of the drive sprocket and the 0.0. and 1.0. of theouter guide.

SERVICE LIMITS:Oil pump drive sprocket 1.0. 32.10 mm (1.264 in)Clutch outer guide 0.0. 31.92 mm (1.257 in)

1.0. 22.09 mm (0.870 in)

Measure the mainshaft 0.0. at the clutch outer guide.

SERVICE LIMIT: 21.92 mm (0.863 in)

GEARSHIFT LINKAGEREMOVAL

Remove the following:- drive sprocket cover (page 8-2)- gearshift pedal arm from the gearshift spindle- right crankcase cover (page 7-3)- clutch assembly (page 7-4)- oil pump drive chain (page 7-5)

Loosen the two oil pipe stay mounting bolts and remove the oilpipe mounting bolt.

Pull the oil pipe out of the stay and oil pump.

7-8

. I(2) CLUTCH OUTER GUIDE

__(1) OIL PUMP DRIVESPROCKET

RTER CLUTCHALTERNATOR/STA

'SS Shown:

3 0 kg-m,30 N·m ( .22 ft-Ibl

8-0

8. ALTERNATOR/STARTER CLUTCHSERVICE INFORMATION

LEFT CRANKCASE COVER REMOVAL

FLYWHEEL REMOVAL

STARTER CLUTCH

SERVICE INFORMATIONGENERAL

8-1

8-2

8-3

8-4

FLYWHEEL INSTALLATION

LEFT CRANKCASE COVERINSTALLATION

8-5

8-6

• This section covers the removal and installation of the alternator, starter clutch and starter gears.• Refer to section 15 for troubleshooting and inspection of the alternator.

SPECIFICATIONSmm (in)

ITEM STANDARD SERVICE LIMIT

Starter driven gear 0.0. 57.749- 57.768 (2.2736-2.2743) 57.60 (2.268)

TORQUE VALUES

Flywheel boltStarter clutch torx bolts

TOOLS

CommonRotor pullerFlywheel holderTorx bit

130 N·m (13.0 kg-m, 94 ft-Ibl Left-hand thread30 N·m (3.0 kg-m, 22 ft-Ib) Apply locking agent to the threads

07733-0020001 or 07933-3290001

07725-0040000}E 0 I 0 II 01 bl 0 USA07703-0010100 QUiva ent commercia y aval a e In • • •

8-1

ALTERNATOR/STARTER CLUTCH

LEFT CRANKCASE COVER REMOVALDisconnect the alternator wire 3P connector (WHITE).

Remove the gearshift arm pinch bolt and shiftarm from thespindle.

Remove the drive sprocket cover.

Place a container under the left crankcase cover to catch theengine oil.

Remove the eleven left crankcase cover bolts and the cover.

Remove the dowel pins and gasket.

STATOR REPLACEMENT

Remove the wire clamp bolts and the clamps.Remove the stator mounting bolts and stator.

Position the new stator and the grommets in the cover.Apply a locking agent to the threads of the stator mountingbolts.Tighten the stator mounting bolts and the clamp bolts.

8-2

FLYWHEEL REMOVALRemove the starter idle/reduction gear by removing the shaft.

ALTERNATOR/STARTER CLUTCH

• The flywheel bolt has left-hand threads.

Hold the flywheel with the flywheel holder and remove the fly­wheel bolt and washer.

TOOL:Flywheel holder

NOTE

07725-0040000 Equivalentcommercially available in U.S.A.

Remove the flywheel with the rotor puller.

TOOL:Rotor puller 07733-0020001 or

07933-3290001 , .

Remove the needle bearing from the crankshaft, then removethe woodruff key.

NOTE

• Do not lose the woodruff key.

8-3

ALTERNATOR/STARTER CLUTCH

STARTER CLUTCHDISASSEMBLY

Reinstall the starter driven gear into the flywheel.

Inspect the starter clutch by turning the starter driven gear.The gear should turn counterclockwise freely and should notturn clockwise: if it turns incorrectly. replace the starterclutch.

111 STcER DRI~N GEAR

Remove the starter clutch outer and oneway clutch.

Hold the flywheel with the flywheel holder and remove thetorx bolts using a torx bit.

TOOLS:Flywheel holderTorx bit

07725-0040000 .07703_0010100}EqUivalent

commerciallyavailable inU.S.A.

INSPECTION

Measure the 0.0. of the starter driven gear.

SERVICE LIMIT: 57.60 mm (2.268 in)

Inspect the oneway clutch for wear or damage and replace ifnecessary.

8-4

(1) STARTER DRIVEN GEAR

(1) ONEWAY CLUTCH

ALTERNATOR/STARTER CLUTCH

ASSEMBLY

Install the oneway clutch into the clutch outer with the flangeside facing inside.

TORQUE: 30 N'm (3.0 kg-m. 22 ft-Ib)

Hold the flywheel with the flywheel holder. Apply lockingagent to the torx bolt threads and tighten the bolts.

TOOLS:Flywheel holderTorx bit

07725-0040000 .07703_0010100}EqUlvalen.t

commerciallyavailablein U.S.A.

FLYWHEEL INSTALLATIONClean the crankshaft and install the woodruff key.

Install the needle bearing onto the crankshaft.

• The flywheel bolt has left hand threads.

TORQUE: 130 N'm (13.0 kg-m. 94 ft-Ib)

Install the driven gear and flywheel. aligning the woodruff keyon the crankshaft with the flywheel keyway.

07725-0040000 Equivalentcommercially available in U.S.A.

Hold the flywheel with the flywheel holder. install the washerand flywheel bolt and tighten the bolt.

NOTE

TOOL:Flywheel holder

8-5

ALTERNATOR/STARTER CLUTCH

Install the starter idle/reduction gear with the longer shaft.

Install the starter drive gear with the "OUT" mark facing outand the shorter shaft, if the gear is removed.

Install the dowel pins and new gasket.

LEFT CRANKCASE COVER INSTALLATIONInstall the left crankcase cover and tighten the cover bolts withthe neutral and oil pressure switch wire harness clamps asshown.

Route the alternator wire and connect the alternator 3P con­nector.

Install the drive sprocket cover.

Install the gearshift arm onto the spindle by aligning the punchmark on the arm with the punch mark on the spindle.

Tighten the gearshift arm pinch bolt.

TORQUE: 12 N'm (1.2 kg-m. 9 ft-Ib)

Install the drive sprocket cover.

Check the engine oil level and add the oil if necessary.

8-6

-~~(1) DRIVE SPROCKET COVER

--'==

CYLINDER HEADIVALVES

'SS Shown:

m 17 ft-Ib)23 N'm (2.3 kg- ,

7 2 ft-Ib)(1 0 kg-m, .10 N'm .

m 17 ft-Ibl23 N'm (2.3 kg- ,

m 17 ft-Ibl23 N'm (2.3 kg- ,

7 2 ft-Ibl10 N'm (1.0 kg-m, .

~

?~ 72ft-lbl~N (10 kg-m, .10 ·m .

9-0

9. CYLINDER HEAD/VALVESSERVICE INFORMATION

TROUBLESHOOTING

CYLINDER HEAD COVER REMOVAL

CAMSHAFT REMOVAL

CYLINDER HEADS

VALVE GUIDE REPLACEMENT

SERVICE INFORMATIONGENERAL

9-1

9-2

9-3

9-3

9-7

9-11

VALVE SEAT INSPECTION/REFACING

CYLINDER HEAD ASSEMBLY

CYLINDER HEAD INSTALLATION

CAMSHAFT INSTALLATION

CYLINDER HEAD COVERINSTALLATION

9-12

9-14

9-15

9-17

9-20

• The cylinder heads can be removed without removing the engine.• Camshaft lubricating oil is fed through an oil pass pipe. Be sure the holes in the oil pass bolts are not clogged.• During assembly apply MOS2 paste grease to the camshaft holders, camshaft journals of the cylinder head, rocker arm

shafts, rocker arm slipper faces and valve stems to provide initial lubrication.

SPECIFICATIONSUnit: mm (in) •

ITEM STANDARD SERVICE LIMIT

Compression pressure 1,324 ± 196 kPa --(13.5 ± 2.0 kg/cm 2 , 192 ± 28 psi)

Camshaft Cam lobe height IN 38.189 (1.5035) 38.17 (1.503)

EX 38.213 (1.5044) 38.19 (1.504)

Journal 0.0. 21.959-21.980 (0.8645-0.8654) 21.95 (0.864)

Runout 0.030 (0.0012) 0.05 (0.002)

Oil clearance 0.040-0.093 (0.0015-0.0037) 0.11 (0.004)

Rocker arm Rocker arm I. D. IN/EX 12.000-12.018 (0.4724-0.4731) 12.03 (0.474)

Rocker arm shaftIN/EX 11.966-11.984 (0.4711-0.4718) 11.96 (0.471)

0.0.

Valve and Valve stem 0.0. IN 5.475- 5.490 (0.2156-0.2161) 5.47 (0.215)valve guide EX 6.555-6.570 (0.2580-0.2587) 6.55 (0.258)

Valve guide 1.0. IN 5.500-5.512 (0.2165-0.2170) 5.53 (0.218)

EX 6.600-6.615 (0.2598-0.2604) 6.66 (0.262)

Stem-to-guide IN 0.010-0.037 (0.0004-0.0015) 0.07 (0.003)clearance EX 0.030-0.060 (0.0014-0.0024) 0.11 (0.004)

Valve seat width 0.9-1.1 (0.035-0.043) 1.5 (0.06)

Valve guide pro- IN 19.4-19.6 (0.76-0.77) --

jection height EX 17.9-18.1 (0.70-0.71) --

Valve spring Free length OUTER IN 42.14 (1.659) 40.58 (1.598)

EX 42.83 (1.686) 41.25 (1.624)

INNER IN 38.11 (1.500) 36.47 (1.436)

EX 38.81 (1.765) 37.51 (1.477)

Cylinder head warpage -- 0.10 (0.004)

9-1

CYLINDER HEAD/VALVES

TORQUE VALUES

Cylinder head cover boltCamshaft holder 8 mm bolt

8 mm nut6 mm bolt

Cylinder head 10 mm nut8 mm bolt8 mm nut6 mm bolt

Camshaft sprocket boltCam chain tensioner boltOil pass pipe 7 mm bolt

8 mm bolt

TOOLS

SpecialValve guide reamer (IN)Valve guide reamer (EX)Valve guide driver attachment (IN)Valve guide driver attachment (EX)

CommonValve guide driver, 5.5 mm (IN)Valve guide driver, 6.6 mm (EX)Valve spring compressor

Valve seat cutter (Not available in U.S.A.)Cutter holder IN 5.5 mm

EX 6.6 mmFlat cutter IN 28 mm (32°)

EX 35 mm (32°)Interior cutter IN 30 mm (60°)

EX 37.5 mm (60°)Seat cutter IN 27.5 mm (45°)

EX 35 mm (45°)

TROUBLESHOOTI NG

10 N·m (1.0 kg-m, 7.2 ft-Ib)23 N'm (2.3 kg-m, 17 ft-Ib)23 N'm (2.3 kg-m, 17 ft-Ib)10 N·m (1.0 kg-m, 7.2 ft-Ib)48 N'm (4.8 kg-m, 35 ft-Ib)23 N'm (2.3 kg-m, 17 ft-Ibl23 N'm (2.3 kg-m, 17 ft-Ib)10 N'm (1.0 kg-m, 7.2 ft-Ibl23 N'm (2.3 kg-m, 17 ft-Ib)10 N'm (1.0 kg-m, 7.2 ft-Ibl10 N'm (1.0 kg-m, 7.2 ft-Ibl23 N'm (2.3 kg-m, 17 ft-Ib)

07984-2000001 or 07984-200000BJU.S.A. only07984-ZE20001 or 07984-ZE2000B07943-MF5010007943-MF50200

07742-001010007742-0010200 or 07942-6570100 U.S.A. only07757-0010000 or 07957-3290001

07781-001010107781-001020107780-001210007780-001230007780-001400007780-001410007780-001020007780-0010400

Engine top-end problems are usually performance-related and can usually be diagonosed by a compression test.Engine noises can usually be traced to the top-end with a sounding rod or stethoscope.

Uneven or low compressionValves- Incorrect valve adjustment- Burned or bent valves- Incorrect valve timing- Broken valve spring

• Cylinder head- Leaking or damaged head gasket- Warped or cracked cylinder headCylinder and piston (Refer to Section 10)

High compressionExcessive carbon build-up on piston crown or combus­tion chamber

9-2

Excessive noiseIncorrect valve adjustmentSticking valve or broken valve springDamaged or worn rocker arm or camshaftLoose or worn cam chainWorn or damaged cam chain tensioner

• Worn cam sprocket teeth

Poor idling• Compression too low

CYLINDER HEAD COVER REMOVALRemove the following parts:- seat- fuel tank (page 4-3)- air cleaner case (page 4-4)- thermostat bolts- radiator mounting bolts, and swing the radiator forward

NOTE

If you will be servicing the inner cylinder head cover compo­nents, remove the carburetors (page 4-4) at this time.

FRONT:

Disconnect the spark plug caps.

Remove the cylinder head cover bolts and cover.

NOTE

If the cylinder head cover is difficult to remove:Remove the radiator mounting bolts and release the radiatorfrom the frame grommets. Suspend the radiator with apiece of rope or something suitable. (refer to 9-8 page).

REAR:

Disconnect the spark plug caps.Remove the cylinder head cover bolts and cover.

CAMSHAFT REMOVALRemove the cylinder head covers and carburetors (page 4-4).Remove the timing hole cap and crankshaft hole cap from theleft crankcase cover.Align the FT mark (rear: RT mark) on the flywheel with theindex mark on the left crankcase cover timing hole by turningthe crankshaft counterclockwise.

CYLINDER HEADIVALVES

(1) SPARK PLUG CAPS'

'6

~J_(2) CYLINDER HEAD COVER

9-3

CYLINDER HEADIVALVES

Make sure the piston is at TDC (TOP DEAD CENTER) on thecompression stroke with cam lobes are all facing down.

If the cam lobe is facing up at TDC, turn the crankshaft 360 0

couterclockwise, and re-align the mark and notch.

Pull wedge A straight up while holding wedge B down.Secure wedge A with a 2 mm pin as shown.

Remove the camshaft holder on the cam sprocket side by re­moving the two mounting bolts.

Remove the cam sprocket bolt, rotate the crankshaft counter­clockwise one turn (360°) and remove the other cam sprocketbolt.

NOTE

Be careful not to let the cam sprocket bolts fall into thecrankcase.

Remove the three camshaft holder mounting bolts and the nut,the oil plate and the holder.

9-4

~-

I

(1) CAM SPROCKET BOLT

Remove the dowel pins.Hang the cam chain on the camshaft behind the camshaftflange and remove the cam sprocket while lifting the camshaftout.

Attach a piece of wire to the cam chain to prevent it frombeing dropped into the crankcase.

INSPECTION

Cylinder headInspect the camshaft holder and cylinder head journal surfacesfor scoring or evidence of insufficient lubrication.

Camshaft runoutSupport both ends of the camshaft with V-blocks and checkthe camshaft runout with a dial indicator.

SERVICE LIMIT: 0.05 mm (0.002 in)

Using a micrometer, measure the height of each cam lobe.

SERVICE LIMIT:IN: 38.17 mm (1.503 in)EX: 38.19 mm (1.504 in)

Check the camshaft journals for wear or damage.Measure the 0.0. of each journal.

SERVICE LIMIT: 21.95 mm (0.864 in)

CYLINDER HEADIVALVES

(3) CAMHEIGHT

9-5

CYLINDER HEAD/VALVES

Camshaft bearing oil clearanceWipe any oil from the journals. Lay a strip of plastigaugelengthwise on top of each camshaft journal.

NOTE

• Avoid placing plastigauge over the oil hole.

Install the camshaft holders and tighten the mounting bolts ina crisscross pattern in 2 or 3 steps.

NOTE

• Do not rotate the camshaft when using plastigauge.

TORQUE:6 mm flange bolt: 12 N'm (1.2 kg-m. 9 ft-Ibl8 mm flange bolt: 23 N'm (2.3 kg-m. 17 ft-Ibl8 mm flange nut: 23 N'm (2.3 kg-m. 17 ft-Ibl

Remove the camshaft holder and measure the width of eachplastigauge. The widest thickness determines the oil clear­ance.

SERVICE LIMIT: 0.11 mm (0.004 in)

When the service limit is exceeded, replace the camshaft andrecheck the oil clearance.

Replace the cylinder head and camshaft holder if the clearancestill exceeds the service limit.

Camshaft holder/Rocker arm shaft/Rocker armRemove the rocker arm shafts by tapping the holder with asoft hammer.

9-6

(1) ROCKER ARM SHAFTS

Remove the rocker arms and wave washers from the shafts.

Inspect the rocker arm shafts and rocker arms for wear ordamage.

Check the rocker arms for clogged oil holes.

Measure the 0.0. of each rocker arm shaft.

SERVICE LIMIT:IN/EX: 11.96 mm (0.471 in)

Measure the 1.0. of each rocker arm.

SERVICE LIMIT: 12.03 mm (0.474 in)

CYLI NDER HEADREMOVAL

NOTE

• The cylinder head can be removed with the engine installed.

Drain the coolant (page 5-3) and remove the following:- camshaft (page 9-3)- exhaust pipes

California model only:Remove the ASV pipes from the cylinder head.

Disconnect the clutch cable from the clutch lifter arm by re­moving the clutch cable holder bolt.Remove the oil pipe from the engine.

NOTE

• Do not bend the oil pipe during removal.

Remove the water pipes.

CYLINDER HEADIVALVES

I1/

(2) ROCKER ARM SHAFT

9-7

CYLINDER HEAD/VALVES

Remove the cam chain tensioner mounting bolts and washersfrom the cylinder head and cylinder.

Loosen the 6 mm bolt, 8 mm bolts, 8 mm nut and 10 mm nuts!washers in a criss-cross pattern in 2 or 3 steps.Remove the bolts and nuts.

FRONT:

Remove the radiator mounting bolts.Release the radiator from the frame grommets and suspend itwith a piece of rope or something suitable.

Remove the upper exhaust port stud to allow frame clearancefor cylinder head removal.Lock two 8 mm nuts together on the stud to aid in removal.

Remove the front cylinder head.

REAR:

Remove the rear cylinder head.

Remove the gasket, dowel pins and cam chain guide from thecylinder.

9-8

(1) CAM CHAIN TENSIONER BOLTSi'WASHERS

CYLINDER HEAD/VALVES

DISASSEMBLYIINSPECTION

Cylinder head

CAUTION

• A void damaging the gasket surfaces.

Check the spark plug hole and valve areas for cracks.Check the cylinder head for warpage with the straight edgeand feeler gauge.

SERVICE LIMIT: 0.10 mm (0.004 in)

NOTE

Mark all parts during disassembly so they can be placedback in their original locations.

Remove the valve spring cotters, retainers, springs, and valvesusing a Valve Spring Compressor.

07757-0010000 or07957-3290001

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

TOOL:Valve spring .compressor

CAUTION

Remove the valve stem seals and valve spring seats.

Remove carbon deposits from the combustion chamber.

(3) VALVE SPRINGS

(4) VALVE

rTIERS

Valve springsMeasure the free length of the inner and outer valve springs.

SERVICE LIMITS:INNER (IN): 36.47 mm (1.436 in)

(EX): 37.51 mm (1.477 in)OUTER (IN): 40.58 mm (1.598 in)

(EX): 41.25 mm (1.624 in)

Replace the springs as a set if they are shorter than the servicelimits.

9-9

CYLINDER HEAD/VALVES

Valve stem-to-guide clearanceInspect each valve for bending, burning, scratches orabnormal stem wear.

Check valve movement in the guide and measure and recordeach valve stem O.D.

SERVICE LIMITS: IN: 5.47 mm (0.215 in)EX: 6.55 mm (0.258 in)

Measure and record each valve guide I. D.

NOTE

Ream the guides to remove any carbon deposits beforechecking clearances.

SERVICE LIMITS: IN: 5.53 mm (0.218 in)EX: 6.66 mm (0.262 in)

Subtract each valve stem O.D. from the corresponding guideI.D. to obtain the stem to guide clearance.

SERVICE LIMITS: IN: 0.07 mm (0.003 in)EX: 0.11 mm (0.004 in)

If the stem-to-guide clearance exceeds the service limits, de­termine if a new guide with standard dimensions wouldbring the clearance within tolerance. If so, replace any guidesas necessary and ream to fit.

TOOLS:Valve guide reamer

IN: 07984-2000001 or 07984-200000BJ U.S.A. onlyEX: 07984-ZE20001 or 07984-ZE2000B

NOTE

It is important that the reamer always be rotated in thesame direction when it is inserted or removed.

If the stem-to-guide clearance exceeds the service limits withnew guides, also, replace the valves.

NOTE

Reface the valve seats whenever the valve guides are re­placed.

9-10

(1) VALVE STEM

VALVE GUIDE REPLACEMENTChill the valve guides in the freezer section of a refrigerator forabout an hour.Heat the cylinder head to 212°F (1 OOOC) with a hot plate oroven. Maximum allowable temperature is 300°F (150°C).

-'-----------To avoid burns, wear heavy gloves when handling the heatedcylinder head.

CAUTION

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

Support the cylinder head and drive out the old guides from thecombustion chamber side of the cylinder head.

TOOLS:Valve guide driver

liN): 07742-0010100(EX): 07742-0010200 or 07942-6570100 (U.S.A.

only)

NOTE

• Avoid damaging the cylinder head.

Make note of the valve guide projection specifications (follow­ing), then drive in new guides from camshaft side of the cylin­der head.

TOOLS:Valve guide driver

5.5 mm (IN): 07742-00101006.6 mm (EX): 07742-0010200

Attachment5.5 mm (IN): 07943-MF501006.6 mm (EX): 07943-MF50200

VALVE GUIDE PROJECTION HEIGHT:IN: 19.4-19.6 mm (0.76-0.77 in)EX: 17.9-18.1 mm (0.70-0.71 in)

Ream the new valve guides after installation.

NOTE

Use cutting oil on the reamer during this operation.It is important that the reamer always be rotated in thesame direction when it is inserted or removed.

Clean the head thoroughly after reaming the valve guides.

TOOLS:Valve guide reamer

IN: 07984-2000001 or 07984-200000B (U.S.A. only)EX: 07984-ZE20001 or 07984-ZE2000B (U.S.A. only)

CYLINDER HEADIVALVES

9-11

CYLINDER HEADIVALVES

VALVESEAT INSPECTION/REFACINGClean the intake and exhaust valves thoroughly to removecarbon deposits.

Apply a light coating of Prussian Blue to each valve seat. Lapeach valve and seat using a rubber hose or other hand-lappingtool.

Remove and inspect each valve.

CAUTION

(1) VALVE

The valves cannot be ground. If a valve face is burned or badlyworn or if it contacts the seat unevenly, replace the valve.

Inspect the width of each valve seat.

STANDARD: 0.9-1.1 mm (0.035-0.043 in)SERVICE LIMIT: 1.5 mm (0.06 in)

If the seat is too wide. too narrow or has low spots, the seatmust be ground.

VALVE SEAT CUTTERS

Honda Valve Seat Cutters, grinder or equivalent valve seatrefacing equipment are recommended to correct a worn valveseat.

NOTE

• Follow the refacer manufacturer's operating instructions.

IN: 07780-0014000(30 </»

EX: 07780-0014100(37.5 </»

C Zl)320

IN: 07780-0012100 (28 </>1EX: 07780-0012300 (35 </»

VALVE SEAT REFACING

Use a 45 degree cutter to remove any roughness or irregulari­ties from the seat.

NOTE

Reface the seat with a 45 degree cutter when a valve guideis replaced.

9-12

IN: 07780-0010200 (27.5 </»EX: 07780-0010400 (35 </>1

(1) ROUGHNESS/IRREGULARITIES

Use a 32 degree cutter to remove the top 1/4 of the existingvalve seat material.

Use a 60 degree cutter to remove the bottom 1/4 of the oldseat. Remove the cutter and inspect the area you haverefaced.

Install a 45 degree finish cutter and cut the seat to the properwidth. Make sure that all pitting and irregularities are removed.Refinish if necessary.

Apply a thin coating of Prussian Blue to the valve seat. Pressthe valve through the valve guide and onto the seat to make aclear pattern.

NOTE

The location of the valve seat in relation to the valve face isvery important for good sealing.

If the contact area is too high on the valve, the seat must belowered using a 32 degree flat cutter.

CYLINDER HEAD/VALVES

(1) CONTACT TOO HIGH

9-13

CYLINDER HEADIVALVES

If the contact area is too low on the valve, the seat must beraised using a 60 degree inner cutter.

Refinish the seat to specifications, using a 45 degree finishcutter.

After cutting the seat, apply lapping compound to the valveface, and lap the valve using light pressure.After lapping, wash all residual compound off the cylinderhead and valve.

NOTE

• Do not allow lapping compound to enter the guides.

CYLINDER HEAD ASSEMBLYInstall the valve spring seats and new stem seals.Lubricate each valve stem with MoSz paste grease and insertthe valve into the valve guide. Turn the valve slowly while in­serting to avoid damaging the seals.

Move the valves up and down to check for smooth operation.

Install the valve springs with the tightly wound coils facing thecombustion chamber.

Install the spring retainers.

9-14

(1 ) CONTACT TOO LOW

(5) COTTERS

(2) STEM SEAL

(1) VALVESPRING

CYLINDER HEADIVALVES

CAUTION

Compress the springs and install the valve cotters.

To prevent loss of tension, do not compress the valve springsmore than necessary to install the valve collers.

07757-0010000 or07957-3290001

TOOL:Valve spring compressor

Tap the valve stems gently with a soft hammer to firmly seatthe cotters.

NOTE

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

Apply locking agent to the threads of the sealing bolts andtighten them, if removed.

..

CYLINDER HEAD INSTALLATIONInstall the cam chain guide into the cylinder.

Make sure that the cam chain guide bosses are in the groovesof cylinder.

Clean the cylinder head surface of any gasket material.

Install the dowel pins and a new head gasket.

9-15

CYLINDER HEADIVALVES

Install the carburetor insulator on the cylinder head, aligningthe boss on the cylinder head with the slot in the insulator.Tighten the screw securely.

Install the cylinder head.Reinstall the upper exhaust port stud securely.Install the 10 mm nut/washer, 8 mm nut/washer, 8 mm bolt/washer and 6 mm bolt and tighten them in a crisscross patternin 2 or 3 steps.

TORQUE:10 mm nut: 48 N'm (4.8 kg-m, 35 ft-Ibl

8 mm bolt: 23 N'm (2.3 kg-m, 17 ft-Ibl8 mm nut: 23 N'm (2.3 kg-m, 17 ft-Ibl6 mm bolt: 10 N'm (1.0 kg-m, 7.2 ft-lbJ

Install the following:- cam chain tensioner with washers and bolts.- water pipes

TORQUE: Cam chain tensioner bolt:10 N'm 11.0 kg-m, 7.2 ft-Ibl

Check the oil pass pipe bolts and oil pass pipe for clogging orbending. •

Install the oil pass pipe, new sealing washers, oil pass pipebolts and the pipe holder bolt.Tighten the bolts.

TORQUE:Oil pass pipe bolt:

7 mm: 10 N'm (1.0 kg-m, 7.2 ft-Ibl8 mm: 23 N'm (2.3 kg-m, 17 ft-Ibl

Install the following:- camshaft (page 9-17)- camshaft holders (page 9-18)

9-16

'88 SHOWN:

CYLINDER HEADIVALVES

NOTE

If the front and rear cylinder camshafts were removed, donot confuse them. Check the identification mark on the endof the shaft.

Install the dowel pins into the cylinder head.

Install the camshaft in the cylinder head through the cam chainand install the cam sprocket on the camshaft.

With the cam lobes all facing down, align the timing marks(index lines) on the cam sprocket with the top of the cylinderhead.

Place the cam chain on the sprocket.

Install the cam sprocket on the camshaft flange and recheckthat the timing marks (index lines) align with the top of the cyl­inder head.

Align the cam sprocket bolt holes in the cam sprocket andcamshaft, install and tighten the cam sprocket bolt.

TORQUE: 23 N·m (2.3 kg-m, 17 ft-Ibl

Install the holder, oil plate, 8 mm bolts, 8 mm nut and 6 mmbolts.

TORQUE:8 mm bolt: 23 N'm (2.3 kg-m, 17 ft-Ibl8 mm nut: 23 N'm (2.3 kg-m, 17 ft-Ib)6 mm bolt: 10 N'm (1.0 kg-m, 7.2 ft-Ib)

Turn the crankshaft counterclockwise 360 0 and install theother sprocket bolt.Install the end holder.

CAUTION

Note the direction of the camshaft end holder, install the flatsurface on the holder facing in.

After installing the front cylinder camshaft, turn the crankshaftcounterclockwise 232 0 (approximately 5/8 turn) and align theRT mark with the index on the timing hole, then install the rearcylinder camshaft using the same procedure as for the frontcylinder.

9-18

--, (2) INDEX MARK

(1) CAM SPROCKET

CYLINDER HEADIVALVES

NOTE

If the front and rear cylinder camshafts were removed, donot confuse them, Check the identification mark on the endof the shaft.

Install the dowel pins into the cylinder head.

Install the camshaft in the cylinder head through the cam chainand install the cam sprocket on the camshaft.

With the cam lobes all facing down, align the timing marks(index lines) on the cam sprocket with the top of the cylinderhead.

Place the cam chain on the sprocket.

Install the cam sprocket on the camshaft flange and recheckthat the timing marks (index lines) align with the top of the cyl­inder head.

Align the cam sprocket bolt holes in the cam sprocket andcamshaft, install and tighten the cam sprocket bolt.

TORQUE: 23 N'm (2.3 kg-m, 17 ft-Ibl

Install the holder, oil plate, 8 mm bolts, 8 mm nut and 6 mmbolts.

TORQUE:8 mm bolt: 23 N'm (2.3 kg-m, 17 ft-Ibl8 mm nut: 23 N'm (2.3 kg-m, 17 ft-Ibl6 mm bolt: 10 N'm (1.0 kg-m. 7.2 ft-Ibl

Turn the crankshaft counterclockwise 360 0 and install theother sprocket bolt.Install the end holder.

CAUTION

Note the direction of the camshaft end holder, install the flatsurface on the holder facing in.

After installing the front cylinder camshaft, turn the crankshaftcounterclockwise 232 0 (approximately 5/8 turn) and align theRT mark with the index on the timing hole. then install the rearcylinder camshaft using the same procedure as for the frontcylinder.

9-18

., (2) INDEX MARK

/'

(1) CAM SPROCKET

Lubricate the cam lobes with fresh engine oil.

If the cylinder head was removed with the engine in the frame,install the following:- radiator- exhaust pipe

REAR CAMSHAFT ONLY

Turn the crankshaft counterclockwise and align the "FT"mark on the flywheel with the index mark on the timing hole.Make sure the FRONT cam lobes are all facing DOWN. If theyare not, turn the crankshaft counterclockwise one revolutionso that the FRONT cam lobes are all facing DOWN.

Continue turning the crankshaft counterclockwise (232 0 ) untilthe "RT" mark on the flywheel aligns with the index mark onthe timing hole (approximately 5/8 turn).

Place the camshaft into correct position with the cam lobes allfacing down.Install the cam sprocket and camshaft holders using the sameprocedure as for the front cylinder (page 9-17). •

CYLINDER HEADIVALVES

FRONT AND REAR CAMSHAFTS

Turn the crankshaft counterclockwise and align the "FT"mark on the flywheel with the index mark on the timing hole.

Install the front camshaft with all the cam lobes facing DOWN.Align the index marks on the cam sprocket with the top of thecylinder head.

Continue turning the crankshaft counterclockwise (232 0 ) untilthe "RT" mark on the flywheel aligns with the index mark onthe timing hole (approximately 5/8 turn).

Install the rear camshaft with all the cam lobes facing DOWN.Align the index lines on the cam sprocket with the top of thecylinder head.

(2) "FT" MARK

~-

I

(3) "RT" MARK

(1) CAM LOBES

9-19

CYLINDER HEADIVALVES

Remove the 2 mm pin holding cam chain tensioner wedge A.

NOTE

Be careful not to let the 2 mm pin fall into the crankcase.Do not forget to remove the 2 mm pin before installing thecylinder head cover.

CYLINDER HEAD COVER INSTALLATIONClean the gasket and apply contact cement to the gasketgroove.

Install the cylinder head cover, rubber washer, washer coverand cylinder head cover bolts.Tighten the cover bolts.

TORQUE: 10 N·m (1.0 kg-m, 7.2 ft-Ibl

Connect the water hose to the water pipe and install the sparkplug caps.Install the following parts:- carburetors (page 4-191- air cleaner case (page 4-4)- fuel tank (page 4-31

Fill the cooling system (page 5-3).

9-20

(2) HEADCOVER

CYLINDER/PISTON

10-0

10. CYLINDER/PISTONSERVICE INFORMATION

TROUBLESHOOTING

CYLINDER

PISTON

SERVICE INFORMATIONGENERAL

10-1

10-1

10-2

10-3

PISTON RING INSTALLATION

PISTON INSTALLATION

CYLINDER INSTALLATION

10-5

10-5

10-6

• This section covers service of the cylinder and piston.• The engine must be removed to service to cylinder/piston.• To service the crankcase stud bolts. refer to page 11-13.

SPECIFICATIONSUnit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder 1.0. 79.000- 79.015 (3.1102-3.1108) 79.05 (3.112)

Warpage across top -- 0.10 (0.004)

Taper -- 0.06 (0.002)

Out-of-round -- 0.06 (0.002)

Piston, Piston ring-to-ring TOP 0.025-0.055 (0.001-0.002) 0.11 (0.004)piston groove clearance SECOND 0.015-0.045 (0.0006-0.0018) 0.10 (0.004)ringsand piston Ring end gap TOP 0.20-0.35 (0.008-0.014) 0.65 (0.026)

pin SECOND 0.35-0.50 (0.014-0.020) 0.65 (0.026)

OIL 0.20-0.80 (0.008-0.031) 0.95 (0.037)

Piston 0.0. 78.970- 78.990 (3.1086-3.1098) 78.92 (3.107)

Piston pin bore 20.002-20.008 (0.7874-0.7877) 20.018 (0.7881)

Connecting rod small end 1.0. 20.016-20.034 (0.7880-0.7887) 20.04 (0.789)

Piston pin 0.0. 19.994-20.000 (0.7871-0.7874) 19.984 (0.7867)

Piston-to-piston pin clearance 0.002-0.014 (0.0001-0.0006) 0.034 (0.0013)

Cylinder-to-piston clearance 0.010-0.035 (0.0004-0.0014) 0.13 10.005)

Piston pin-to-connecting rod0.016-0.040 (0.0006-0.0016) 0.060 10.0024)

small end clearance

TROUBLESHOOTI NG

m

Low or uneven compressionWorn cylinder or piston rings.Leaking head gasket.Incorrect valve timing.

Excessive smokeWorn cylinder and piston rings.Improperly installed piston rings.Damaged piston or cylinder.

OverheatingExcessive carbon deposits on piston or combustionchamber.Faulty water pump.

Piston noise• Worn cylinder and piston.• Excessive carbon deposits.

10-1

CYLINDER/PISTON

CYLINDERREMOVAL

Remove the following:- engine from the frame (page 5-2).- cylinder head cover (page 9-3)- cylinder head (page 9-7)- gaskets, dowel pins, and cam chain guides.Disconnect the water hose from the coolant connector.

Remove the clip and slide the cylinder joint collar toward eitherthe front or rear cylinder.

Remove the cylinder to be serviced.Remove the cylinder gasket and dowel pins from the crank­case.

INSPECTION

Clean the top of each cylinder thoroughly.

Inspect the cylinder walls for scratches and wear.

Measure and record the cylinder 1.0. at three levels in both anX and Y axis. Take the maximum reading to determine the cyl­inder wear.

SERVICE LIMIT: 79.05 mm (3.112 in)

Calculate the piston-to-cylinder clearance. Take the maximumreading to determine the clearance.

SERVICE LIMIT: 0.13 mm (0.005 in)

Calculate the cylinder for taper at three levels in an X and Yaxis. Take the maximum reading to determine the taper.

SERVICE LIMIT: 0.06 mm (0.002 in)

Calculate the cylinder for out-of-round at three levels in an Xand Y axis. Take the maximum reading to determine the out­of-round.

SERVICE LIMIT: 0.06 mm (0.002 in)

The cylinder must be rebored and an oversize piston fitted ifthe service limits are exceeded.

The following oversize pistons are available:0.25 mm (0.010 in) and 0.50 mm (0.020 in)

The cylinder must be rebored so that the clearance to an over­size piston is 0.010-0.035 mm (0.0004-0.0014 in).

10-2

(1)IN <;::J~

(3) TOP r-""*",""""~~

(4) M IDOLE I:----I------+j

(5) BOTTOM t---r-----+j

c::> (2) EXX

Inspect the cylinders for transverse warpage across the top.

NOTE

Measure warpage using a straight edge and feeler gauge asshown.

SERVICE LIMIT: 0.10 mm (0.004 in)

PISTONREMOVAL

Place a shop towel into the crankcase and remove the pistonpin clips.

NOTE

• Do not let the clips fall into the crankcase.

Push the piston pin out and remove the piston.

INSPECTION

Clean the piston domes, ring lands and skirts.

Measure the piston ring-to-groove clearance.

SERVICE LIMITS:Top: 0.11 mm (0.004 in)Second: 0.10 mm (0.004 in)

If clearance is excessive, replace the piston ring.

Remove the piston rings and mark them to indicate the correctcylinder and piston position for reassembly.

NOTE

• Do not damage the piston rings when removing them.

CYLINDER/PISTON

10-3

CYLINDER/PISTON

Measure the piston 0.0.

NOTE

Take measurements 10 mm (OA in) from the bottom, and90 0 to the piston pin hole.

SERVICE LIMIT: 78.92 mm (3.107 in)

Calculate the piston-to-cylinder clearance by subtracting thepiston 0.0. from the cylinder 1.0. (page 10-2).

SERVICE LIMIT: 0.13 mm (0.005 in)

Measure the top and second piston ring end gaps: using a pis­ton, push the ring into the cylinder squarely and make the mea­surement.

SERVICE LIMITS:Top: 0.65 mm (0.026 in)Second: 0.65 mm (0.026 in)Oil: 0.95 mm (0.037 in)

Measure each piston pin bore.

SERVICE LIMIT: 20.018 mm (0.7881 in)

Measure each piston pin 0.0.

SERVICE LIMIT: 19.984 mm (0.7867 in)

Calculate the piston pin-to-piston clearance.

SERVICE LIMIT: 0.034 mm (0.0013 in)

Measure the 1.0. of the connecting rod small end.

SERVICE LIMIT: 20.04 mm (0.789 in)

Calculate the piston pin-to-connecting rod clearance.

SERVICE LIMIT: 0.060 mm (0.0024 in)

Refer to section 11 for connecting rod replacement.

10-4

(2) PISTON PIN

CYLINDER/PISTON

PISTON RING INSTALLATION

(7)20 mm (0.8 in)OR MORE

\.~~eE:~~"--B-(1) TOP RING

~:::::::::::i~~:::>J - --(2) SECOND RING

(4) SIDE RAIL J~(5) SPACER (3) OIL~ RING

(6) SIDE RAIL

(7)20 mm(0.8 in)OR MORE

Be careful not to damage the piston and piston rings duringassembly.

Insert the outside surface of the ring into the proper ringgroove and roll the ring around in the groove to make surethat the ring has a free fit around the piston's circum­ference.

Stagger the ring end gaps 120 0 apart from each other asshown.

Carefully install the piston rings onto the piston with the mark­ings facing up.

NOTE

NOTE

NOTE

To install the oil ring, install the spacer first, then install theside rails.

After installing the rings, check that they rotate freely withoutsticking.

PISTON INSTALLATIONPlace a shop towel into the crankcase.Coat the rod small end with molybdenum disulfide grease. As­semble the piston and connecting rod with the piston' andpiston pin clips as shown.

NOTE

Install the pistons with the mark "IN" facing towards theintake side.After installing the piston pin clips, make sure that they areseated properly and the end gaps are not aligned with thecut-out in the piston.Do not let the piston pin clips fall into the crankcase.

CYLINDER INSTALLATIONClean the cylinder gasket surface.

Install the dowel pins and new gasket.

10-5

CYLINDER/PISTON

Coat the cylinder. piston rings/grooves and piston with cleanengine oil.

Install the piston assembly into the cylinder from the top of thecrankcase while compressing the piston rings with your fin­gers.Be sure each assembly is returned to its original position asnoted during removal.

NOTE

Be careful not to damage the piston rings during assembly.When the cylinder is halfway over the piston. route the camchain through the cylinder.

Install a new a-ring onto the cylinder joint and install the cylin­der joint collar by sliding the collar toward either cylinder.Install the clips securely.

Install a new a-ring into the connector and install and tightenthe connector mounting bolts, if the connector was removed.

If only the water hose was removed, connect the hose withthe clamp.

Clean the cylinder gasket surface.

NOTE

• Avoid damaging the gasket surface.

Install the cam chain guide.

NOTE

Align the guide boss with the groove in the cylinder.Make sure that the end of the guide is inserted into place inthe crankcase.

Install the dowel pins and a new gasket.Install the cylinder heads and covers (Section 9).

10-6

CRANKSHAFT/TRANSMISSION

'SS Shown:

20-30 N'm (2.0-3.0 kg-m,----=----~\14-22 ft-Ibl

11-0

30-50 N'm (3.0-5.0 kg-m,22-36 ft-Ib)

20-30 N'm(2.0-3.0 kg-m,14-22 ft-Ib)

11. CRANKSHAFT/TRANSMISSIONSERVICE INFORMATION

TROUBLESHOOTING

CRANKCASE SEPARATION

CRANKSHAFT/CONNECTING ROD

TRANSMISSION

SERVICE INFORMATIONGENERAL

11-1

11-2

11-3

11-4

11-9

CRANKCASE

TRANSMISSION ASSEMBLY/INSTALLATION

CRANKCASE ASSEMBLY

11-11

11-15

11-16

• To service the connecting rods, crankshaft, transmission and oil pump, the engine must be removed from the frame (Sec­tion 6).

• All bearing inserts are select fitted and are identified by color code or code letter. Select replacement bearings from thecode tables.After installing new bearings, recheck them with plastigauge to verify clearance.

• Apply molybdenum disulfide grease to the main journals and crankpins during assembly.• Before separating the crankcase, the following parts must be removed.

Cylinder head (Section 9) Flywheel (Section B)• Cylinder/piston (Section 10) Starter motor (Section 17)• Clutch/gearshift linkage (Section 7) Water pump (Section 5)

SPECIFICATIONSmm (in)

ITEM STANDARD SERVICE LIMIT

Crankshaft/ Connecting rod big end side clearance 0.05-0.20 (0.002-0.008) 0.3 (0.012)connecting rod Crankpin oil clearance 0.028-0.052 (0.0011-0.0020) 0.08 (0.003)

Main journal oil clearance 0.025-0.041 (0.0010-0.0016) 0.05 (0.002)

Crankshaft runout -- 0.05 (0.002)

Transmission Gear 1.0. C1 24.000-24.021 (0.9449-0.9457) 24.03 (0.946)

M4, M5, C2, C3 28.000-28.021 (1.1024-1.1032) 28.03 (1.103)

Gear bushing 0.0. C1 23.959-23.980 (0.9433-0.9441) 24.95 (0.982)

M4, M5, C2, C3 27.959-27.980 (1.1007-1.1016) 27.95 (1.100)

Gear bushing I. D. C1 20.016-20.037 (0.7880-0.7889) 20.05 (0.789)

M4, C2, C3 25.000-25.021 (0.9843-0.9851) 25.03 (0.985)

Bushing-to- M4, C3 0.020-0.062 (0.0008-0.0024) 0.08 (0.003)shaft clearance C2 0.010-0.049 (0.0004-0.0019) 0.07 (0.003)

Gear-to- M4, M5, C1,0.020-0.062 (0.0008-0.0024) 0.08 (0.003)

bushing clearance C2, C3

Mainshaft 0.0. M4 bushing 24.959-24.980 (0.9826-0.9835) 24.95 (0.982)

Countershaft 0.0. C1 bushing 19.980-19.993 (0.7866-0.7871) 19.97 (0.786)

C2 bushing 24.972-24.990 (0.9831-0.9839) 24.96 (0.983)

C3 bushing 24.959-24.980 (0.9826-0.9835) 24.95 (0.982)

Shift fork/ Claw thickness 5.93-6.00 (0.233-0.236) 5.83 (0.230)fork-shaft Right and left shift fork 1.0. 13.000-13.018 (0.5118-0.5125) 13.03 (0.513)

Shaft 0.0. 12.966-12.984 (0.5105-0.5112) 12.96 (0.510)

Shift drum 0.0. (at the left side journal) 11.966-11.984 (0.4711-0.4718) 11.96 (0.471)

11-1

II]

CRANKSHAFT/TRANSMISSION

TORQUE VALUES

Connecting rod bearing cap nutCrankcase 8 mm stud bolt

10 mm stud bolt

TOOLS

SpecialMain bearing driver attachmentBearing remover set- remover handle- bearing remover set- remover weight

CommonDriverAttachment, 42 x 47 mmPilot, 20 mmAttachment, 52 x 55 mmPilot, 22 mmPilot, 25 mm

TROUBLESHOOTI NGExcessive noise• Crankshaft- Worn main bearing- Worn crankpin bearing• Connecting rod- Worn rod small end- Worn crankpin bearing

Hard to shiftShift fork bent

• Shift fork shaft bentShift spindle claw bentShift drum cam grooves damagedShift fork guide pin damaged

Transmission jumps out of gearGear dogs wornShift shaft bentShift fork bent

11-2

34 N'm (3.4 kg-m, 25 ft-Ib)20-30 N'm (2.0-3.0 kg-m, 14-22 ft-Ibl30-50 N'm (3.0-5.0 kg-m, 22-36 ft-Ibl

07HMF-MM9040007936-371000107936-371010007936-371060007741-0010201 or 07936-3710200 U.S.A. only

07749-001000007746-001030007746-004050007746-001040007746-004100007746 - 0040600

CRANKCASE SEPARATIONRemove the engine from the frame (Section 6).Remove the oil filter.Refer to the service information (page 11-1) for the parts thatmust be removed before the separating the crankcase.

Remove the oil pipe stay and cam chain tensioner set plate byremoving the bolts.

Remove the rear cam chain and cam chain drive sprocket.

Remove the bolt and cam chain tensioner set plate.Remove the front cam chain from the crankshaft.

Remove the 8 mm bolts and 6 mm bolts from the left crank­case.

NOTE

Remove the bolts in a crisscross pattern in 2 or 3 steps.• Loosen the 6 mm bolts first, then loosen the 8 mm bolts.

'88 Only:Remove the countershaft set plate bolt and the plate.

After '88:Remove the countershaft set plate bolts (2 pcs.) and the plate.

'88, After '88:Remove the 8 mm bolts and 6 mm bolts from the right crank­case.

NOTE

Remove the bolts in a crisscross pattern in 2 or 3 steps.• Loosen the 6 mm bolts first, then loosen the 8 mm bolts.

CRANKSHAFT{TRANSMISSION

11-3

CRANKSHAFT/TRANSMISSION

Place the left crankcase side down and separate the rightcrankcase from the left crankcase while prying where indicat­ed at the points shown and tapping the cases at several loca­tions with a soft hammer.

Remove the dowel pins and clean the crankcase halves of anysealant material.

CRANKSHAFT/CONNECTING RODCRANKSHAFT SIDE CLEARANCE INSPECTION

Remove the crankshaft from the left crankcase.Check the connecting rod side clearance with feeler gauge.

SERVICE LIMIT: 0.30 mm 10.012 inl

If either side clearance exceeds the service limit, replace theconnecting rod and recheck.If still beyond the limit. replace the crankshaft.Inspect the crankshaft for rough spots or damage.

CONNECTING ROD DISASSEMBLY

Remove the connecting rod bearing caps noting their loca­tions.

NOTE

• Tap the side of the cap lightly if it is hard to remove.

CAUTION

Do not interchange the crankpin bearings. They must be in­stalled in their original positions or the correct bearing oil clear­ance may not be obtained resulting in engine damage.

11-4

11) BEARING CAPS

CRANKSHAFT RUNOUT INSPECTION

Place the crankshaft on a stand or V blocks.Set a dial indicator on the main journals. Rotate the crankshafttwo revolutions and read the runout.

SERVICE LIMIT: 0.05 mm (0.002 in)

NOTE

The crankshaft cannot be repaired. Replace it if the journalsor crankpins are burnt, cracked, or if the runout is beyondlimits.

CONNECTING ROD BEARING INSPECTION

CRANKSHAFT/TRANSMISSION

Inspect the bearing inserts for damage or separation.Clean all oil from the bearing inserts and crankpins.

(2) SEPARATION (1) DAMAGE

OIL CLEARANCE INSPECTION

Put a piece of plastigauge on each crankpin avoiding the oilhole.

Install the bearing caps and rods on the correct crankpins, andtighten them evenly.

TORQUE: 34 N'm (3.4 kg-m, 25 ft-Ibl

NOTE

• Do not rotate the crankshaft during inspection.

Remove the caps and measure the compressed plastigauge atits widest point on each crankpin to determine the oil clear­ance.

SERVICE LIMIT: 0.08 mm (0.003 in)

If the rod bearing clearance is beyond tolerance, select re­placement bearings.

11-5

CRANKSHAFT{TRANSMISSION

CONNECTING ROD BEARING SELECTION

Determine the connecting rod I. D. code number.The code will be either a number 1 or 2 located on the rod inthe area shown.

Determine the corresponding crankpin 0.0. code (or measurethe crankpin 0.0.1. The code will be either a letter A or B onthe crank weight.

Cross reference the crankpin and connecting rod codes to de­termine the replacement bearing color.

1\CRANKPIN 0.0. CODEA B

39.982- 39.974-

\ 39.990 mm 39.983 mmCONNECTING (1.5741- (1.5738-ROD 1.0. CODE 1.5744 in) 1.5741 in)

143.000-43.008 mm C B(1.6929-1.6932 in) (BROWN) (BLACK)

243.008-43.016 mm B A(1.6932-1.6935 in) (BLACK) (BLUE)

BEARING INSERT THICKNESSA (BLUE): 1.495-1.499 mm (0.0589-0.0590 in)B (BLACK): 1.491-1.495 mm (0.0587 -0.0589 in)C (BROWN):1.487-1.491 mm (0.0585-0.0587 in)

MAIN BEARING INSPECTION

Measure the main journal 0.0. and record it.

11-6

(1) 1.0. CODE NUMBER

CRANKSHAFT/TRANSMISSION

Measure the main journal bearing 1.0. and record it. (1) CRANKCASE•

Calculate the clearance between the main journal and the mainbearing.

SERVICE LIMIT: 0.06 mm (0.002 in)

If the oil clearance is beyond the service limit, select a replace­ment bearings as follows:

MAIN BEARING SELECTION (1) CRANKSHAFT

Determine the crankshaft main journal 0.0. code. The codewill be either a number 1 or 2 on the crank weight.

Determine the corresponding main bearing 1.0. code. The codewill be either a letter A or B on the crankcase.

(2) MAIN BEARING

~~~

~

'r-----0,[\ F

'th thd. btChoose rep acemen main eanngs In accor ance WI etable below. MAIN JOURNAL 0.0. CODE [on crank weightl

1 2

44.992-45.000 mm 44.984-44.992 mm(1.7713-1.7717 in) (1.7710-1.7713 in)

MAIN 8EARINGA

48.990-49.000 mm C 81.0. CODE (1.9287-1.9291 in) (BROWN) (BLACK)[on crankcasel 49.000-49.010 mm B A

B(1.9291-1.9295 in) (BLACK) (BLUE)

BEARING INSERT THICKNESSA (BLUE): 2.003-2.013 mm (O.0789-0.0793 in)B (BLACK): 1.998-2.008 mm (O.0787-0.0791 in)C (BROWN): 1.993-2.003 mm (O.0785-0.0789 in)

11-7

CRANKSHAFT/TRANSMISSION

MAIN BEARING REPLACEMENT

Press the main bearing out of the crankcase using a hydraulicpress and special tools.

NOTE

• Always use a press to remove the main bearing.

TOOLS:Driver 07749-0010000Main bearing remover attachment 07HMF-MM90400

Mark a vertical line below each side of the bearing tab.

Apply molybdenum disulfide grease to the outer surface of themain bearing.

Align the marks on the bearing with the groove in the bearinghole, and press the main bearing into the crankcase.

(2) MARKS

CAUTION (3) GROOVE

• Be careful not to damage the bearings.

CONNECTING ROD SELECTION

A letter stamped on the connecting rod is the code for therod's weight.

When replacing the connectring rod, select the new rod bycross-matching the front and rear cylinder connecting rodweights using the selection table below.

(1) DRIVER

(2) ATTACHMENT07749-001000007HMF- MM90400

TOOLS:DriverMain bearing driver attachment

NOTE

The "0" mark in the table indicates that the matching ispossible in the crossed codes.

SELECTION TABLE

1\ Front rod codeA B C D

Rear rod code \

A 0 0 ------ ----------B 0 0 0

----------C

--------0 0 0

D

-------- --------0 0

m~'91

(1) WEIGHT CODE LETTER

11-8

CONNECTING ROD ASSEMBLY

Install the bearing inserts on the rods and caps.

NOTE

Align the boss on the bearing with the groove in the rod orcap.Apply molybdenum disulfide grease to the bearing.

Install the connecting rods and caps on the crankpin. Be sureeach part is installed in its original position, as noted during re­moval.

Tighten the bearing cap nuts.

NOTE

Align the 1.0. code on the cap and rod.Tighten the nuts in two or more steps. After tightening,check that the rods move freely without binding.

TORQUE: 34 N'm (3.4 kg-m. 25 ft-Ibl

Install the crankshaft in the left crankcase.Install the dowel pins and assemble the crankcase (page 11­16).

TRANSM ISSIONREMOVAL

Remove the mainshaft. countershaft, shift fork shaft and shiftdrum as an assembly.

Separate the shift forks/shaft, mainshaft and countershaft as­semblies from each other.

DISASSEMBLY/INSPECTION

Bend down the lock washer tabs and remove the bolt and lockwasher from the center shift fork.Remove the shift fork shaft.

Disassemble the mainshaft and countershaft.

CRANKSHAFT/TRANSMISSION

(1) Apply molybdenum disulfide grease

(1) TRANSMISSION ASSEMB\

(1) LOCK WASHER

11-9

CRANKSHAFT/TRANSMISSION

Inspect the shift drum end for scoring, scratches, or evidenceof insufficient lubrication. Check the shift drum grooves fordamage.Measure the shift drum shaft 0.0. at the left side journal.

SERVICE LIMIT: 11.96 mm (0.471 in)

Check the bearing inner and outer races for damage.The bearing should turn smoothly and quietly.

Check the shift fork shaft for scratches, scoring or evidence ofinsufficient lubrication.Measure the shift fork shaft 0.0.

SERVICE LIMIT: 12.96 mm (0.510 in)

Measure the 1.0. of each shift fork and the fork claw thickness.

SERVICE LIMITS:1.0.: 13.03 mm (0.513 in)CLAW THICKNESS: 5.83 mm (0.230 in)

Inspect the shift drum and shift fork shaft journals for exessivewear or damage.

Measure the 0.0. of mainshaft and countershaft.

SERVICE LIMITS:A: M4 bushing 24.95 mm (0.982 in)B: C1 bushing 19.97 mm (0.786 in)C: C2 bushing 24.96 mm (0.983 in)0: C3 bushing 24.95 mm (0.982 in)

11-10

(2) SHIFT FORK

--------

\ b(2) COUNTERSHAFT

Check each shaft's grooves for damage.

Replace if necessary.

CRANKSHAFT/TRANSMISSION

"(2) SNAP RINGGROOVE

Check the gear dogs, holes and teeth for excessive orabnormal wear, or evidence of insufficient lubrication.Measure the I. D. of each gear.

SERVICE LIMITS:M4, M5, C2, C3 gears: 28.03 mm (1.103 in)C1 gear: 24.03 mm (0.946 in)

Measure the I.D. and O.D. of each gear bushing.

SERVICE LIMITS:M4, M5, C2, C3 bushings 0.0.: 27.95 mm 11.100 in)C1 bushing 0.0.: 24.95 mm 10.982 in)M4, C2, C3 bushing I.D.: 25.03 mm 10.985 in)C1 bushing 1.0.: 20.05 mm 10.789 in)

Calculate the bushing to shaft clearances and gear to bushingclearance.

SERVICE LIMITS:bushing-to-shaft (M4, C3):

0.08 mm (0.003 in)(C2):

0.07 mm (0.03 in)gear-to-bushing (M4, M5, C1, C2, C3):

0.08 mm (0.003 in)

CRANKCASEBEARING REPLACEMENT

Turn the inner race of each bearing with your finger. The bear­ings should turn smoothly and quietly. Also check that thebearing outer race fits tightly in the crankcase.

Remove and discard the bearings if the races do not turnsmoothly, quietly, or if they fit loosely in the crankcase.

(1) CRANKCASE BEARING

11-11

CRANKSHAFT/TRANSMISSION

Drive the countershaft bearing and oil seal out of the crank­case.

Left crankcaseRemove the left mainshaft bearing using the special tools.

TOOLS:Bearing remover set- remover handle- bearing remover set- remover weight

07936-371000107936-371010007936 - 371 060007741-0010201 or07936-3710200 U.S.A.only

Install the new mainshaft bearing set plate on the left crank­case.

NOTE

Install the new bearings with the following tools.

Apply fresh engine oil to the new crankcase bearings beforeinstallation.

07749-001000007746-0010300

07749-001000007746-001040007746-0040600

TOOLS:Left mainshaft bearing:

DriverAttachment. 42 x 47 mm

Left countershaft bearing:DriverAttachment. 52 x 55 mmPilot. 25 mm

Install a new countershaft oil seal.Check the gearshift spindle oil seal for wear or damage. re­place if necessary.

(1) OIL SEAL

11-12

CRANKSHAFT/TRANSMISSION

07749-001000007746-001030007746-0040500

07749-001000007746-001040007746-0041000

TOOLS:Right mainshaft bearing

DriverAttachment, 52 x 55 mmPilot, 22 mm

Right countershaft bearingDriverAttachment, 42 x 47 mmPilot, 20 mm

Right crankcase "(3) COUNTERSHAFT BEARINGRemove the mainshaft bearing set plate and drive the counter­shaft bearing, mainshaft bearing and shift drum bearing out ofthe crankcase.

Apply a locking agent to the threads of the mainshaft bearingset plate <lttaching bolt.

Install the set plate aligning the edge of the set plate with theslot on the bearing outer and tighten the bolt securely.

INSPECTION (1) 10 mm STUD BOLT HOLES

Crankcase studsCheck that the studs are tight. If any are loose, remove them,clean their threads with contact cleaner, then reinstall tn~musing Honda Anaerobic Thread Lock, or equivalent.

EME~oco"I~.q-

I~00 COCO'co~-

~

E"E~0"001~oo

10000""':~-

(1) 8 mm STUD BOLT (2) 10 mm STUD BOLT

TORQUE: 8 mm stud bolt:20-30 N'm (2.0-3.0 kg-m, 14-22 ft-Ibl10 mm stud bolt:30-50 N·m (3.0-5.0 kg-m, 22-36 ft-Ibl

After installing, be sure to measure the distance from the topof each stud to the crankcase surface.

Tighten the stud bolts to the specified torque.

11-13

CRANKSHAFT/TRANSMISSION

Oil jetRemove the oil jets from the front cylinder bore of the right andleft crankcase.

Check the O-ring for fatique and damage.

Check the oil jet orifice for clogging.

TRANSMISSION ASSEMBLY/INSTALLATIONApply MOS2 grease to the shift fork journals of M3, C4 and C5gears.

Clean all parts in solvent and dip them in clean engine oil.

CAUTION

Align the oil holes in the bushings and gears with the oil holes inthe shaft.

Mainshaft

11-14

o0q)(()OO 00M5 M3

CRANKSHAFT{TRANSMISSION

(1) COUNTERSHAFT

~~©o~®oC2 r-----'-::..-----------l

CountershaftApply molybdenum disulfide grease to the following.- shift fork grooves- inside and outside of the bushings- outside of the spline bushings

Install the shift forks onto the shaft as follows.

Left side: "MN8L" mark facing R. crankcase.Center: "C" mark facing L. crankcase.Right side: "MM9R" mark facing R. crankcase.

Tighten the bolt with the lock washer and bend up the tabs ofthe lock washer.

Assemble the mainshaft, countershaft, shift fork shaft andshift drum.Install them into the left crankcase as an assembly.

(1) TRANSMISSION ASSEMBLY

\

11-15

CRANKSHAFT/TRANSMISSION

CRANKCASE ASSEMBLYApply sealant to the crankcase mating surfaces.Install the dowel pins.

Assemble the right and left crankcases being careful to alignthe dowel pins and ~hafts.

CAUTION

Do not force the crankcase halves together; if exessive force isrequired, something is wrong. Remove the right crankcase andcheck for misaligned parts.

Apply oil to all crankcase bolts.Install and tighten the right crankcase bolts in a crisscross pat­tern in 2 or 3 steps.

NOTE

• Tighten the 8 mm bolts first, then tighten the 6 mm bolts.

Install and tighten the left crankcase bolts in a crisscross pat­tern in 2 or 3 steps.

NOTE

• Tighten the 8 mm bolts first, then tighten the 6 mm bolts.

'88 Only:Install the countershaft set plate with the attaching bolt.

After '88:Install the countershaft set plate with the attaching bolts (2

pes).

11-16

(2) RIGHT CRANKCASE

1

'88, After '88:Install the rear cam chain drive sprocket over the crankshaft,aligning the extra-wide splines in the sprocket and crankshaft.

Install the rear cam chain over the drive sprocket.

Install the oil pipe stay and cam chain tensioner set plate.Tighten the bolt sercurely.

Install the front cam chain over the front cam chain drivesprocket.Install the cam chain tensioner set plate and tighten the boltsecurely.

Install the remaining parts in the reverse order of removal(page 11-3).

CRANKSHAFT/TRANSMISSION

11-17

FRONT WHEEl/SUSPENSION/STEERING

~22 N'm (2.2 kg-m. 16 ft-Ib)

12-0

105 N'm (10.5 kg-m, 76 ft-Ib)

11 N'm (1.1 kg-m, 8 ft-Ibl

12. FRONT WHEEL/SUSPENSION/STEERINGSERVICE INFORMATION

TROUBLESHOOTING

HANDLEBARS

FRONT WHEEL

12-1

12-2

12-3

12-7

FORK

HEADLIGHT BRACKET

STEERING STEM

12-12

12-19

12-20

SERVICE INFROMATION

-'------------------------Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brakeassemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazardcaused by airborne asbestos fibers.

GENERAL

• A jack or other support is required to support the motorcycle during front end service.• For front brake service, refer to section 14.• For headlight, instrument and ignition switch services and inspections, refer to section 18.

SPECIFICATIONSUnit: mm (in)

ITEM STANDARD SERVICE LIMIT

Axle runout -- 0.2 (0.01)

Front wheel rim runout Radial -- 2.0 (0.08)

Axial -- 2.0 (0.08)

Fork spring free length -- 336.4 (13.2)

Fork tube runout -- 0.2 (0.01)

Fork fluid capacity '88: 497 cc (16.8 US OZ, 17.4 Imp oz)--

After '88: 502 cc (16.9 US OZ, 17.6 Imp OZ)

Fork fluid level '88: 133 (5.2)--

After '88: 128 (5.0)

Steering bearing preload 1.0-1.5 kg (2.2-3.3Ib) --

TORQUE VALUES

m

Master cylinder holder boltFront axle boltFront axle pinch boltFork top pinch boltFork bottom pinch boltFork tube capFork socket boltBrake disc retaining boltBrake caliper mounting boltSteering bearing adjustment nutSteering stem nutHandlebar pinch boltIgnition switch mounting bolt

12 N'm (1.2 kg-m, 9 ft-Ib)60 N'm (6.0 kg-m, 43 ft-Ib)22 N'm (2.2 kg-m, 16 ft-Ib)11 N'm (1.1 kg-m, 8 ft-Ib)50 N'm (5.0 kg-m, 36 ft-Ib)23 N'm (2.3 kg-m, 17 ft-Ib)17 N'm (1.7 kg-m, 12 ft-Ib) Apply locking agent to the threads40 N'm (4.0 kg-m, 29 ft-Ib) Apply locking agent to the threads27 N'm (2.7 kg-m, 20 ft-Ib)20 N'm (2.0 kg-m, 14 ft-Ib)105 N'm (10.5 kg-m, 76 ft-Ib)27 N'm (2.7 kg-m, 20 ft-Ib)25 N·m (2.5 kg-m, 18 ft-Ibl

12-1

FRONT WHEEL/SUSPENSION/STEERING

TOOLS

SpecialSteering stem socketBall race remover set

- Driver attachment A 47 mm- Driver attachment B 55 mm- Driver assembly shaft- Bearing remover A 47 mm- Bearing remover B 55 mm- Assembly baseSteering stem socketSnap ring pliersSteering stem driver

CommonLock nut wrench, 30 x 32 mmExtension barDriverAttachment, 42 x 47 mmAttachment, 52 x 55 mmPilot, 20 mmFork seal driver- Driver attachmentBearing remover shaftBearing remover head, 20 mm

TROUBLESHOOTING

07916-371010007946-KM90001 orTAdjustable bearing puller 07736-A01000A

[Attachment, 42 x 47 mm 07746-0010300Attachment, 52 x 55 mm 07746-0010400

07946-KM9010007946-KM9020007946-KM9030007946-KM9040107946-KM9050007946-KM9060007916-371010007914-323000 -Equivalent commercially available in U.S.A.07946-MBOOOOO

07716-0020400,Equivalent commercially available in U.S.A.07716-0020500...J07749-001000007746-001030007746-001040007746-004050007947-KA5010007947-KF0010007746-0050100T Equivalent commercially available in U.S.A.07746-0050600

Soft SuspensionWeak fork springs

• Insufficient fluid in fork legs

Hard Steering• Steering bearing adjustment nut too tight• Faulty steering stem bearings

Insufficient air in front tire

Steers to One Side or Does Not Track StraightBent fork legsBent front axle, wheel installed incorrectlyUnequal oil quantity in each fork tube

Front Wheel WobblingDistorted rimWorn front wheel bearingsFaulty tireAxle or axle holder not tightened properly

12-2

, .Hard Suspension

Fork oil level too high• Fork tube(s) bent or fork slider(s) damaged

Front Suspension NoiseSlider bindingInsufficient fluid in fork legsLoose fork leg fasteners

HANDLEBARSREMOVAL

Disconnect the front brake light switch wires from the switch.Remove the following:- rear view mirror from the master cylinder- master cylinder holder mounting bolts and holder- right handlebar switch screws and switch- the right handlebar retainer ring and loosen the handlebar

pinch bolt.- the right handlebar from the fork tube.

(6) PINCH BOLT

Disconnect the clutch switch wires from the switch terminals.Remove the following:- rear view mirror from the clutch lever holder.- clutch lever holder mounting bolts and holder.- left handlebar switch screws and switch.

Disconnect the choke cable and remove the left handlebarswitch from the choke lever.

Remove the left handlebar retainer ring and loosen the lefthandlebar pinch bolt.

Remove the left handlebar from the fork tube.

FRONT WHEEL/SUSPENSION/STEERING

(2) HANDLEBAR SWITCH

(4) THROTTLE CABLES

(5) HOLDER

(1) RETAINERRING

12-3

FRONT WHEEL/SUSPENSION/STEERING

HANDLEBAR WEIGHT REPLACEMENT

Remove the grip from the handlebar.Straighten the weight retainer tab by the screwdriver or centerpunch.

Remove the handlebar weight by turning the grip end weight.

NOTE

• Apply lubricant spray (CRC 5-56 or equivalent) through thetab hooking hole to the rubber suspension in order to easyremoval.

Remove the grip end weight by removing the mounting screwfrom the handlebar weight.Discard the used retainer.

(3) HOOKING HOLE

(1) GRIP END WEIGHT

(5) GRIP END WEIGHT

Install the new retainer onto the handlebar weight.Install the grip end weight onto the handlebar weight aligningthe boss with slot.Clean and apply a locking agent to the mounting screw threadsand tighten it securely.

Insert the handlebar weight assembly onto the handlebar.(1 ) RETAINER

(3) HANDLEBARWEIGHT

(3) HOOKING HOLE

Hooking the retainer tab to the hooking hole securely.

Install the grip onto the handlebar.

(4) GRIP END WEIGHT

Apply Honda bond A to the inside surface of the grips and tothe clean surface of the left handlebar and throttle pipe. Wait3-5 minutes and install the grips.Rotate the grips for even application of the adhesive.

NOTE

• Allow the adhesive to dry for an hour before using.

12-4

(1) GRIP

INSTALLATION

Install the right handlebar onto the fork tube, aligning the pinon the bottom of the handlebar holder with the cut-out in thefork bridge. Install the retainer ring. Tighten the handlebarpinch bolt.

TORQUE: 27 N'm (2.7 kg-m. 20 ft-Ib)

Align the locating pin on the right handlebar switch with thehole in the handlebar.

Apply clean grease to the throttle cables and apply clean oil tothe throttle pipe sliding surface and connect the throttle cablesto the throttle pipe.

Slide the throttle pipe onto the handlebar.Install the right grip end weight and tighten the screw.

(2) MASTER CYLINDER

(6) PINCHBOLT

------.~~.((

Place the front brake master cylinder on the handlebar and in­stall the master cylinder holder with the "UP" mark facing up.

FRONT WHEEL/SUSPENSION/STEERING

Align the end of the holder with the punch mark on the handle­bar. Tighten the upper holder bolt first, then tighten the lowerbolt.

TORQUE: 12 N'm (1.2 kg-m, 9 ft-Ibl

Connect the front brake switch wire.

Install the right handlebar switch mounting screws.Tighten the front screw first, then tightne the rear screw.Install the throttle cables to the carburetor and adjust thethrottle grip free play (page 3-5).

Install the right rear-view mirror into the master cylinder hold­er.

12-5

FRONT WHEEL/SUSPENSION/STEERING

Install the left handlebar onto the fork tube in the same manneras a right handlebar.Connect the choke cable to the choke lever.Install the left handlebar switch by aligning the locating pinwith the hole in the handlebar.Tighten the front screw first, then tighten the rear screw.

Install the right rear view mirror in the holder.Secure the wires with wire bands.

(1) LOCATING PIN

Install the clutch lever and holder with the "UP" mark facingup.Align the end of the holder with the punch mark on the handle­bar and tighten the upper bolt first then tighten the lower bolt.

TORQUE: 12 N·m (1.2 kg-m. 9 ft-Ibl

Adjust the following:- throttle operation and free play (page 3-41-- clutch lever free play (page 3-16).

12-6

(2) RETAINER RING

FRONT WHEELREMOVAL

Raise the front wheel off the ground.

Disconnect the speedometer cable from the speedometer gearbox by removing the cable set screw.Remove the brake caliper mounting bolts and brake caliper.

CAUTION

Support the caliper assembly so that it does not hang on thebrake hose. Do not twist the brake hose.

NOTE

If you squeeze the front brake lever after the caliper is re­moved, the caliper piston will move out and make assemblydifficult.

Loosen the right and left front axle pinch bolts, and remove theaxle bolt.

Remove the axle and the front wheel.

Remove the side collar from the right side and remove thespeedometer gear box from the left side.

FRONT WHEEl/SUSPENSION/STEERING

12-7

FRONT WHEEL/SUSPENSION/STEERING

INSPECTION

AxleSet the axle in V blocks and measure the runout.

SERVICE LIMIT: 0.2 mm (0.01 in)

Wheel rim runoutCheck the rim runout by placing the wheel in a truing stand.Spin the wheel slowly and read the runout using a dial indica­tor.

SERVICE LIMITS:RADIAL RUNOUT: 2.0 mm (0.08 in)AXIAL RUNOUT: 2.0 mm (0.08 in)

Wheel Balance

CAUTION

Wheel balance directly affects the stability, handling and over­all safety of the motorcycle. Always check balance when thetire has been removed from the rim.

NOTE

For optimum balance, the tire balance mark (a paint dot onthe side wall) must be located next to the valve stem.Remount the tire if necessary.

Mount the wheel, tire and brake disc assembly in an inspectionstand.Spin the wheel, allow it to stop, and mark the lowest(heaviest) part of the wheel with chalk.Do this two or three times to verify the heaviest area. If thewheel is balanced, it will not stop consistently in the same po­sition.

12-8

(1) AXLE

(1) INSPECTIONSTAND

FRONT WHEEL/SUSPENSION/STEERING

To balance the wheel, install wheel weights on the highestside of the rim, the side opposite the chalk marks. Add justenough weight so the wheel will no longer stop in the same po­sition when it's spun.Do not add more than 60 grams to the front wheel.

Wheel bearingTurn the inner race of each bearing with your finger. The bear­ings should turn smoothly and quietly. Also check that thebearing outer race fits tightly in the hub.

Remove and discard the bearings if the races do not turnsmoothly, quietly, or if they fit loosely in the hub.

NOTE

• Replace hub bearings in pairs.

BEARING REPLACEMENT

Remove the brake disc mounting bolts and discs.Remove the dust seal from both sides.Remove the speedometer gear retainer.

NOTE

If the bearings are removed, they must be replaced withnew ones.

Install the bearing remover head into the bearing.From the opposite side install the bearing remover shaft anddrive the bearing out of the wheel.

07746-005010007746-0050600

TOOLS:Bearing remover shaftBearing remover head, 20 mm

12-9

FRONT WHEEL/SUSPENSION/STEERING

Remove the distance collar from the wheel hub.Remove the other bearing from the hub using the same tools.

Drive a new right bearing into the wheel until it is fully seatedfirst.

Install the distance collar into the wheel hub.Drive a new left bearing into the wheel until it is fully seated.

• Do not allow the bearings to tilt while driving them in.Never install an old bearing, once a bearing is removed, itmust be replaced with a new one.

07749-001000007746-001030007746-0040500

NOTE

TOOLS:DriverAttachment, 42 x 47 mmPilot, 20 mm

ASSEMBLY

NOTE , -

• The front wheel has no rim band.

-'-----------• Do not get grease on the brake disc or stopping power will bereduced.

(4) SPEED­OMETERGEARBOX

(2) BEARING"IB~

(1) DUST SEAL '

.-$iiiR

(3) SPEEDOMETER

RETAINER (5) BRAKE DISC

12-10

Install the brake disc onto the wheel hub with the minimumthickness marking (MIN TH 4.0 mm) facing out.Clean and apply locking agent to the mounting bolt threads.Tighten the bolts to the specified torque in a crisscross patternin 2 or 3 steps.

TORQUE: 40 N·m (4.0 kg-m. 29 ft-Ibl

-'-------------Do not get grease on the brake disc or stopping power will bereduced.

Coat the speedometer gear retainer with clean grease and in­stall the retainer into the wheel hub. aligning the tangs withthe slots in the hub.Apply clean grease to the dust seal lip and install the dust sealover the gear retainer.

Fill the speedometer gear box with clean grease and install thedrive gear.

Install the speedometer gear box into the wheel hub.

Apply clean grease to the right dust seal lip and install the sealinto the wheel.Install the side collar.

FRONT WHEEL/SUSPENSION/STEERING

12-11

FRONT WHEEl/SUSPENSION/STEERING

INSTALLATION

Position the wheel between the fork legs.Insert the axle from the leftside, through the left fork leg andwheel hub.

Position the tang on the speedometer gear box against theback of the lug on the left fork leg.

Insert and tighten the axle bolt.

TORQUE: 60 N'm (6.0 kg-m. 43 ft-Ibl

Tighten the axle pinch bolts.

TORQUE: 22 N'm (2.2 kg-m. 16 ft-Ibl

Install the brake caliper with the caliper bracket.Install the caliper mounting bolts and tighten the bolts.

TORQUE: 27 N'm (2.7 kg-m. 20 ft-Ibl

Connect the speedomater cable with the set screw.

FORKREMOVAL

Remove the following:- handlebars (page 12-3).- front wheel (page 12-7).- brake caliper (page 14-11).- mounting bolts and fender.

12-12

(1) CALIPER__;.:M.OllliL1NG SOLTS

Loosen the fork top bridge pinch bolts.If the fork legs will be disassembled, loosen the fork tube capsbut do not remove them yet.

CAUTION

Do not use an adjustable wrench to loosen the fork tube caps, itmay damage them.

Loosen the fork bottom pinch bolts and remove the fork legsfrom the fork top bridge and steering stem.

DISASSEMBLY

Remove the fork tube cap and the spring.

-'------------The cap is under spring pressure. Use care when removing itand wear eye and face protection.

Drain the oil by pumping the tube up and down several times.

Hold the fork slider in a vise with soft jaws or use a shop towel.

Remove the socket bolt with a hex wrench.

NOTE

Temporarily reinstall the spring and cap if the bolt is difficultto remove.

FRONT WHEEL/SUSPENSION/STEERING

(2) PINCH SOLT

12-13

FRONT WHEEL/SUSPENSION/STEERING

Remove the dust seal and the stop ring with a screwdriver.

CAUTION

• Do not scratch the fork lube sliding surface.

Pull the fork tube out until resistance from the slider bushing isfelt. Then move it in and out, tapping the bushing lightly untilthe fork tube separates from the slider. The slider bushing willbe forced out by the fork tube bushing.

Remove the oil lock piece from the piston.Remove the piston and rebound spring from the fork tube.

Remove the oil seal, back-up ring and slider bushing from thefork tube.

NOTE

Do not remove the fork tube bushing unless it is necessaryto replace it with a new one. See bushing inspection, page12-15.

12-14

(2) STOPPER RING

(2) FORK TUBE

(1) PISTON

//

(2) OIL LOCK PIECE

(2) BACK-UP RING

I

7(4) FORK TUBE BUSHING

INSPECTION

Fork springMeasure the fork spring free length.

SERVICE LIMIT: 336.4 mm (13.2 in)

Replace the spring if it is shorter than the service limit.

FRONT WHEEL/SUSPENSION/STEERING

Fork tube/slider/pistonCheck the fork tube, fork slider and piston for score marks andexcessive or abnormal wear.Replace any components which are worn or damaged.

Check the fork piston ring for wear or damage.Check the rebound spring for fatigue or damage.

(4) REBOUND SPRING

7' PISTON RING

Set the fork tube in V blocks and read the runout.Use 1/2 the total indicator reading to determine the actual run­out.

SERVICE LIMIT: 0.20 mm (0.008 in)

(1) FORK TUBE

(1) BUSHING

BushingsVisually inspect the slider and fork tube bushings.Replace the bushings if there is excessive scoring or scratch­ing, or if the teflon is worn so that the copper surface appearson more than 3/4 of the entire surface.

Check the back-up ring; replace it if there is any distortion atthe points shown.

(5) TEFLONSURFACE

, , ,

(4) COPPERSURFACES

(2) BACK-UP RING

(3) CHECK POINTS

12-15

FRONT WHEEL/SUSPENSION/STEERING

ASSEMBLY

Before assembly, wash all parts with a high flash point or non­flammable solvent and wipe them off completely.

(16) DUST SEAL (17) FORK TUBE

(15) STOP RING \ ,------,

1141 OIL SEAL ~ /

1131 BACK-UP RING~1121 SUOERBUSHIN~

Assemble the rebound spring onto the piston.Insert the piston assembly into the fork tube.Place the oil lock piece on the end of the piston and insert thefork tube assembly into the slider.

(2) FORK TUBE CAP

~

I(2) OIL LOCK PIECE

Place the fork slider in a vise with soft jaws or use a shop towelto avoid damaging the slider.Clean and apply a locking agent to the socket bolt threads andscrew the bolt into the piston.Temporarily install the fork spring and cap to tighten thesocket bolt.Tighten the bolt with a 6 mm hex wrench.

TORQUE: 17 N'm (1. 7 kg-m, 12 ft-Ibl

12-16

FRONT WHEEL/SUSPENSION/STEERING

Drive the bushing into place with the seal driver.

Place the slider bushing over the fork tube and rest it on theslider.

Coat a new oil seal with ATF or equivalent and install it withthe seal markings facing up. Drive the seal in with the seal driv­er.

07947-KA5010007947-KF00100

TOOLS:Fork seal driver- driver attachment

Install the stop ring securely into the groove in the fork slider.

CAUTION

• Do not scratch the fork tube sliding surface.

Install the new dust seal onto the fork slider.

Compress the fork tube and pour in the recommended fork oilto the specified level.

RECOMMENDED FORK OIL: ATF or EQUIVALENTSPECIFIED LEVEL: '88: 133 mm (5.2 in)

After '88: 128 mm (5.0 in)CAPACITY: '88: 497 cc (16.8 US OZ, 17.4 Imp oz)

After '88: 502 cc (16.9 US OZ, 17.6 Imp ozl

; .

Gently install the fork spring in the fork tube then install thespring seat and spacer.

NOTE

Note the spring direction; the tapered end must face towardthe bottom.

Loosely install the fork tube cap with a new O-ring.

CAUTION

• Do not damage the fork tube sliding surface.

11IFORKSP~

I 1

I I

~!

12-17

REAR WHEEL/SUSPENSION

13-0

15 N'm (1.5 kg-m, 11 ft-Ibl

wTiro120 N'm (12.0 kg-m, 87 ft-Ibl

Revised: June. 1991© 1991 American Honda Motor Co., Inc. - All Rights ReservedMSV 5511 (9106) '88-'91 NT650

13. REAR WHEEL/SUSPENSIONSERVICE INFORMATION

TROUBLESHOOTING

REAR WHEEL

SPROCKET

ECCENTRIC BEARING CARRIERREMOVAL

BEARING REPLACEMENT

SPINDLE

SERVICE INFORMATIONGENERAL

13-1

13-2

13-3

13-6

13-6

13-9

13-11

ECCENTRIC BEARING CARRIERINSTALLATION

SHOCK ABSORBER

SWINGARM

MUFFLER/EXHAUST PIPE

SEAT

REAR COWLING

13-12

13-14

13-19

13-24

13-25

13-25

• Never ride on the rim .• When using a lock nut wrench, use a 20 inch long deflecting beam type torque wrench. The lock nut wrench increases the

torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut._l-- _A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a highquality brake degreasing agent.Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brakeassemblies. Use an OSHA-approved vacuum cleaner ot alternate method approved by OSHA designed to minimize the hazardcaused by airborne asbestos fibers.The shock absorber contains nitrogen gas under high pressure. Do not allow fire or heat near the shock absorber.Before disposal of the shock absorber, release the nitrogen. (see page 13-16). IIIE"I::l~---=--------------~=--------~

SPECI FICATIONSUnit: mm (in)

ITEM - STANDARD SERVICE LIMIT

Rear wheel rim runout Radial -- 2.0 (0.08)

Axial -- 2.0 (0.08)

Shock absorber spring free length -- 148.3 (5.84)

Shock absorber spring preload adjuster position 3 --

Compression force at 10 mm (004 in) compressed 15-20 kg (33.1-44.1 Ib) 14.9 kg (32.8 Ib)

TORQUE VALUES

Sprocket mounting boltBrake disc retaining boltBrake disc retaining bolt lock nutRear wheel nutEccentric bearing carrier pinch boltShock absorber mounting bolt: upper sideShock absorber mounting bolt: lower sideDamper rod lock nutSwingarm pivot nutSwingarm pivot lock nutSwingarm pivot adjusting boltBrake torque rod boltsSub-frame mounting boltsFuel filter base mounting boltEccentric bearing carrier lock nut

43 N'm (4.3 kg-m, 31 ft-Ibl35 N'm (3.5 kg-m, 25 ft-Ibl9 N'm (0.9 kg-m, 7 ft-Ibl120 N'm (12.0 kg-m, 87 ft-Ibl75 N'm (7.5 kg-m, 54 ft-Ibl65 N'm (6.5 kg-m, 47 ft-Ibl45 N'm (4.5 kg-m, 33 ft-Ibl62 N'm (6.2 kg-m, 45 ft-Ib) Apply a locking agent to the threads65 N'm (6.5 kg-m, 47 ft-Ibl65 N·m (6.5 kg-m, 47 ft-Ibl15 N'm (1.5 kg-m, 11 ft-Ibl35 N·m (3.5 kg-m, 25 ft-Ibl40 N'm (4.0 kg-m, 29 ft-Ibl22 N'm (2.2 kg-m, 16 ft-Ibl165 N'm (16.5 kg-m, 120 ft-Ibl Staked nut

13-1

REAR WHEEL/SUSPENSION

TOOLS

SpecialSnap ring pliersShock absorber compressor attachmentDriver shaftBearing remover set- Driver headSpherical bearing driverLock nut wrenchOil seal driver

CommonDriverAttachment, 24 x 26 mmAttachment, 32 x 35 mmAttachment, 42 x 47 mmAttachment, 52 x 55 mmAttachment, 62 x 68 mmPilot, 15 mmPilot, 17 mmPilot, 20 mmPilot, 22 mmPilot, 35 mmPilot, 40 mmDriver handle

TROUBLESHOOTI NGWobble or vibration in motorcycle• Bent rim

Loose wheel hub bearing(s)Damaged tireAxle not tightened properly

• Swingarm pivot bearing wornBent frame or swingarmDamaged drive pin and pin hole

Soft suspensionWeak springImproper shock absorber spring preloadLeaking damper

Hard suspensionImproper shock absorber spring preloadBent shock absorber rodSwingarm pivot bearings damagedBent frame or swingarm

Suspension noiseFaulty rear damper

• Loose fasteners

13-2

07914-323000-Equivalent commercially available in U.S.A.07967-KE1000007946-MJ0010007946 - MJOOOOO07946-MJ0020007946-KA30200 Not available in U.S.A.07908-ME9000007965-KE80100

07749-001000007746-001070007746-001010007746-001030007746-001040007746-001050007746-004030007746-004040007746-004050007746-004100007746 - 004080007746-004090007949-3710001

REAR WHEELREMOVAL

-'------------Do not service the rear wheel (removal/installation) while ex­haust system is hot.

CAUTION

Cover the left rim edge, spindle edge and brake caliper withtape to avoid damaging the wheel.

NOTE

The sprocket and driven flange dampers can be removedwithout removing the wheel (see page 13-6).

Place the motorcycle on its center stand.Remove the center cap and cotter pin. Loosen the wheel nut,but do not remove it.

Loosen the eccentric bearing carrier pinch bolt and turn thecarrier counterclockwise until it stops to obtain maximumchain slack.Remove the chain from the rear sprocket and place it on theoutside of the sprocket.Rotate the eccentric bearing carrier to its rearward most (maxi­mum chain slack) position.

Remove the wheel nut, shim and axle center collar.

Tap the axle with soft hammer and push the axle in until itclears the wheel.

Attach tape to the wheel rim, edge of the spindle and brakecaliper to avoid damaging the wheel.

Remove the wheel from the drive pins, then angle it to the rightand pull it backward to go between the brake disc and muffler.

CAUTION

Be careful not to damage the wheel rim and brake disc when re­moving the wheel.

Then, as the wheel reaches the hub, angle it to the left and pullit out backward as shown.

CAUTION

Be careful not to damage the wheel rim and brake caliper whenremoving the wheel.

REAR WHEel/SUSPENSION

(1) TAPE

13-3

REAR WHEEL/SUSPENSION

INSPECTION

Wheel rim runoutCheck the rim runout by placing the wheel in a truing stand.Spin the wheel slowly and read the runout using a dial indica­tor.

SERVICE LIMITS:RADIAL RUNOUT: 2.0 mm (0.08 in)AXIAL RUNOUT: 2.0 mm (0.08 in)

NOTE

The wheel cannot be repaired and must be replaced with anew one if the service limits are exceeded.

Wheel Balance

CAUTION

Wheel balance directly affects the stability, handling and over­all safety of the motorcycle. Always check balance when thetire has been removed from the rim.

NOTE

For optimum balance, the tire balance mark (a paint dot onthe side wall) must be located next to the valve stem.Remount the tire if necessary.

Remove the dust seal from the wheel.Mount the wheel and tire assembly in an inspection stand.Spin the wheel, allow it to stop, and mark the lowest(heaviest) part of the wheel with chalk.Do this two or three times to verify the heaviest area. If thewheel is balanced, it will not stop consistently in the same po­sition.

To balance the wheel, install wheel weights on the highestside of the rim, the side opposite the chalk marks. Add justenough weight so the wheel will no longer stop in the same po­sition when it's spun.Do not add more than 60 grams to the rear wheel.

Drive pin holeCheck the drive pin holes for the damage.

Inspection and replacement of the drive pin: turn to page13-11 .

13-4

~~(2) TIRE BALANCE MARK

(1) WHEEL WEIGHT

INSTALLATION

������L-- _

Do not service the rear wheel (removal/installation) while ex­haust system is hot.

CAUTION

Cover the left rim edge, spindle edge and brake caliper withtape to avoid damaging the wheel.Use care not to damage the wheel rim and brake disc when re­moving the wheel.

Install the rear wheel in the reverse order of removal.

Clean the wheel and spindle mating surface.Align the index marks and install the wheel hub over the drivepins.

Insert the axle in the wheel hub, making sure the splines arecorrectly aligned.

Tap the axle with soft hammer to seat the axle securely.

Turn the eccentric bearing carrier counterclockwise until itstops.Install the drive chain onto the rear sprocket.

Clean and apply clean grease to the axle threads.

CAUTION

• Make sure that the axle threads are applied clean grease toobtain the specified torque.

Install the axle center collar, shim and wheel nut.Tighten the wheel nut to the specified torque.

TORQUE: 120 N'm (12.0 kg-m, 87 ft-Ibl

Install a new cotter pin and cap securely.

Apply the rear brake several times and check for free wheel ro­tation when released.

Adjust the drive chain slack (page 3-12).

REAR WHEEL/SUSPENSION

(1) INDEX MARKS

3) DRIVECHAIN

,A'\~ i I fh-'l/lit 1/(1) AXLE CENTER COLLAR---- - \ ""

/,

13-5

REAR WHEEL/SUSPENSION

SPROCKETREMOVAL

Turn the eccentric bearing carrier to loose the drive chain, thenremove the chain from the sprocket.

Remove the sprocket mounting bolts and the sprocket.

INSTALLATION

Install the sprocket by using the bolts and nuts.

TORQUE: 43 N·m (4.3 kg-m, 31 ft-Ibl

Reinstall the drive chain and adjust the slack (page 3-12).

ECCENTRIC BEARING CARRIERREMOVAL

Remove the rear wheel (page 13-3).Loosen the eccentric bearing carrier pinch bolt and turn thecarrier to loosen the drive chain.

\\(1) REAR WHEEL '.

(1) SPROCKET

Tap the axle with a soft hammer until the splines clear thedriven flange cover.

Remove the axle to the left side.

13-6

Unstake the eccentric bearing carrier lock nut and remove thenut.Remove the lock washer and side collar.

Remove the brake caliper mounting bolts.Swing the brake caliper from the brake disc while holding itwith a piece of wire or something suitable.

Remove the spindle.Remove the final driven flange assembly and remove the drivechaine from the sprocket.

Remove the snap ring and brake disc guard plate.Remove the eccentric bearing carrier from the swingarm.

REAR WHEEl/SUSPENSION

(2) FINAL DRIVEN FLANGE'

p:::iBAKE DISC GUARD PLATE

\

13-7

REAR WHEEL/SUSPENSION

INSPECTION

BearingTurn the inner races of the ball bearings with your finger.The bearing should turn smoothly and quietly.

Also check that the bearing outer races fits tightly in theeccentric bearing carrier.Check the right bearing needle rollers for obvious signs ofwear.

Remove and discard the ball bearings if they do not turnsmoothly, quietly, or if they fit loosely in the eccentric bearingcarrier (page 13-9).

NOTE

• Replace the bearings in pairs.

Replace the needle bearing if it is damaged.

(5) ECCENTRIC BEARINGCARRIER

DamperSeparate the driven flange cover with the sprocket from theflange.

Check the driven flange damper for damage.Replace the dampers if necessary.

(2) FLANGE COVER

(1) FLANGE BEARING

(4) DAMPER

13-8

(1) BEARING

(3) DRIVEN FLANGE

REAR WHEEL/SUSPENSION

BEARING REPLACEMENTEccentric bearing carrierRemove the dust seals and bearing stop rings.

(1) DUST SEAL,

Press the ball bearings out of the carrier first with the specialtools.

TOOLS:DriverAttachment, 42 x 47 mmPilot 40 mm

07749-001000007746-001030007746-0040900

(2) ECCENTRIC BEARING CARRIER

....._--(1) DRIVER

Press the needle bearing out of the carrier with the specialtools.

TOOLS:DriverAttachment 52 x 55 mm

07749-001000007746-0010400

(2) ECCENTRICBEARINGCARRIER

NOTE

• Install the bearing with marks facing out.

Install the inner dust seal in the carrier.Carefully press the new needle bearing into the carrier firstwith the special tools.

(3)ECCENTRICBEARING CARRIER

(2) ATTACHMENT

07749-001000007746-0010500

TOOLS:DriverAttachement 62 x 68 mm

13-9

REAR WHEEL/SUSPENSION

Apply clean grease to the dust seal lip.Install the bearing stop ring and dust seal securely.

NOTE

• Install the bearing with sealed end facing out.

Carefully press the new ball bearings in with the special tools.

(3) ATTACHMENT/PILOT

(2) ECCENTRICBEARING CARRIER

07749-001000007746-0010500

TOOLS:DriverAttachment 62 x 68 mm

Apply clean grease to the dust seal lip.Install the bearing stop ring and dust seal securely.

, .

Driven flangeSeparate the cover and the flange.Remove the dampers and the a-ring. ()8i~3)DAMPER

~(4) O-RING

(2) FLANGE

13-10

Press the bearing and dust seal out of the cover with the spe­cial tools.

Carefully press the new bearing in with the special tools.

TOOLS:DriverAttachment 52 x 55 mmPilot 35 mm

TOOLS:DriverAttachment 62 x 68 mmPilot 35 mmOil seal driver

Install the dust seal securely.

07749-001000007746-001040007746-0040800

07749-001000007746-001050007746-004080007965-KE80100

REAR WHEEL/SUSPENSION

(1) DRIVER

SPINDLEINSPECTION

Check the following of the spindle:- splines for damage- drive pins for damage- lock nut threads for damage

If necessary, remove the brake disc retaining bolts and nutsand lock nut, and separate the brake disc from the spindle.

Apply a locking agent to the drive pin bolt threads and tightenthe drive pin bolts to the drive pin if replaced them.

TORQUE: 15 N'm (1.5 kg-m, 11 ft-Ibl

Install the brake disc to the spindle and tighten the disc retain­ing bolts and nuts.

TORQUE: 35 N'm 13.5 kg-m. 25 ft-Ib)

Install the disc retaining bolt lock nut onto the anywhere bolt.

TORQUE: 9 N'm (0.9 kg-m. 7 ft-Ib)

(1 ) RETAINING BOLTS

(4) LOCK NUT

(2) BRAKE DISC (3) SPINDLE (5) DRIVE PIN/BOLT

13-11

REAR WHEEl/SUSPENSION

ECCENTRIC BEARING CARRIERINSTALLATION

(12) DRIVEN FLANGE/SPROCKET

(11) ECCENTRICBEARING CARRIER ----:::::.::.....-.I!I

(10) ECCENTRIC BEARING CARRIERPINCH BOLT

(9) BRAKE DISC RETAININGBOLT

(8) BRAKE DISC

35 N'm (3.5 kg-m, 25 ft-Ibl

Install the eccentric bearing carrier onto the swingarm.Loosely install the eccentric bearing carrier pinch bolt.

Install the brake disc guard plate onto the eccentric bearingcarrier by using the snap ring.

13-12

(2) LOCK NUT(3) LOCK WASHER

(6) SNAP RING

27 N'm (2.7 kg-m. 20 ft-Ib)

(2) PINCH BOLT

(1) ECCENTRIC BEARING CARRIER

REAR WHEEL/SUSPENSION

(1) SPINDLE

(4) SPLINES

(2) ECCENTRIC BEARING CARRIER

(31 DRIVEN FLANGEISPROCKET

"Install the drive chain on the sprocket and position the flangeagainst the eccentric bearing carrier.Insert the spindle through the bearing carrier and driven flange.Engage the driven flange and the spindle, making sure thesplines are correctly mated.

CAUTION

• Use care not to damage the pads when installing the caliper.

Install over the brake caliper onto the brake disc.Install and tighten the mounting bolts.

TORQUE: 27 N'm (2.7 kg-m. 20 ft-Ibl

(1) CALIPER MOUNTING BOLT

~

Install the rear axle from the left side.

Install the side collar onto the driven flange.

Install the lock washer onto the spindle as shown. ..~"'NS'DE

Install the eccentric bearing carrier lock nut and stake it.

TORQUE: 165 N'm (16.5 kg-m. 120 ft-Ib)

13-13

REAR WHEEl/SUSPENSION

Install the rear wheel (page 13-51.Adjust the drive chain slack (page 3-12).

Tighten the eccentric bearing carrier pinch bolt.

TORQUE: 75 N·m (7.5 kg-m. 54 ft-Ibl

Operate the brake pedal to seat the caliper piston against thepads.

SHOCK ABSORBER������ _

The rear shock absorber contains nitrogen under high pressure.Do not allow fire or heat near the shock absorber.Before disposal of the shock absorber, release the nitrogen.

NOTE

• If you plan to disassemble the shock absorber. set thespring adjuster to the softest position at this time.

REMOVAL

Raise the rear wheel off the ground by placing the motorcycleon its center stand.

Remove the seat (page 13-25).Remove the shock absorber lower mounting bolt while sup­porting the wheel.

Remove the following:- sub-frame upper mounting bolts- shock absorber upper mounting bolt and nut- fuel filter base mounting bolt and nut- fuel filter base

Loosen the sub-frame lower mounting bolts and lower the sub­frame.

Pull the shock absorber out from the frame through the uppersub-frame pipes.

Remove the shock absorber lower mounting collar.

13-14

(2) LOWER MOUNTING COLLAR

(6) LOWER MOUNTING BOLTS

REAR WHEEL/SUSPENSION

DISASSEMBLY

Make sure the spring adjuster is set to the softest positionbefore disassembly.Set the shock absorber in the hydraulic press with the specialtool.

TOOL:Shock absorber compressor attachement 07967 - KE10000

Compress the spring until the stop ring can be removed, andremove the stop ring from the shock absorber.

(1) SHOCK ABSORBERCOMPRESSORATTACHMENT

(10) UPPER SPRING SEAT

jl LOWER JOINT

(3) SPRING GUIDE

(2) SPRING(1) LOWER SPRING SEAT

(11) STOP RING

(12) DAMPER-__~

Remove the following:- upper spring seat- spring- lower spring seat- spring adjuster- dust seal- lock nut and lower joint- stop rubber- seat

INSPECTION

Inspect the following parts:- damper unit for oil leaks- damper rod for bends or damage- stop rubber for wear or damageInspect all the other parts for wear or damage.

Measure the spring free length.

SERVICE LIMIT: 148.3 mm (5.84 in)

(1) SPRING

13-15

Install the following:- stop rubber onto the damper rod- spring guide- spring adjuster, set to the softest position- dust seal- lower spring seat- spring with the tapered end upward- upper spring seat

(1) SPRING

Install the shock' absorber drain tube on the seat.

Make sure the tab of the seat is aligned with the groove of thespring guide.

NOTE

• Make sure the spring adjuster is set to the softest position.

Set the shock absorber in the hydraulic press with the specialtool.

TOOL:Shock absorber compressor attachment 07967-KE10000

Compress the spring until the stop ring can be installed, and in­stall the stop ring.

REAR WHEEL/SUSPENSION

(2) SPRING GUIDE

~6' LOWER JOINT

(1) SEAT

(2) ALIGN

(1 )SHOCK ABSORBERCOMPRESSOR IATTACHEMENT

13-17

REAR WHEEL/SUSPENSION

LOWER MOUNTING BEARING REPLACEMENT

Remove the dust seals from the lower mount.Press the needle bearing out of the shock absorber with thespecial tool.

Apply clean grease to a new needle bearing and drive it intothe shock absorber until it is flush with lower mount surface.

Apply clean grease to the dust seal lips and install them ontothe lower mount.

TOOL:Spherical bearing driver

TOOLS:DriverAttachment 24 x 26 mmPilot 17 mm

07946 - KA30200Not available in U.S.A.

07749-001000007746-001070007746-0040400

(1) DRIVER

/

INSTALLATION

Install the lower mounting collar into the mount.Install the shock absorber in the frame with the drain tubefacing forward.Tighten the shock absorber upper mounting bolt.

TORQUE: 65 N'm (6.5 kg-m, 47 ft-Ibl

Install the fuel filter base and mounting bolt.

TORQUE: 22 N'm (2.2 kg-m. 16 ft-Ibl

Install the sub-frame upper mounting bolts.

TORQUE: 40 N·m (4.0 kg-m. 29 ft-Ibl

Tighten the sub-frame lower mounting bolts.

TORQUE: 40 N'm (4.0 kg-m, 29 ft-Ibl

13-18

(1) SHOCK ABSORBER

(2) LOWER MOUNTINGCOLLAR

(4) FUEL FILTERBASE MOUNTING BOLT

Route and clamp the shock absorber drain tube.Install the shock absorber lower mounting bolt.

TORQUE: 45 N·m {4.5 kg-m, 33 ft-Ibl

SWINGARMREMOVAL

Raise the rear wheel off the ground by placing the motorcycleon its center stand.Remove the rear wheel (page 13-3) and eccentric bearing car­rier (page 13-6).

Remove the shock absorber lower mounting bolt.

Remove the swingarm pivot nut.

Unhook the rear brake hose and remove the rear brake caliper(page 14-15).

REAR WHEEL/SUSPENSION

/;.

Loosen the lock nut and remove it.Do not pull the swingarm pivot bolt out at this time.

TOOL:lock nut wrench 07908 - ME90000

Using a hex wrench, turn the pivot bolt and adjusting boltcounterclockwise together.

13-19

REAR WHEEL/SUSPENSION

Pull the pivot bolt out the frame while supporting the swing­arm.Remove the swingarm from the frame.Remove the pivot collars and bushing.

DISASSEMBLY

Remove the following components:- drive chain slider- driven sprocket guard plate- brake disc guard plate- brake torque rod- shock absorber drain tube clamp- brake hose clamp

(6) BRAKE HOSE CLAMP

(2) DRIVEN SPROCKET (3) BRAKE DISCGUARD PLATE GUARD PLATE

PIVOT BEARING REPLACEMENT (1) SNAP RING,

Remove the dust seals from the swingarm.Remove the snap ring from the right side.

(2) SWINGARM

13-20

Press the right pivot bearings out of the swingarm using a hy­draulic press and the driver shaft.

Press the left pivot needle bearing out of the swingarm using ahydraulic press and the special tool.

Apply clean grease to the new pivot bearings.Press the right pivot bearing into the swingarm until it is flushwith the surface.

Apply clean grease to the pivot needle bearing.Press the left needle pivot bearing into the swingarm until it isflush with the surface.

TOOL:Driver shaftDriver handle

TOOL:Driver shaft set

TOOLS:DriverAttachment. 32 x 35 mmPilot. 15 mm

TOOLS:DriverAttachment. 32 x 35 mmPilot. 22 mm

07746-MJ00100 or07949-3710001

07746-MJOOOOO

07749-001000007746-001010007746-0040300

07749-001000007746-001010007746-0041000

I I

Ii

REAR WHEEL/SUSPENSION

(1) DRIVERSHAFT SET

(1) DRIVER

13-21

REAR WHEEl/SUSPENSION

Install the snap ring into the groove in the swingarm.Apply clean grease to the dust seal lips and install the dustseals in the swingarm pivots.

(2) SWINGARM

(1) SNAP RING

ASSEMBLY

(2) BRAKE HOSE CLAMP

(3) SHOCK ABSORBERDRAIN TUBE CLAMP

(1) DRIVE CHAIN SLIDER

TORQUE: 35 N'm 13.5 kg-m. 25 ft-Ibl

Install the brake torque rod with a new cotter pin.

Install the following components:- drive chain slider- driven sprocket guard plate- brake disc guard plate- shock absorber drain tube clamp- brake hose clamp

(6) DRIVEN SPROCKETGUARD PLATE

(5) BRAKE DISCGUARD PLATE

INSTALLATION

Install the pivot collars and bushing in the swingarm.

Loosely install the pivot adjusting bolt then install theswingarm to the frame.Insert the pivot bolt through the adjusting bolt fully.

13-22

Turn the pivot bolt and adjusting bolt together clockwise untilthey touch the left pivot collar.Tighten the adjusting bolt.

TORQUE: 15 N·m (1.5 kg-m, 11 ft-Ib)

REAR WHEEl/SUSPENSION

TORQUE:Actual: 65 N·m (6.5 kg-m, 47 ft-Ib)Indicated: 59 N·m (5.9 kg-m, 43 ft-Ib)

Loosely install the lock nut.Tighten the lock nut while holding the adjusting bolt and pivotbolt.

TOOL:Lock nut wrench 07908 - ME90000

Install the pivot nut and tighten to the specified torque.

TORQUE: 65 N·m (6.5 kg-m, 47 ft-Ib)

Install the following:- eccentric bearing carrier (page 13-12).- rear brake caliper (page 14-17).- shock absorber lower mounting bolt (page 13-19).- rear wheel (page 13-51.

, .

13-23

REAR WHEEL/SUSPENSION

MUFFLER/EXHAUST PIPEREMOVAL_L- _• Do not service the exhaust system while it is hot.

Remove the following:- four joint nuts- two mounting bolts- exhaust pipe and muffler as assembly.

Loosen the exhaust pipe band bolt and separate the mufflerand exhaust pipes.

INSTALLATION

Installation is the reverse order of removal.

Install the exhaust pipe and muffler as an assembly.

TORQUE:Exhaust pipe joint nut: 27 N'm (2.7 kg-m. 20 ft-IblMuffler mounting bolt: 27 N'm (2.7 kg-m. 20 ft-IblMuffler band bolt: 27 N·m (2.7 kg-m. 20 ft-Ibl

CAUTION

Be sure the new exhaust pipe gaskets are correctly seated on thepipe flange before installing the pipes.

13-24

(1 I EXHAUST PIPEGASKET

(2) EXHAUST PIPE JOINT NUTS

(3) EXHAUST PIPE

SEATREMOVAL/INSTALLATION

Insert the ignition key into the helmet holder and turn it cloc­kwise.

Pull the holder hook down to release the seat lock.

Remove the seat from the frame.

Installation is the reverse order of removal.

NOTE

• Apply clean grease to the seat lock striker and latch.

(2) HOLDER HOOK

REAR WHEEL/SUSPENSION

REAR COWLI NGREMOVAL/INSTALLATION

Remove the seat.Disconnect the tail/brake and turn signal light wire harnessesconnectors.Remove the four rear cowling mounting bolts and the cowling.

Installation is the reverse order of removal.

13-25

HYDRAULIC BRAKE

14-0

1.5 N·m (0.15 kg-m, 1.4 ft-Ibl

I12 N·m(1.2 kg-m,9 ft-Ib)

J

27 N·m (2.7 kg-m.20 ft-Ibl

14. HYDRAULIC BRAKESERVICE INFORMATION

TROUBLESHOOTING

BRAKE FLUID REPLACEMENT/BLEEDING

BRAKE PADS/DISCS

FRONT MASTER CYLINDER

SERVICE INFORMATIONGENERAL

14-1

14-2

14-3

14-5

14-8

FRONT BRAKE CALIPER

REAR BRAKE MASTER CYLINDER

REAR BRAKE CALIPER

BRAKE PEDAL

14-11

14-13

14-15

14-17

-'-----------------------A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a highquality brake degreasing agent.Use only DOT 4 brake fluid.The brake caliper and brake pads can be removed without disconnecting the hydraulic system.Once the hydraulic system has been disassembled, or if the brakes feel spongy, the system must be bled.Do not allow foreign material to enter the system when filling the reservoir.Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic and rubberparts by covering them with a shop towel. If fluid does get on these parts, wipe it off immediately with a clean cloth.Always check brake operation before riding the motorcycle.Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brakeassemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazardcaused by airborne asbestos fibers.

SPECIFICATIONSUnit: mm (in)

ITEM STANDARD SERVICE LIMIT

Brake disc Thickness 5.0 (0.19) 4.0 (0.16)

Warpage.

0.3 (0.01)--

Master cylinder I. D. Front 12.700-12.743 (0.5000-0.5016) 12.76 (0.502)

Rear 12.700-12.743 (0.5000-0.5016) 12.76 (0.502)

Master piston 0.0. Front 12.657-12.684 (0.4983-0.4993) 12.65 (0.498)

Rear 12.657-12.684 (0.4983-0.4993) 12.65 (0.498)

Caliper cylinder I. D. Front 30.230-30.280 (1.1902-1.1921) 30.29 (1.193)

Rear 38.180-38.230 (1.5031-1.5051) 38.24 (1.505)

Caliper piston 0.0. Front 30.148-30.198 (1.1870-1.1889) 30.14 (1.187)

Rear 38.115-38.148 (1.5005-1.5018) 38.11 (1.500)

Brake fluid DOT 4 only --

14-1

HYDRAULIC BRAKE

TORQUE VALUES

Front master cylinder holder boltRear master cylinder mounting boltBrake oil boltBrake reservoir screwCaliper bleed valveFront caliper mounting boltFront caliper pin boltRear caliper mounting boltRear caliper pivot boltRear caliper pad pinCaliper pad pin plugTorque rod boltFront disc retaining boltRear disc retaining boltRear disc retaining bolt lock nut

TOOL

SpecialSnap ring pliers

TROUBLESHOOTINGBrake lever/pedal soft or spongy

Air in hydraulic system• Low fluid level

Hydraulic system leaking

Brake lever/pedal too hardSticking piston(slClogged hydraulic systemPads glazed or worn excessively

Brake dragHydraulic system stickingSticking piston(s)Clogged hydraulic systemIncorrect pedal adjustmentCaliper slide pins sticking

• Disc or wheel misaligned

14-2

12 N'm (1.2 kg-m, 9 ft-Ibl12 N'm (1.2 kg-m, 9 ft-Ibl30 N'm (3.0 kg-m, 22 ft-Ibl1.5 N'm (0.15 kg-m, 1.4 ft-Ibl6 N'm (0.6 kg-m, 4.3 ft-Ibl27 N'm (2.7 kg-m, 20 ft-Ibl28 N'm (2.8 kg-m, 20 ft-Ib)27 N'm (2.7 kg-m, 20 ft-Ib)22 N'm (2.2 kg-m, 16 ft-Ib)17 N'm (1. 7 kg-m, 12 ft-Ib)2.5 N'm (0.25 kg-m, 1.8 ft-Ibl35 N'm (3.5 kg-m, 25 ft-Ibl40 N'm (4.0 kg-m, 29 ft-Ibl Apply a locking agent to the threads35 N'm (3.5 kg-m, 25 ft-Ibl9 N'm (0.9 kg-m, 7 ft-Ib)

07914-3230001

Brakes grabPads contaminated

• Disc or wheel misaligned

Brake chatter or squealPads contaminatedExcessive disc runoutCaliper installed incorrectly

BRAKE FLUID REPLACEMENT/AIR BLEEDINGCAUTION

Be careful not to allow dust or water to enter the brake systemwhen filling the reservoir.USE ONL Y DOT 4 BRAKE FLUIDDo not mix different types of fluid since they are notcompatible.A void spilling fluid on painted surfaces. Place a rag over thefuel tank whenever the system is serviced.

Check the fluid level with the reservoir parallel to the ground.Remove the reservoir cover, set plate and diaphragm.

BRAKE FLUID DRAINING

Connect a bleed hose to the bleed valve.

Loosen the caliper bleed valve and pump the brake lever. Stopoperating the lever when fluid stops flowing out of the bleedvalve.

, .

BRAKE FLUID FILLING

NOTE

Check the fluid level often while bleeding the brakes to pre­vent air from being pumped into the system.When using the Brake Bleeder, follow the manufacturer'sinstructions.Do not mix brake fluid types and never reuse the fluid whichhas been bled out of the system; it may impair the efficien­cy of the brake system.

Close the bleed valve, fill the reservoir with DOT 4 brake fluidto the upper level.Install the diaphragm and reservoir cover.

HYDRAULIC BRAKE

«1) FRONT>

14-3

HYDRAULIC BRAKE

Connect a Brake Bleeder or equivalent to the bleed valve.

Pump the brake bleeder and loosen the bleed valve. Add fluidwhen the fluid level in the master cylinder reservoir is low.Repeat above procedures until no air bubbles appear in theplastic hose.

NOTE

If air is entering the system from around the bleed valvethreads, seal the threads with teflon tape.

..•

(2) BLEED VALVE.\

I

If a brake bleeder is not available, fill the system as follows:

Pump up the system pressure with the lever or pedal untilthere are no air bubbles in the fluid flowing out of the reservoirhole and lever or pedal resistance is felt.

AIR BLEEDING

Bleed the system as follows:1) Connect a bleed hose to the bleed valve.2) Squeeze the brake lever lor depress the brake pedal), then

open Ithe bleed valve 1/4 turn and close the valve.

NOTE

Do not release the brake lever (or pedal) until the bleedvalve has been closed.

3) Release the brake lever (or pedal) slowly and wait severalseconds after it reaches the end of its travel.

Repeat steps 2 and 3 until bubbles cease to appear in the fluidat the end of the hose.Tighten the bleed valve.

TORQUE: 6 N'm (0.6 kg-m, 4.3 ft-Ibl

Close the bleed valve, fill the reservoir with DOT 4 brake fluidto the upper level.

Reinstall the diaphragm and reservoir cover.

-----------A contaminated brake disc or pad reduces stopping power. Dis­card contaminated pads and clean a contaminated disc with ahigh quality brake degreasing agent.

14-4

BRAKE PADS/DISCSFRONT BRAKE PAD REPLACEMENT-'------------Inhaled asbestos fibers have been found to cause respiratory

disease and cancer. Never use an air hose or dry brush to cleanbrake assemblies. Use an OSHA-approved vacuum cleaner oralternate method approved by OSHA designed to minimize thehazard caused by airborne asbestos fibers.

NOTE

Always replace the brake pads in pairs to assure even discpressure.

'88 Only:Remove the cotter pin.

'88 and After '88:Remove the pad pin plug and loosen the pad pin.

Push the pistons' all the way in to allow installation of newbrake pads.

NOTE

Check the brake fluid level in the reservoir as this operationcauses the level to rise.

Pull the pad pin out of the caliper and remove the brake pads.

Insert the new brake pads.Install the pad pin by pushing the pads against the caliper todepress the pad spring.

Tighten the pad pin.

TORQUE: 17 N'm /1.7 kg-m, 12 ft-Ibl

Install the pad pin plug.

TORQUE: 2.5 N'm (0.25 kg-m, 1.8 ft-Ibl

HYDRAULIC BRAKE

14-5

HYDRAULIC BRAKE

'88 Only:Install the new cotter pin onto the pad pin.

NOTE

Operate the brake lever to seat the caliper pistons againstthe pads.

REAR BRAKE PAD REPLACEMENT

NOTE

Always replace the brake pads in pairs to assure even discp·ressure.

Remove the pad pin plug.

Loosen the pad pin.

Remove the caliper pivot bolt.

Swing the brake caliper from the brake disc.Pull the pad pin out of the caliper.Remove the brake pads.

14-6

Position the pad spring in the caliper as shown.

Push the piston all the way in to allow installation of new brakepads.

NOTE

Check the brake fluid level in the reservoir as this operationcauses the level to rise.

Insert the new brake pads.Install the pad pin by pushing the pads against the caliper todepress the pad spring.

Install the caliper onto the brake disc so the disc is positionedbetween the pads. being careful not to damage the pads.

Install the caliper pivot bolt and tighten it., .

TORQUE: 22 N'm (2.2 kg-m. 16 ft-Ibl

Tighten the pad pin.

TORQUE: 17 N'm (1.7 kg-m. 12 ft-Ibl

Install the pad pin plug.

TORQUE: 2.5 N'm (0.25 kg-m. 1.8 ft-Ibl

Operate the brake pedal to seat the caliper piston against thepads.

HYDRAULIC BRAKE

14-7

HYDRAULIC BRAKE

DISC THICKNESS

Measure the thickness of each disc.

SERVICE LIMITS: Front: 4.0 mm (0.16 in)Rear: 4.0 mm (0.16 in)

Brake disc removal is refer to:Front: page 12-18.Rear: page 13-11.

BRAKE DISC WARPAGE

Measure the brake discs for warpage with a dial indicator asshown.

SERVICE LIMIT: Front/Rear: 0.30 mm (0.012 in)

FRONT MASTER CYLINDERREMOVAL

Drain brake fluid from the hydraulic system.Remove the rear view mirror from the master cylinder and dis­connect the brake light switch wires.Disconnect the brake hose by removing the oil bolt and sealingwashers.

CAUTION

A void spilling brake fluid on painted surfaces. Place a rag overthe fuel tank whenever the brake system is serviced.

NOTE

When removing the oil hose bolt, cover the end of the hoseto prevent contamination. Secure the hose to prevent fluidfrom leaking out.

Remove the master cylinder holder bolts and holder, thenremove the master cylinder from the handlebar.

DISASSEMBLY

Remove the brake lever and brake light switch.

14-8

(1) BRAKE LEVER

I

(2) BRAKE LIGHT SWITCH

Remove the boot.

Remove the piston and spring by removing the snap ring.

TOOL:Snap ring pliers 07914-3230001

or equivalent commerciallyavailable in U. S. A.

HYDRAULIC BRAKE

(1) SNAP RING

Clean the inside of the master cylinder, reservoir, spring andpiston with clean brake fluid.

INSPECTION

Measure the master cylinder I. D.

SERVICE LIMIT: 12.76 mm (0.502 in)

Check the master cylinder for scores, scratches or nicks.

Measure the master piston 0.0. at the location shown.

SERVICE LIMIT: 12.65 mm (0.498 in)

Check the primary and secondary cups for damage before as­sembly.

ASSEMBLY

CAUTION

• Handle the master cylinder piston, cylinder and spring as a set.

Coat all parts with clean brake fluid before assembly.Install the spring in the master .cylinder with its large diameterfacing inside.Install the piston.

CAUTION

When installing the piston, do not allow the cup lips to turninside out.

(4) SNAP RING

~(3)PISTON~

(2) SPRING

(1) MASTER CYLINDER--::!$~

(2) MASTER CYLINDER

/

A (4) SNAP RING

II f@/(3) PISTON~,

(2) SPRING

(1) MASTER CYLINDER

14-9

HYDRAULIC BRAKE

CAUTION

• Be certain that the snap ring is seated firmly in the groove.

Install the snap ring using a snap ring pliers.Install the boot.

(1) SNAP RING

07914-3230001or equivalent commerciallyavailable in U.S.A.

TOOL:Snap ring pliers

Install the brake lever and brake light switch. (1) BRAKE LEVER,

INSTALLATION

Set the master cylinder onto the handlebar with the holder"UP" mark facing up.Temporarily install the holder bolts. Align the slit of the mastercylinder with the punch mark on the handlebar.Tighten the upper bolt first. then the lower bolt.Connect the brake light switch wires to the switch terminals.Install the rear view mirror.Connect the brake hose with the oil bolt and two sealing wash­ers and tighten the oil bolt.

TORQUE: 30 N'm (3.0 kg-m. 22 ft-Ibl

Fill the reservoir with DOT 4 brake fluid to the casting ledgeand bleed the brake system (page 14-3).

Operate the brake lever to seat the caliper pistons against thepads.

14-10

FRONT BRAKE CALIPERREMOVAL

Place a clean container under the caliper and disconnect thebrake hose from the caliper by removing the oil bolt and sealingwashers.

CAUTION

• A void spilling brake fluid on painted surfaces.

Remove the brake pads (page 14-5l.Remove the caliper mounting bolts and caliper.

DISASSEMBLY

Remove the following:- pad spring and pin bolt boot from the caliper- pin bolt boot from the bracket

If necessary, apply compressed air to the caliper fluid inlet toget the pistons out. Place a shop rag under the caliper to cush­ion the pistons when they are expelled. Use the air in shortspurts.

-----------Do not use high pressure air or bring the nozzle too close to theinlet.

Push the dust seals and piston seals in, lift them out and dis­card them.

NOTE

• The seals must be replaced whenever they are removed.

Clean the seal grooves with clean brake fluid.

CAUTION

• Be careful not to damage the piston sliding surfaces.

INSPECTION

Check the pistons for scoring, scratches or other faults.Measure the piston 0.0.

SERVICE LIMIT: 30.14 mm (1.187 in)

Check the caliper cylinder for scoring, scratches or otherfaults.Measure the caliper cylinder 1.0.

SERVICE LIMIT: 30.29 mm (1.193 in)

HYDRAULIC BRAKE

14-11

HYDRAULIC BRAKE

ASSEMBLY

Coat new piston seals and dust seals with clean brake fluidand install them in the caliper.Install the pistons with the dished ends toward the pads.

Install the pad spring on the caliper as shown.Apply silicone grease to the inside of the boot, and install it.

Install the pads and pad pins in the caliper.

Install the caliper assembly over the brake disc so that the discis positioned between the pads.

CAUTION

• Be careful nol 1o damage rhe pads.

Install and tighten the caliper mounting bolts.

TORQUE: 27 N·m (2.7 kg-m, 20 ft-Ibl

Tighten the pad pins and install and tighten the pad pin plug(page 14-5).

Connect the brake hose to the caliper with the oil bolt and twonew sealing washers.

TORQUE: 30 N'm (3.0 kg-m, 22 ft-Ibl

Bleed the air from the brake system (page 14-3),

14-12

(2) DUST SEALS

HYDRAULIC BRAKE

REAR BRAKE MASTER CYLINDERREMOVAL

Drain the rear brake hydraulic system (page 14-3).Remove the brake oil bolt and disconnect the brake hose.Remove the following:- right foot peg bracket bolts- muffler mounting bolt and nut- right foot peg bracket

Remove the connector screw and disconnect the reservoirhose from the master cylinder.

\(2) MASTER CYLINDER

Remove the cotter pin and joint pin, and disconnect the brakeactuating arm from the master cylinder push rod.Remove the rear master cylinder from the foot peg bracket.

DISASSEMBLY

CAUTION

Remove the rubber boot.

• The push rod will pop out when the snap ring is removed.

07914-3230001Equivalent commerciallyavailable in U.S.A.

Remove the snap ring and push rod from the master cylinderbody.

TOOL:Snap ring pliers

14-13

HYDRAULIC BRAKE

Remove the master piston and spring.

It may be necessary to apply a small amount of air pressure tothe fluid outlet to remove the master piston and spring.

(1) MASTER CYLINDER

(3) PISTON

INSPECTION

Check the inside of the master cylinder for scores, scratchesor nicks.

Measure the inside diameter of the master cylinder bore.

SERVICE LIMIT: 12.76 mm (0.502 in)

Check the piston and piston cups for damage. wear or deterio­ration.

Measure the master piston 0.0.

(2) MASTER CYLINDER

i

SERVICE LIMIT: 12.65 mm (0.498 in)

ASSEMBLY

Clean the master cylinder with compressed air.

Dip the piston cups in clean brake fluid before assembly.

Install the spring and master piston together.

NOTE

The master cylinder piston, cups and spring must be in­stalled as a set.

CAUTION

(2) SNAP RING

When installing the cups, do not allow the lips to turn insideout and be certain the snap ring is seated firmly in the groove.

Install the push 'rod into the master cylinder.Install the washer. snap ring and rubber boot.

Adjust the push rod standard length so that the distance fromthe center of the master cylinder lower mount hole to thecenter of the joint pin hole is 80 mm (3.15 in).Tighten the lock nut. (3) JOINT PIN

~f04--- (1) PUSH ROD

l.J......!~-- (2) LOCK NUT

80 mm(3.15 in)

07914-3230001TOOL:Snap ring pliers

14-14

Connect the rear brake actuating arm to the master cylinderpush rod with the joint pin, and secure the joint pin with thewasher and new cotter pin.

Hook the rear brake pedal return spring and brake light switchspring to the actuating arm.Install the brake light switch, switch stay and rear brakemaster cylinder. Tighten the master cylinder mounting boltssecurely.

Connect the reservoir hose to the master cylinder with thenew O-ring and screw.

Install the right foot peg bracket. Tighten the mounting bolts.

TORQUE: 22 N'm (2.2 kg-m, 16 ft-Ibl

Install the muffler mounting bolt and nut.

TORQUE: 27 N'm (2.7 kg-m, 20 ft-Ibl

Connect the rear brake hose with the oil bolt and two newsealing washers.

TORQUE: 30 N'm (3.0 kg-m, 22 ft-Ibl

Fill and bleed the rear brake system (page 14-3).Check the brake light switch operation.

Operate the brake pedal to seat the caliper piston against thepads.

REAR BRAKE CALIPERREMOVAL

Drain the brake fluid from the hydraulic system.

Disconnect the brake hose from the caliper.

Remove the brake pads (page 14-6).Remove the caliper mounting bolts and torque link bolt.Remove the brake caliper.

HYDRAULIC BRAKE

(5) MOUNTING BOLi-s::'"

"

~(1) PUSH ROD

14-15

HYDRAULIC BRAKE

DISASSEMBLY

Remove the pad spring, boots and collar from the rear brakecaliper.

Place a shop towel over the piston, position the caliper withthe piston down and apply small squirts of air pressure to thefluid inlet to remove the piston.

------------Do not use high pressure air or bring the nozzle too close to theinlet.

Push the dust and piston seals in and lift them out.

Wash the caliper cylinder, seal gooves and caliper piston withclean brake fluid.

CAUTION

• Be careful not to damage the piston sliding surface.

INSPECTION

Check the caliper piston for scratches, scoring or other dam­age.

Measure the caliper cylinder I.D.

SERVICE LIMIT: 38.24 mm (1.505 in)

Measure the caliper piston a.D.

SERVICE lIMIT:.38.11 mm (1.500 in)

14-16

HYDRAULIC BRAKE

/(3) COLLAR

,

?3USTSEAl

(4) PISTON /'SEAL (6) PISTON

TORQUE: 35 N'm (3.5 kg-m, 25 ft-Ib)

Assemble the bracket and caliper.Install the pads (page 14-6).Install the caliper onto the brake disc so the disc is positionedbetween the pads, being careful not to damage the pads.

Install the torque link bolt and tighten it.

Apply silicone grease to the collar and the insides of the bootsand install them into the caliper.Make sure that the boot is seated in the collar and calipergrooves properly.Install the pad spring.

ASSEMBLY

Check the boot and replace it if it is hardened or deteriorated.

Coat the piston and dust seals with clean brake fluid and installthem with the small diameter facing in.Lubricate the caliper cylinder and piston with clean brake fluidand install the piston into the caliper cylinder with the pistondished end facing toward the pads.

The piston and dust seals must be replaced whenever they areremoved.

Install the brake hose with the oil bolt and the new sealingwashers. Tighten the oil bolt.

TORQUE: 30 N'm 13.0 kg-m, 22 ft-Ib)

Install the caliper mounting bolts and tighten them.

TORQUE: 27 N'm 12.7 kg-m, 20 ft-Ibl

Install the caliper pivot bolt and tighten it.

TORQUE: 22 N'm 12.2 kg-m, 16 ft-Ibl

Operate the brake pedal to seat the caliper piston against thepads.

BRAKE PEDALREMOVAL/INSTALLATION

Remove the right foot peg bracket bolts and the mufflermounting bolt and nut.

14-17

HYDRAULIC BRAKE

Remove the cotter pin and joint pin, and disconnect the brakeactuating arm from the master cylinder push rod.

Remove the following:- brake pedal return spring- brake light switch spring- snap ring- brake pedal

Apply clean grease to the brake pedal pivot and install thepedal into the bracket with the snap ring.

Installation is the reverse order of removal.

Install the right foot peg bracket. Tighten the mounting bolts.

TORQUE: 22 N'm (2.2 kg-m. 16 ft-Ibl

Install the muffler mounting bolt and nut.

TORQUE: 27 N'm (2.7 kg-m. 20 ft-Ibl

14-18

BATTERY/CHARGING SYSTEM

(1) IGNITION SWITCH

(4) MAIN FUSE

(6) R: Red(7) W: White(8) G: Green(9) Y: Yellow

L- y__......

ilnl1l1'l1f'..:.1-----y---.....1

----y---_......(5) ALTERNATOR

15-0

G G

11-= ~

(1) IGNITION SWITCH

•.&... (2)

~ BATTERYj 12VBAh

15. BATTERY/CHARGING SYSTEMSERVICE INFORMATION

TROUBLESHOOTING

BATTERY

SERVICE INFORMATIONGENERAL

• Battery charging

NOTE

15-1

15-3

15-4

CHARGING SYSTEM

REGULATOR/RECTIFIER

ALTERNATOR

15-7

15-8

15-10

Refer to the instructions in the Operation Manual for the Honda Battery Tester and Christie Battery Charger for detailedbattery charging steps.

After activation, the maintenance-free battery must be charged at the appropriate ampere-hour rating for the proper length oftime.Set the Battery Amp. Hr. Selector Switch on the Christie Charger (#MC 1012/2) for the size of the battery being charged. Setthe Timer to the NEW BATT position and connect the battery clamps. When the timer reaches the "trickle" position, thecharging cycle is complete.After charging, test the condition of the new battery using the Honda Battery Tester (#BM-21 0) m refer to the OperationManual for complete details.

Battery charging/Testing equipmentThe Christie Battery Charger (#MC1 012/2) is a constant current (amperage) type designed to produce current at a constantrate for the duration of the charge, even if the voltage varies.The Honda Battery Tester (#BM-21 0) puts a "load" on the battery so that the actual battery condition at the time of the loadcan be measured.This provides an accurate determination of the battery condition --- good (green). fair (yellow). or poor (red).

• Quick charge a battery only in an emergency. Slow-charging is preferred.• Remove the battery from the motorcycle when charging. If the battery must be charged on the motorcycle, disconnect the

battery cables. IIrI;l• When inspecting the charging system, check the system components and lines step-by-step according to the trouble~

shooting on page 1 5-3.• The battery on this motorcycle is a sealed type. Do not try to remove the filler hole caps even during charging. Do not use a

non-sealed battery as a replacement.

-------------------------The battery generates hydorogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery,expecially while charging it.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.The exhaust contains posisonous carbon monoxide gas that may cause loss of consciousness and, lead to death.

15-1

BATTERY/CHARGING SYSTEM

SPECIFICATIONS

ITEM STANDARD

Battery Capacity 12V-8Ah

Voltage at 20°C (68°F) Fully cahrged 13.0-13.2 V

Needs charging 12.3 V

Leakage ampere at 20°C (68°F) 0.1 A max.

Charging current 0.9 amperes

Charging time 5 Hr

Regulator/rectifier Type Three-phase/full-wave

Regulated voltage/Amperage 13.5-15.5 V/0.5 A (3,000 rpm)

Alternator Charging coil resistance at 20°C (68°F) 0.1-1.0 nOutput 0.24 kw/5,OOO rpm

Charging start rpm 1,200 ± 100 rpm

TOOLS

MULT1TESTER:07411-0020000KS-AHM-32-00307308-0020001TH-5H

(KOWA Digital type)(KOWA Digital type; U.S.A. only)(SANWA Analogue type)(KOWA Analogue type)

Christie battery charger #MC 101 2/2Honda battery tester 07GMJ-0010000

15-2

BATTERY/CHARGING SYSTEM

TROUBLESHOOTI NG

y y

I Measure the battery leakage (page 15-7). I ABNORMALI Check the regulator/rectifier resistances be

tween each regulator/rectifier terminals (page15-9)

NORMALNORMAL . Short circuit in wire

harnessABNORMAL ~. Faulty ignition

l-. switch

I Check for an overcharged battery (page 15-7). IABNORMAL

Faulty regulator/

NOT OVE~CHARGED Irectifier

REGULATED . Fault batter

Measure the voltage between the R/W (+) and Gwith terminals (-) of the regulator/rectifier 4PBlack connector. (wire harness side) (page 15-8)

NO VOLTAGEOpen or short circuit in wire harnessLoose connector

BATTERY VOLTAGE COMES

+

STANDARDLoose 3P connectorI

ABNORMALl- ---l~. Faulty stator coil

Disconnect the 3P connector of the regulator/rectifier, check the alternator stator coilresitances (page 15-10)

Check the regulator/rectifier resistances be­tween each regulator/rectifier terminal (page15-9)

ABNORMAL

..Faulty regulator/rectifier

NORMAL

,-I------------------i..~. Faulty battery

15-3

BATTERY/CHARGING SYSTEM

BATTERY___________________ '88 Shown:

The battery gives off explosive gases; keep sparks. flames andcigarettes away. Provide adequate ventilation when charging.

• The battery contains sulfuric acid (electrolyte). Contact withskin or eyes may cause severe burns. Wear protective clothingand a face shield.- If electrolyte gets on your skin, flush with water.- If electrolyte gets in your eyes, flush with water for at least

15 minutes and call a physician.Electrolyte is poisonous.- If swallowed, drink large quantities of water or milk and

follow with milk of magnessia or vegetable oil and call aphysician.

REMOVAL

Remove the seat and turn OFF the ignition switch.Remove the battery case cover bolts and cover.Disconnect the negative (-) terminal cable first, thenpositive (+) terminal cable at the battery.Pull the battery out of the battery holder.

INSTALLATION

Install the battery in the reverse order of the removal.After installing the battery, coat the terminals withclean grease.

(1) COVER BOLTS

(4) POSITIVE TERMINAL

(5) BATTERY

VOLTAGE INSPECTION

VOLTAGE: Fully charged: 13.0-13.2 VUnder charged: Below 12.3 V

TESTING WITH HONDA BATTERY TESTER

NOTE

Remove the seat.Remove the battery case cover.Measure the battery voltage.

07411-0020000 (KOWAlKS-AHM-32-003(U.S.A. only)TH-5H (KOWAl07308-0020001 (SANWAI

Circuit tester

TOOLS:Digital multimeter

Refer to the Service Letter #48 and the Operation Manualfor the Honda Battery Tester and the Christie battery Charg­er for battery Testing Procedure.Use the Honda battery Tester (BM-21 0) to test the battery.

Remove the battery.Securely connect the tester's positive (+) cable first, then con­nect the negative (-) cable.

NOTE

For accurate test results, be sure the tester's cables andclamps are in good working condition and that a secureconnection can be made at the battery.

(1) HONDA BATTERY TESTER

15-4

Set the temperature switch to "HIGH" or "LOW" dependingon the ambient temperature.

HIGH: 15°C (GOOF) or higherLOW: 15°C (GOOF) or lower

Push in the "5.5 Ah-9 Ah" test button for threee seconds andread the condition of the battery on the meter.

NOTE

• Be sure to push the correct test button.For the first check. DO NOT charge the battery before test­ing.

CAUTION

• Tester damage can result from overheating when:- the test button is pushed in for more than three seconds.- testing more than one battery and the tester is not allowed to

cool for at least one minute between tests.- more than tests are performed consecutively without allow­

ing at least a 30-minute cool-down period.

The battery is OK if the meter reading registers in the GREENzone.

If the metter reading registers in the YELLOW or RED zone,charge the battery, and re-test and judge it in accordance withthe chart below.

First check:Green : OKYellow, Red: Charge

Second check:First check Yellow:Green : OKYellow : ReplaceFirst check Red:Green : OKYellow : RechargeRed: Replace

Third check:Green : OKYellow Replace

CHARGING

NOTE

Refer to the instructions in the Operation Manual for theHonda Battery Tester and Christy Battery Charger for de­tails on battery charging steps.

Remove the battery.Connect the charger positive (+) cable to the battery positive(+) terminal.Connect the charger negative (-) cable to the battery negative(-) terminal.

BATTERY/CHARGING SYSTEM

HIGHQ@@@@@@@O

LOW

7EST BUTTONS

1/""~·OOOOO@@~'-' '--'

YELLOW(-1)

--- Standard Quick

Charging current 0.9 A 4.0 A

Charging time 5 hours 1 hour

Specified voltage 12 V min.

15-5

(1) CHRISTIE BATTERYCHARGER

BATIERY/CHARGING SYSTEM

-'-------------• Keep flames and sparks away from a charging battery.Turn power ON/OFF at the charger, not at the battery termi­nals.

CAUTION

Quick-charging should only be done in an emergency; slowcharging is preferred.For battery charging, do not exceed the charging current andtime specified on the battery. Using excessive current or extend­ing the charging time may damage the battery.

CHARGING WITH CHRISTIE BATTERY CHARGER

NOTE

Use the CHRISTIE Battery Charger (MC 1012/2) to chargethe battery.

Before operating the charger:Be sure the area around the charger is well ventilated andclear of flammable materials, heat, humidity, water anddust.Clean the battery terminals and position the battery as faraway from the charger as the leads will permit. Do not placethe battery below the charger gases from the battery maycorrode and damage the charger.Do not place the battery on top of the charger. Be sure theair vents are not blocked.

-'-------------During operation, the charger will grenerate heat. To avoidcausing a fire, always clear the work area offlammable materi­als such as gasoline, brake fluid, electrolyte, or cloth towels.

Turn the Power Switch to the OFF position.

Set the Battery Amp. Hr. Selector Switch to the "5.5 to 9.0"position.

Set the Timer to the position indicated by the Honda BatteryTester: RED -3. RED -2. or YELLOW -1. If you are charging anew battery, set the switch to the NEW BATT position.

(1) BATTERY

®®. ~

DOD®®

!1!l •

Attach the clamps to the battery terminals; RED to Positive.BLACK to Negative.

CAUTION

• Connect the battery cables only when the Power Switch is OFF.

Turn the Power Switch to the ON position.

When the timer reaches the "Trickle" position, the chargingcycle is complete. Turn the Power Switch OFF and disconnectthe clamps.

15-6

NEWBATT

YELLOW --II-I.."'}-1

r-I---..., RED

NOTE

The charger will automatically switch to the Trickle modeafter the set charging time has elapsed.

Re-test the battery using the Honda Battery Tester and re­charge if necessary using the previous steps.

NOTE

For accurate test results, let the battery cool for at least tenminutes or until gassing subsides after charging.

Install the battery (page 15-4).

CHARGING SYSTEMNOTE

• When inspecting the charging system, check the systemcomponents and lines step-by-step according to thetroubleshooting on page 15-3.

• With large capacity circuits that exceed the ratings of thefuse contained in the tester, measuring errors can causedamage to testing equipment.Before starting each test, set the tester at the high capacityrange first, then adjust it to the small capacity circuits rangein order that you have the correct range.

LEAKAGE INSPECTION

BATTERY/CHARGING SYSTEM

CAUTION

When measuring small capacity circuits, keep the ignitionswitch off. If the switch is suddenly turned on during a test, thetester fuse may blow. , •

Check the battery ampere leakage before making the regulatedampere inspection.Turn the ignition switch off and disconnect the battery nega­tive cable from the battery.Connect the tester between the negative cable and the nega­tive battery terminal.

The tester should indicate within 0.1 A with the ignitionswitch OFF.

(1) BATTERYNEGATIVE TERMINAL

,(2) BATTERY

NEGATIVECABLE

LEAKAGE AMPERE: 0.1 A max (20 oC/6BoFI

REGULATED VOLTAGE/AMPERE INSPECTION

Warm up the engine to normal operating temperature.Stop the engine, and connect the voltmeter as shown.

-~---------• If the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss of consciousness and lead to death.

15-7

BATTERY/CHARGING SYSTEM

Remove the seat and rear cowling (page 13-25l.Disconnect the main fuse connector and remove the mainfuse.Reconnect the connector securely.

Connect the tester as shown.

CAUTION

Be careful not to let the battery positive cable contact the framewhile testing.

Restart the engine and allow it to idle, then increase the enginespeed gradually.The voltage and amperage should be controlled as specifiedbelow:

STANDARD: 13.5-15.5 V/0.5 A (3,000 rpm) (20 0 C/68°Fl (3) STARTERRELAY

ES:JA

REGULATOR/RECTI FI ERSYSTEM INSPECTION

Remove the seat and rear cowling.Disconnect the 3P (WHITE) and 4P (BLACK) regulatorlrectifierconnectors.

Check the connectors for loose or corroded terminals.

If the regulated voltage reading was out of specification,check the circuits between the connector terminals (wire har­ness side and alternator side) following the chart on next page.

NOTE

The regulator/rectifier is semiconductorized unit; the speci­fied tester. If a different tester is used the test results willbe out of specification.You'll get a false reading if your finger touches the testerprobes.If the pointer of the tester fails to swing to zero when theadjusting knob is turned fully clockwise or counter­clockwise, replace the tester dry battery.

15-8

Tester:07411-0020000KS-AHM-32-00307308-0020001TH-5H

(KOWA Digital type)(KOWA Digital type; U.S.A. only)(SANWA Analogue type)(KOWA Analogue type)

BATTERY/CHARGING SYSTEM

Tester Range

SANWA kO

KOWA RX100

ITEM TERMINALS STANDARDS

Battery charging line Red/White (+) and Green (-) Battery voltage should come

Alternator coil line Yellow and Yellow 0.1-1.00 (20°C/68°F)

Check the resistances between the leads with an ohmmeter. Ifthe resistance is out of the specifications, make a UNIT IN­SPECTION indicated below.

UNIT INSPECTIONUnit: k{l

Provided the circuit on the wire harness side are normal andthere are no loose connections at the connector, inspect theregulator/rectifier unit by measuring the resistance betweenthe termi.nals.

NOTE

You'll get false readings if the probes touch your fingers.Use the specified multitesters. Using other equipment maynot allow you to obtain the correct results.This is due to the characteristic of semiconductors, whichhave different resistance values depending on the appliedvoltage.

SPECIFIC MULTITESTER:- 07411-0020000 (KOWA Digital type)- KS-AHM-32-003 (KOWA Digital type; U.S.A. only)- 07308-0020001 (SANWA Analogue type)- TH-5H (KOWA Analogue type)

Select the following range:SANWA: kOKOWA: X100

• An old battery stored in the multitester could cause inaccu­rate readings. Check the battery if the multitester resis­tance incorrectly.

• When using the KOWA multitester, remember that all read­ings should be multiplied by 100.

Replace the regulator/rectifier unit if the resistance value be­tween the terminals is abnormal.

I'" EB Probe Red/ Yellow Yellow YellowGreen

8 Probe '"White 1 2 3

Red/White

---------20-100 20-100 20-100 10-50

Yellow 1 0.5-10 ~ 30-500 30-500 20-200

Yellow 2 0.5-10 30-500~ 30-500 20-200

Yellow 3 0.5-10 30-500 30-500~ 20-200

Green 1-20 0.5-10 0.5-10 0.5-10

---------Manufacture Range

SANWA kO

KOWA RX100

15-9

BATTERY/CHARGING SYSTEM

ALTERNATORINSPECTION

NOTE

It is not necessary to remove the stator coil to make thistest.

Remove the seat and rear cowling (page 13-25).

Disconnect the alternator 3P (WHITE) connector.

Measure the resistance between the yellow wire terminals andcheck for no continuity between each terminal and ground.

STANDARD: 0.1-1.0 n (20°C/68°F)

Replace the stator if the resistance is out of specification or ifthere is continuity between any yellow wire terminal andground.

15-10

(1) ALTERNATOR3P (WHITE) CONNECTOR

IGNITION SYSTEM

(1) ENGINE STOP SWITCH

(2) FRONTIGNITIONCOIL

(9) SPARK -#-....,.::;.~~~~...PLUGS

(8) PULSEGENERATORS

(6) MAINFUSE

\

\ \

-= (5) BATTERY

I1

(7) SPARK UNIT

+--+....-BIIW--...

tt it ~8JAR-=- -:::- - - IGNITION

COIL

(9)FRONTIGNITIONCOIL

ITo fuel pump relay][To tachometer]

(1) ENGINESTOP (2) (3) IGNITION (4)SWITCH FUSE 10 A SWITCH MAIN FUSE 30 A

~I---~~(10) W: White(11) G: Green(12) Y: Yellow(13) Bu: Blue(14) BI: Black

16-0

16. IGNITION SYSTEMSERVICE INFORMATION

TROUBLESHOOTING

IGNITION SYSTEM INSPECTION

16-1

16-2

16-3

IGNITION COIL

PULSE GENERATOR

IGNITION TIMING

16-3

16-4

16-4

SERVICE INFORMATIOND����L-- _

If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in on enclosed area.The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

GENERAL

• Ignition timing cannot be adjusted since the spark unit is non-adjustable. If ignition timing is incorrect, check the systemcomponents and replace any faulty parts.

• For spark plug gap inspection and adjustment procedure, see page 3-6.• For alternator removal and installation, see section 8.• For pulse generator removal and installation, see section 7.• When inspecting the ignition system, check the system components and lines step-by-step according to the troubleshoot­

ing on next page.• Each pair of spark plugs (Front and Rear) has its own ignition circuit.• To test the neutral switch, refer to section 18.

SPECIFICATIONS

Spark plug

Spark plug/ For cold climate NGK DPR7EA-9Saprk plug gap (Below 5°C, 41°F) ND X22EPR-U9

Standard NGK DPR8EA-9 0.8-0.9 mm

ND X24EPR-U9 (0.031-0.035 in)

For extended high KiGK DPR9EA-9speed riding ND X27EPR-U9

Ignition system

ITEM STANDARDS

Ignition timing Initial (F mark) 10° BTDC/idle

Ignition coil Primary circuit 2.2-2.6 f!resistance Secondary circuit With plug wire 30-36 kf!(20°C/68°F)

Without plug wire 20-25 kf!

Pulse generator coil resistance (20°C/68°F) 450-550 f!

Firing order Front- (232 0) - Rear- (488 0) - Front

TOOLS

Tester07411 -0020000KS-AHM-32-00307308-0020001TH-5H

(KOWA Digital type)(KOWA Digital type; U.S.A. only)(SANWA Analogue type)(KOWA Analogue type)

16-1

IGNITION SYSTEM

TROUBLESHOOTI NGB���� _

When performing a spark test, keep open flames or sparks away from the work area.

No spark at one spark plugFaulty spark plug

• Faulty spark plug wire

No spark at all plugs

• Faulty pulse gener­ator

• Open or short Circuitin wire harness

• Loose connectors

1. Check the spark unit connectors for loose ABNORMAL• Loose connectors.

contact.

NORMALFaulty• Fuel pump relay (page 18-7)

2. Measure voltage between the Bl (+) and G - • Fuel pump (page 18-8)(-)/between the BuIY (+) and G (-)/between • Open circuit in wire harnessY (+) and G (-) of the spark unit 6P connec- ABNORMAL

NORMAL· (page 20-1)tor. Battery voltage should appear with theignition switch ON and engine stop switch at FaultyRUN. - • Neutral switch (page 18-8)

• Short circuit in wire harness

NORMAL

3-1, Check the pulse generator resistances at ABNORMALI 3-2. Check the pulse generator (page 16-4).

the spark'unit 4P connector (page 16-4).

NORMAL l. !ABNORMAL

No spark at either spark group (Front or Rear)-(CHECK WRONG SPARK GROUP)

1

1. Check the ignition secondary coil resistance 'f-r-_A_B_N_O_R_M_A_L__ .• Faulty ignition coil(page 16-3). I • Faulty spark plug wire

NORMAL

ABNORMAL

• Faulty ignition coil• Open circuit in wire

harness

• Loose connectors• Open or short circuit

in wire harness

NORMAL

1

2-1. Check the ignition primary coil resistance 1f-_Ac..:.::B-'-N:..c0:..cR...:.M...:...cAc..:L=---_at the spark unit 6P connector (page 16-3), I '-----,---"-------'-'----''---r-------'

ABNORMAL

• Faulty pulse gener­ator

• Open or short circuitin wire harness

• Loose connectors.

NORMAL

1

3-1. Check the pulse generator resistances at II-_A_B_N_O_R_M_A_L__the spark unit 4P connector (page 16-4) . I L----.------'--..::-----'-r--=--------'

1

4. Exchange the ignition coil and try the spark I,--_G=..O.::...::O..:D-=.J..:U_M_P__,- • Faulty ignition coil

test. I

16-2

IGNITION SYSTEM INSPECTIONRemove the seat and rear cowling (page 13-25).

NOTE

Check the system components and lines step-by-step ac­cording to the troubleshooting chart on page 16-2.

Disconnect the spark unit connectors and check them forloose or corroded terminals.

Measure the data between connector terminals using the fol­lowing chart.

<6P CONNECTOR>

IGNITION SYSTEM

ITEM TERMINALS STANDARD (20°C/68°F)

Ignition primary coil Y and BI/W (Rear) Bu/Y and BI/W (Front) 2.2-2.6 fl

DC power supply circuit line BI (+) and G H, Bu/Y (+) and G H, Y (+) and G Battery voltage should come.(-) with the ignition switch "ON" and engine stopswitch "RUN"

<4P CONNECTOR>

ITEM TERMINALS STANDARD (20°C/68°F)

Pulse generator coil W/Y and Y (Front) W/Bu and Bu (Rear) 450-550 fl

Each terminal and body ground NO CONTINUITY

IGNITION COILINSPECTION

Remove the seat and fuel tank (page 13-25).Measure the primary coil resistance of the front and rear igni­tion coils.

NOTE

• The rear ignition coil is behind the swingarm pivot nut.

PRIMARY COIL RESISTANCE:STANDARD: 2.2-2.6 fl (20°C/68°F)

Disconnect the spark plug caps from the plugs and measurethe secondary coil resistance with the spark plug caps in place.

STANDARD: 30-36 kfl (20°C/68°F)

If the resistance is out of range, remove the spark plug capsand measure the resistance between the secondary coil termi­nals.

STANDARD: 20-25 kfl (20°C/68°F)

(1) FRONT IGNITION COIL

16-3

IGNITION SYSTEM

PULSE GENERATORINSPECTION

NOTE

It is not necessary to remove the pulse generator to makethis inspection.

Remove the seat and rear cowling (page 13-24).Disconnect the pulse generator 4P connector (WHITE).Measure the resistances between the white/yellow and yellowwires (front pulse generator) and white/blue and blue wires(rear pulse generator)

STANDARD: 450-550 n (20°C/68°F)

For pulse generator replacement, refer to section 8.

IGNITION TIMINGNOTE

The spark unit system is factory pre-set and cannot be ad­justed. Ignition timing inspection procedures are given to in­spect the function of the spark unit components.Connect the timing light to the other spark plug wire if yousee that the ignition timing is incorrect, and you might beable to see the timing is correct.

Warm up the engine to operating temperature.

-'-----------If the engine must be running to do some work, make sure thearea is well-ventilated. Never run the engine in an. enclosedarea.The exhaust contains poisonous carbon monoxide gas that maycause loss of consciousness and lead to death.

Remove the timing inspection hole cap on the left crankcasecover.

Connect the timing light to the front spark plug wire.

The timing is correct if the "F" mark aligns with the indexmark on the right crankcase cover at idle for each cylinder.

Raise the engine rpm and the "F" mark should begin to rotatecounterclockwise for each cylinder.

If the ignition timing is incorrect, make a ignition system in­spection (page 16-3) and replace any faulty parts.

16-4

(2) INDEXMARK

(1) "F" MARK

ELECTRIC STARTER

(7) CLUTCHSWITCH

(1) STARTERSWITCH

(4) STARTERRELAY SWITCH

(3) CLUTCHDIODE

(1) STARTER RELAY SWITCH

(2) STARTERMOTOR

(6) STARTER SWITCH(7) SUB FUSE15 A

=- (3)G~D'~~/~~EUTRALTCH

L..--------G/R--- (5) ~LUTCH SWITCH IG G

'*" +Y/R,-------J

(9)R/W-+ TO REGULATOR/RECTIFIER

R~I------C1'"'-O~---O"'1:(8) IGNITION SWITCH

(10) MAIN FUSE30 A

17-0

17. ELECTRIC STARTERSERVICE INFORMATION

TROUBLESHOOTING

STARTER MOTOR

SERVICE INFORMATIONGENERAL

17-1

17-1

17-3

STARTER RELAY SWITCH

CLUTCH DIODE

17-6

17-7

• The starter motor and pulse generator can be removed with the engine in the frame.• To inspect the pulse generator, refer to Section 16.• Refer to section 8 for starter clutch removal and installation.

SPECIFICATIONUnit: mm (in)

ITEM STANDARD SERVICE LIMIT

Starter motor brush length 12.5 (0.49) 6.5 (0.26)

TROUBLESHOOTI NGNOTE

The starter motor should turn when the transmission is in neutral and the clutch is disengaged.Check for the following before troubleshooting the system.- Blown main (30A) or sub (1 OAl fuse.- Loose battery and starter motor cables.- Discharged battery.

Starter motor does not turn

1-1 . Check the starter relay switch operation. "CLICK"

You should hear the relay "CLICK" when I'lEARD I 1-2. Apply battery voltage to the starter motor Ithe starter switch button is depressed. I directly and check the operation.(page 17-6)

TURNS ! .!DOES NOT TURN

• Loose cables . Faulty starter motor"CLICK" NOT HEARD · Faulty starter relay (page 17-3)

switch (page 17-6)

ABNORMAL2. Check the neutral indicator function. · Faulty neutral switch (page 18-1)

· Loose neutral switch connectorsNORMAL · Faulty ignition switch (page 18-4)

3. Check the starter relay switch voltage NO VOLTAGE · Loose clutch diode connector(page 17-6) · Faulty starter relay switch (page 17-6)

BATTERY · Faulty clutch diode (page 17-7)

VOLTAGE COMES · Open or short circuit in wire harness

4. Check the starter relay switch for continuity ABNORMAL · Faulty starter relay switch(page 17-7)

NORMAL · Loose starter relay switch connector

17-1

ELECTRIC STARTER

Starter motor turns engine slowlyLow specific gravityExcessive resistance in circuitBinding in starter motor

Starter motor turns, but engine does not turnFaulty starter clutch

• Faulty starter motor gears

Starter motor and engine turns, but engine does not startFaulty ignition systemEngine problems- Low compression- Fouled spark plugs

17-2

STARTER MOTORREMOVAL

B���� _With the ignition switch OFF, remove the negative cable at thebattery before servicing the starter motor.

Remove the rubber cap and disconnect the starter motorcable.Remove the motor mounting bolts.Remove the motor from the left side.

DISASSEMBLY

Remove the following components:- motor case screws.- front and rear covers.- armature.

NOTE

• Record the location and number of shims.

ELECTRIC STARTER

(2) CASE

INSPECTION

Measure each brush length.

SERVICE LIMIT: 6.5 mm (0.26 in)

Check for continuity from the cable terminal to the motor caseand from the cable terminal to the brush wire (black).

CABLE TERMINAL-MOTOR CASENO CONTINUITY: NORMAL

CABLE TERMINAL-BRUSH (BLACK WIRE)CONTINUITY: NORMAL

Disassemble the brush holder if necessary.

(1) CONTINUITY

17-3

ELECTRIC STARTER

Inspect the commutator bars for discoloration.Bars discolored in pairs indicate grounded armature coils.

Check for continuity between pairs of commutator bars.

There should be continuity.

Check for continuity between individual commutator bars andthe armature shaft.

There should be no continuity.

Check the front cover oil seal for wear or fatigue.

17-4

(1) COMMUTATOR

(1) OIL SEAL

ELECTRIC STARTER

ASSEMBLY

(2) CASE

<.

(4) SHIMS(7) a-RING

(1) FRONT COVER

(5) BRUSH HOLDER

(4) SHIMS

~?~(4) SHIMS

(10) CABLE TERMINAL AND BRUSHES

(9) REAR COVER

Set the brushes on the brush holder.Align the starter motor case notch with the brush holder tab.

Install the armature in the case.Set the brush springs.

Install the rear shims in the same location and number asbefore disassembly.Install the a-ring on the case.Install the rear cover, aligning its slot with the brush holder pin.

17-5

ELECTRIC STARTER

Install the front shims in the same location and number asbefore disassembly.

Install the a-ring on the case.Install the lock washer, aligning its tabs with the slots of thefront cover.Apply grease to the dust seal and install the front cover.

Align index marks of the front cover, case and rear cover asshown.

Install and tighten the starter motor case screws and apply oilto the a-ring and install it on the front cover.

INSTALLATION

(5) LOCK WASHER

(1) ALIGN

(2) a-RING

Install the starter motor in the engine.Install and tighten the motor mounting bolts securely.

NOTE

• Install the ground cable with one mounting bolt as shown.

Connect the motor cable to the motor terminal and install therubber cap over the terminal.

Connect the battery negative cable.

STARTER RELAY SWITCHOPERATION INSPECTION

Depress the starter switch button with the ignition switch ON.The coil is normal if the starter relay switch clicks.

VOLTAGE INSPECTION

If you don't hear the switch "CLlCK", disconnect the switchconnector.Shift the transmission into neutral and turn the ignition switchON.Measure the voltage between the Yellow/Red (+) and Green/Red (-) wires of the relay connector as you press the starter.The tester should show battery voltage. If it does not, makethe following continuity inspection.

17-6

CONTINUITY INSPECTION

Remove the starter relay switch.Connect an ohmmeter to the switch large terminals.

Connect a fully charged 12 V battery positive wire to the start­er relay switch Yellow/Red wire terminal, and the battery neg­ative wire to the Green/Red wire terminal.

There should be continuity while the battery is connected tothe terminals, and no continuity when the battery is discon­nected.

CLUTCH DIODEREMOVAL

Remove the rear cowling (page 13-25).Remove the clutch diode from the wire harness.

INSPECTION

Check for continuity with an ohmmeter.

Connect the positive probe to the (+) terminal and the negativeprobe to the (-) terminal of the diode.

There should be continuity, then reverse the probes, thereshould be no continuity.

NOTE

The test results shown above are for a positive ground ohm­meter and the opposite results will be obtained when a neg­ative ground ohmmeter is used.

ELECTRIC STARTER

(1 )

STARTERRELAY SWITCH

(1) CLUTCH DIODE

17-7

18. LIGHTS/METERS/SWITCHESSERVICE INFORMATION

TROUBLESHOOTING

SWITCHES LOCATION

HEADLIGHT

IGNITION SWITCH/METER

HANDLEBAR SWITCHES

THERMOSTATIC SWITCH

18-1

18-2

18-2

18-3

18-4

18-6

18-7

TEMPERATURE SENSOR

TEMPERATURE GAUGEFUEL PUMP RELAYFUEL PUMP

OIL PRESSURE SWITCH

NEUTRAL SWITCH

TURN SIGNAL RELAY

18-7

18-8

18-8

18-9

18-9

18-9

18-10

SERVICE INFORMATION������ _

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.The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.Do not smoke or allow flames or sparks in the work area or where gasoline is stored.

GENERAL

• Some wires have different colored bands around them near the connector. These are connected to other wires which cor­respond to the band color.

• All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned whenreconnecting.

• To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usuallybe made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester orvolt-ohmmeter to the terminals or connections.

• A continuity tester is useful when checking to find out whether or not there is an electrical connection between the twopoints. An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance in­volved, or when checking for high resistance caused by corroded connections.

SPECIFICATIONS

Headlight 12 V 60 W/55 W

Brake/taillight 12 V 32/3 cp (27/8 W) x 2

Turn signal lights Front 12 V 32/3 cp (23/8 W) x 2

Rear 12 V 32 cp (23 W)

License light 12 V 4 cp

Indicator lights Turn signal 12 V 3 W

Neutral 12 V 3 W

High beem 12 V 3 W

Meter light 12 V 3.4 W x 1. 1.7 W x 2

Main fuse 30 A

Sub-fuse10 A x 6. 15A x 1 (brake/turn/horn)

(fan, ignition, headlight, oil/neutral, brake/turn/horn, parking)

Fuel pump flow capacity/min 600 cc (0.630 US qt, 0.528 Imp qt)

TORQUE VALUES

Radiator thermostatic switchOil pressure switchIgnition switch mounting bolt

18 N·m (1.8 kg-m, 13 ft-Ibl - Apply sealant to the threads12 N·m (1.2 kg-m, 9 ft-Ibl - Apply sealant to the threads25 N·m (2.5 kg-m, 18 ft-Ibl

18-1

LIGHTS/METERS/SWITCHES

TOOL

CommonTorx bit

TROUBLESHOOTI NG

07703-0010100 -Equivalent commercially available in U.S.A.

No Lights Come On When Ignition Switch Is Turned ON:Bulb at fault or burned outFaulty switchWiring to that component has open circuitFuse blownWiring loose, broken. or at faultBattery dead or disconnected

SWITCHES LOCATION

All Lights Come On. but Dimly, when Ignition Switch IsTurned ON:• Battery voltage low• Faulty bulb

Headlight Beam Does Not Shift When HI-LO Switch Is Op­erated:

Faulty dimmer switch• Wiring loose, broken, or at fault

(1) METERS (2) IGNITION SWITCH,

(8) OIL PRESSURE SWITCH

HEADLIGHTREMOVAL/INSTALLATION

Remove the two screws and headlight.

Disconnect the headlight connector and remove the rubberprotector.

LIGHTS/METERS/SWITCHES

(1) HEADLIGHT CONNECTOR

~"~\.

Remove the headlight retainer clip and replace the headlightbulb.

CAUTION

This motorcycle is equipped with a halogen headlight bulb.Do not put finger prints on the headlight bulb, they may createhot spots on the hulb.Ifyou touch the bulb with your bare hands, clean it with a clothmoistened with alcohol to prevent its early failure.Do not try to replace the bulb or clean the headlight with thelight ON.After replacing the bulb, instal/the rubber boot tightly againstthe unit.

(1) RETAINE

NOTE

• Install the rubber protector with the top mark facing up.

Install the headlight in the reverse order of removal.

(1) "TOP" MARK

~"L------'-\.

/

\p(2) RUBBER PROTECTOR

18-3

LIGHTS/METERS/SWITCHES

IGNITION SWITCH/METERIGNITION SWITCH INSPECTION

Check for continuity between the ignition switch connectorterminals in each switch position.

Continuity should exsist between the color coded wires asshown in the chart below.

BAT IG FAN TLl TL2 P

ON ~ ~ ~ ~ ~~ ~ ~ ~ ~

OFF

P

COLOR R RIBI BulO Br/W Br Y/BI

REMOVAL

Disconnect the speedometer cable from the meter cover.Remove the headlight.Disconnect the meter harness connectors and ignition switchconnectors in the headlight case.

Remove the mounting bolts and meters.

(3) SPEEDO­METERHARNESS

(2) 6P BLACK::;J\CONNECTOR

(1) SPEEDOMETERCABLE

'S8 Only:Remove the mounting bolts and ignition switch.

After'S8:Remove the (torx) mounting bolts using the special tool andthe ignition switch.

TOOL:Torx bit

18-4

07703-0010100or equivalent commerciallyavailable in U.S.A.

After'SS: a._-;;;;;;:-(1) TORX BOLTS

LIGHTS/METERS/SWITCHES

METER BULB REPLACEMENT

Remove the meter cover mounting screws and cover.Replace the burned bulb(s) as required. I

(1) ATTACHINGSCREW

(6) TRIP-METER'

KNOB ~

'\•

(2) SPEEDOMETER

'0. ~ ~ []

_ • ~ 0

0-0'~~

\ e.(5) COVER

~(4) MOUNTING

SCREWSAssemble the removed parts in the reverse order of disassem­bly.

INSTALLATION

'88 only:Install the meters and ignition switch in the reverse order of re­moval.

After '88:Install the meters in the reverse order of removal.

Install the ignition switch and tighten the torx bolts using thespecial tool.

TORQUE: Ignition switch mounting bolt25 N'm (2.5 kg-m, 18 ft-lbJ

After '88:

(2) IGNITIONSWITCH

07703-0010100or equivalent commerciallyavailable in U.S.A.

TOOL:Torx bit

18-5

LIGHTS/METERS/SWITCHES

HANDLEBAR SWITCHESThe handlebar switches (dimmer, turn signals, horn, starter,engine stop, etc.) must be replaced as assemblies.Remove the headlight.

LEFT HANDLEBAR SWITCH

Disconnect the left handlebar switch connector (9P Whitel­And check for continuity between the terminals.Continuity should exsit between the color coded wires in eachchart.

Dimmer Switch

----- HL2 Hi Lo

Lo ~ ~~ ~

(N) ~ ~ ~~ ~ ~

Hi

Color code Bu/W Bu W

Turn Signal Switch

-------. W R L TL2 PR PL

RIGHT ~ ~ ~~ ~

N

LEFT (). .()

Color code Gr Lb 0 Br/B Lb/W O/W

Horn Button

(1) LEFT HANDLEBARSWITCH

(1) RIGHT HANDLEBARSWITCH

I

-------. HOl H02

Released

Depressed ~ ~

Color code WIG Lg

, .

RIGHT HANDLEBAR SWITCH

Disconnect the right handlebar switch connector (9P Red) andcheck for continuity between the terminals.Continuity should exist between the color coded wires as indi­cated in each chart.

Starter Switch

----- IGl ST HL HLl

Released ~ ~~ ~

Pushed ~ ~~ ~

Color code BI VIR BI/R Bu/W

Engine Stop Switch

-------. IG, IG2

RUN ~~ ~

OFF

Color code BI BI/W

18-6

THERMOSTATIC SWITCHThe cooling fan motor is actuated by the thermostatic switchlocated in the bottom of the radiator.

If the fan motor does not start, disconnect the Black/Blue leadfrom the thermostatic switch and ground it with a jumper wireas shown.Turn the ignition switch ON. The cooling fan motor shouldstart running. If it does not start, check for battery voltagefrom the Black/Blue lead of the fan motor connector andground with ignition switch ON.If there is no voltage, check for a blown fuse, loose terminalsor connectors, or an open circuit.If there is voltage, inspect the thermostatic switch as follows:Remove the switch.Connect one lead of an ohmmeter to the connector of thethermostatic switch and the other to the body.

Suspend the thermostatic switch in a pan of coolant (50-50mixture) and check the temperatures at which the switchopens and closes.Make sure that there is no continuity at room temperature andthen gradually raise the coolant temperature. Theswitch should show continuity (close) at 93° -97°C (199°­207°F).NOTE

Keep the temperature constant for 3 minutes to confirmcontinuity.A sudden change of temperature will cause error tempera­ture reading between the thermometer and switch.Do not let the switch or thermometer touch the pan as it willgive a false reading.Immerse the switch in coolant up to its threads.

Install a new a-ring on the switch.Apply sealant to the switch threads and install it.Tighten the switch to the specified torque.

TORQUE: 18 N·m (1.8 kg-m, 13 ft-Ibl

NOTE

• Do not over tighten the switch.

TEMPERATURE SENSORRemove the seat and fuel tank.Disconnect the Green/Blue wire from the temperature sensor.Check for continuity between the sensor body and ground.There should be continuity.If there is no continuity, check the thermostat housing forlooseness and recheck. If there is still no continuity, remove.The temperature sensor from the thermostat housing.

LIGHTS/METERS/SWITCHES

18-7

LIGHTS/METERS/SWITCHES

Suspend the temperature sensor in a pan of coolant over aheater and measure the resistance through the sensor as thecoolant heats up.

Temperature50°C 100°C

(122°F) (212°F)

Resistance 130-180 {} 25-30 {}

-'--------------Wear gloves and eye protection.

NOTE

(1 ) TEMPERATURE SENSOR

(2) THERMOMETER

Coolant must be used as the heated liquid to check thefunction above 100°C (212°F).You will get false readings if either the sensor orthermometer touches the pan.

Replace the sensor if it is out of specification by more than10% at either temperature.

TEMPERATURE GAUGEDisconnect the wire from the temperature sensor and short itto ground.

Turn the ignition switch ON. The temperature gauge needleshould move all the way to (H).

CAUTION

Do not leave the temperature sensor wire grounded for longerthan a Jew seconds or the temperature gauge will be damaged.

FUEL PUMP RELAY

-'------------• Gasoline is extremely flammable and is explosive under certainconditions. Work in a well ventilated area. Do not smoke orallow flames or sparks in the your work area or where gasolineis stored.

(1) JUMPER WIRE

Inspect as follows:Disconnect the connector and test the wires on the main har­ness side.

Remove the seat.Check the sub-fuse (10 A).Remove the relay from the rubber bracket and check the relayconnector terminals for looseness and corrosion.

ITEM

Between BI (+) and body ground (-)with the ignition switch "ON"

Y/Bu wire between the pumprelay and spark unit

BI/Bu wire between the pumprelay' and fuel pump

18-8

STANDARD

Battery voltageshould come.

CONTINUITY

CONTINUITY

(1) FUEL PUMP RELAY

FUEL PUMPSYSTEM INSPECTION

Turn the ignition switch OFF. Remove the seat and disconnectthe fuel pump relay wire connectors. Short the black andblack/blue wire teminals with a jumper wire.Disconnect the fuel tube from the T-joint near the carburetorand hold a graduated beaker under the fuel tube.

-'-------------Gasoline is extremely flammable and is explosive under certainconditions. Work in a well ventilated area with the enginestopped. Do not smoke or allow flames or sparks in the workarea or where gasoline is stored.

Turn the ignition switch ON and let fuel flow into the beakerfor 5 seconds, then turn the ignition switch OFF.Multiply the amount in the beaker by 12 to determine the fuelpump flow capacity per minute.

FUEL PUMP FLOW CAPACITY:600 cc (0.630 US qt 0.528 Imp qt)/minute at 10 V

OIL PRESSURE SWITCHMake sure that the oil pressure warning light comes on withthe ignition switch "ON".If the light does not come on, inspect as follows:Remove the drive sprocket cover.Disconnect the oil pressure switch wire from the switch by re­moving the terminal screw. Short it to ground using a jumperwire.Turn the ignition switch "ON".

The oil pressure warning light should come on.If the light does not come on, check the bulb, sub-fuse (10 A)and wires for a loose connection or an open circuit.Start the engine and make sure that the light goes out. If thelight does not go out, check the oil pressure (page 2-41-If the oil pressure is normal, replace the oil pressure switch.(page 2-4)

NEUTRAL SWITCHINSPECTION

Remove the drive sprocket cover and disconnect the con­nector.Check the neutral switch for continuity between the lightgreen/red connector and body ground.There should be continuity between the light green/red con­nector and body ground.There should be continuity with the transmission in neutral andno continuity with the transmission in any gear.If there is no continuity in neutral, remove the drive sprocketcover (page 8-2) and check the wire connection for an opencircuit.

LIGHTS/METERS/SWITCHES

18-9

LIGHTS/METERS/SWITCHES

TURN SIGNAL RELAYRemove the seat and rear cowling (page 13-25).Remove the turn signal relay from the rubber bracket.

Check the turn signal circuit for proper connections beforemaking this test.

Connect each terminal as indicated below:White/Green: D.C. 12 V Positive (+)Green: D.C. 12 V Negative (-)Gray: Turn signal wire of one side; connect the

other side to ground (frame).

Check the left and right turn signal operation.

If the turn signal relay fails this test, replace it.

18-10

19. WIRING DIAGRAM

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lUTllUA1'\Jilt>SIGIW. 'l~nwl

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UIlt.UI!lAME lhI'I $MTCH

-=-

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GENfAATOR

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nlQ'lI.R("A llfV.o:t TURN SoGNAI,:t.OllOl

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CD=L--"IU.,F1lOHJ~SKAo.:.lll'1ll.O(ll,l·l

ItGofI F1lOHJ fUl'IflSlGlw. 1!"'k~l1l.

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- - II' II' II.. ..~~~~~.~~:.2 5~ ~

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.~~L~;l~~L ~'" ." ..

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tACHOMfTEFI

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­.............uon ..........

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..... .' .....mi:::K10f0IC

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r---------------------S~'Qol C(JI(TMITY

I)~S.lIO<

20. TROUBLESHOOTINGENGINE DOES NOT START

ENGINE IS HARD TO START ORSOON STOPS

ENGINE LACKS POWER WITHNORMAL LOADING

ENGINE DOES NOT START

20-1

20-2

20-3

POOR ENGINE PERFORMANCE ATLOW AND IDLE SPEEDS

POOR ENGINE PERFORMANCE ATHIGH SPEEDS

POSSIBLE CAUSE

20-5

20-6

WEAK OR NO SPARK------....,....,· .-Refer to page 16-2

WET PLUG ----------_"'. Mixture too richCarburetor floodedChoke valve stuck openCylinder floodedDirty air cleaner

ENGINE STARTS._--------....• Faulty choke systemFuel contaminatedCarburetor incorrectly adjustedIntake pipe leakingClogged carburetor passage or jets

1. Drain float chamber and check flow NOT REACHING CARBURETOR---....-· Clogged fuel line or fuel filter/to carburetor. strainer

I Clogged fuel tank breather holeREACHING CARBURETOR Loose or disconnected fuel pump

and relay wireFaulty fuel pump relayFaulty fuel pumpSticking float valveFaulty floatClogged carburetor body

2. Check spark plug

INO PROBLEM

I3. Perform the spark test

IGOOD SPARK

~4. Pour 1-2 cc (0.03-0.06 US OZ,

0.04-0.07 Imp OZ) fuel intocylinders through the spark plughole, reinstall spark plugs and tryto start engine without chokeapplied, with full-throttle.

IENGINE DOES NOT START

•5. Test cylinder compression using LOW COMPRESSION----------l..~· Valve stuck opencompression gauge Damaged cylinder head gasket

I Improper valve timing ~COMPRESSION NORMAL Improper valve and seat contact ~

I

Worn cylinder and piston ringsDamaged piston

----------------------------"'. Improper ignition timing(Faulty pulse rotor or generator withferrous burrs)

20-1

TROUBLESHOOTING

ENGINE IS HARD TO START OR SOON STOPSPOSSIBLE CAUSE

1. Drain and check fuel flow to carbure­tor

IREACHING CARBURETOR

2. Try to start with choke ON

IDOES NOT START

3. cJeck spark plug

INO PROBLEM

NOT REACHING CARBURETOR------t...• Clogged fuel line or fuel filter/strainer

• Clogged fuel tank breather hole• Loose or disconnected fuel pump

and relay wireFaulty fuel pump relayFaulty fuel pumpFaulty floatClogged carburetor body

ENGINE STARTS-----------i...• Clogged carburetor jets

WET PLUG-----------...-· Dirty air cleanerLoose spark plugMixture too richCarburetor floodedChoke valve stuck openDirty air cleaner elementCylinder floodedImproper spark plug

WEAK OR NO SPARK-------.· Refer to page 16-2(ONE CYLINDER)

LOW COMPRESSION---------i...• Improper valve and seat contactDamaged cylinder head gasketValve stuck openWorn cylinder and piston rings

4. Spark test both cylinders

INO PROBLEM

5. J, "Ii"d" <omp,,,,;o" ,,;",compression gauge

INO PROBLEM

6. cJeck valve train NO GOOD-------------.· Valve clearance too smallI • Improper valve timing

COMPRESSION NORMAL Worn camshaftI Loose valve adjuster and lock nut

------------------------------.. Improper ignition timing(Faulty pulse rotor or generator withferrous burrs)

• Clogged carburetor passage or jets

20-2

TROUBLESHOOTING

ENGINE LACKS POWER WITH NORMAL LOADING.NOTE

Check the engine oil level and condition. Be sure the oil is not contaminated by coolant or metal burrs.Start the engine and warm it up to operating temperature, then check to see if the temperature gauge indicates the normalrange. If the gauge reading is abnormal, refer to sections 5, 18.Check for engine mechanical noise: Cam chain and cam chain tensioner; improper valve clearance; worn camshaft androcker arm sliding surfaces; broken piston rings, worn piston pin and connecting rod small end.Check that the wheels spin freely, check for brake drag, faulty wheel bearings, incorrect drive chain slack, bent fork, bentframe. Refer to sections 12, 13, 14.

POSSIBLE CAUSE

1. Check exhaust smoke at half-throttle

INO PROBLEM

2. c1, '0' '"'9'09 '""09 ",,1"'00I

NO PROBLEM

3. chLk spark plug condition

INORMAL

4. Check the specified fuel flowcapacity

INO PLOBLEM

5. Telt cylinder compression usingcompression gauge

ICOMPRESSION NORMAL

[cJntinued on following page)

BLUE--------------<...• Engine oil leaking; refer to sections(OIL IN FUEL) 9, 10

GRAY-------------....• Rich mixture(EXCESSIVE CARBON) Worn piston rings

Incorrect ignition timing

SURGING------------.. Incorrect adjusted pilot screws• Incorrect synchronization

Intake pipe leakingClogged crankcase breather

WET PLUG-----------..... Loose connection between sparkplug caps and wireDirty air cleaner elementImproper float levelRich mixture

DISCOLOURED---------....• Improper heat range(Light gray, White) Lean mixture

Improper float levelLeaking intake pipe

UNDER THE SPECIFIED------••• Dirty fuel filterClogged fuel linesFaulty fuel pump

LOW COMPRESSION---------..,.... Valve stuck open• Damaged cylinder head gasket

Improper valve and seat contact

20-3

TROUBLESHOOTING

POSSIBLE CAUSE

BETTER------------......• Clogged air passagesClogged jets

VALVE SURGING--------_.. • Improper valve clearance (too small)Weak valve spring

ABNORMAL----------_..• Improper ignition timing(Faulty pulse rotor or generator withferrous burrs)

[Continued)

6 ChI

k. .. .. . ..

. ec Ignition timing uSing timinglight

7. ChJk valve train

INO PROBLEM

8. Cle:n the carburetors: air passages

and ~ets

DOES NOT IMPROVE1-1----------------------------_... Seized cylinder and piston

Seized connecting rod bearingDamaged main bearing

20-4

TROUBLESHOOTING

POOR ENGINE PERFOMANCE AT SLOW AND IDLE SPEEDSNOTE

Check the engine oil level and condition. Be sure the oil is not contaminated by coolant or metal burrs.Start the engine and warm it up to operating temperature, then check to see if the temperature gauge indicates the normalrange. If the gauge reading is abnormal, refer to sections 5, 18.Check the idle speed: specified 1,200 ± 100 rpm.

POSSIBLE CAUSE

NO GOOD------------<.-· Incorrect synchronization

WEAK OR NO SPARK------••• Refer to page 16-2

BETTER-------------<.~. Clogged air passagesClogged jets

ABNORMAL-----------.. Improper ignition timing(Faulty spark unit, pulse rotor, orgenerator)

INCORRECT-----------.· Improper valve clearance (too small)• Faulty cam chain tensioner and cam

chain guideWorn cam chain

LOW COMPRESSION-------....~·· Improper valve and seat contactValve stuck open

• Improper valve timing• Damaged cylinder head gasket• Worn cylinder and piston rings

BETTER CONDITION--------.· Intake pipe leaking• Improper carburetor adjustment

Clogged carburetor slow jetImproper float level

'BETTER CONDITION--------<.~· Dirty air cleaner elementImproper carburetor adjustmentClogged carburetor air passagesImproper float level

1. Check engine condition with chokeapplied

IDO NOT IMPROVE

2. chick engine condition without aircleaner element

IDO NOT IMPROVE

3. chIck spark plugs on both cylinders

INO PROBLEM

4. chIck carburetor synchronization

INO PROBLEM

5 T ~ I' ... est cy Inder compression uSingcompression gauge

ICOMPRESSION NORMAL

6 Ch!k'" .. . ... ec Ignition timing uSing timinglight with "F" mark.

INORMAL

7. chick valve train

INO PROBLEM

~ .8. Clean the carburetors: air passages

and jets

IDOES NOT IMPROVE

....1-------------------------------<.~. Seized cylinder and pistonSeized connecting rod bearingDamaged main bearing

20-5

TROUBLESHOOTING

POOR ENGINE PERFOMANCE AT HIGH SPEEDSNOTE

Check the engine oil level and condition. Be sure the oil is not contaminated by coolant or metal burrs.Start the engine and warm it up to operating temperature, then check to see if the temperature gauge indicates the normalrange. If the gauge reading is abnormal, refer to sections 5, 18.Check the idle speed: specified 1,200 ± 100 rpm.Check that the wheels spin freely: Also, see sections 12, 13, 14.

POSSIBLE CAUSE

1. Check spark plug condition

INORMAL

2. Check exhaust smoke at half-throttle

INO PROBLEM

3. ChL '"0'"' ,,,,.,m,",, wtthchoke applied

IDOES NOT IMPROVE

C!. .4. heck engine performance without

air cleaner element

IDOES NOT IMPROVE

5. Tes\ the specified fuel flow

INO PROBLEM

6 T tl' ... est cy Inder compression uSingcompression gauge

ICOMPRESSION NORMAL

7 Ch!k' .. .. . ... ec Ignition timing uSing timinglight with full-advanced

INORMAL

Icottinued on following page)

20-6

WET PLUG-----------...... Rich mixtureDirty air cleaner elementImproper heat range

DISCOLOURED----------.. • Improper heat range(Light gray, White) Lean mixture

Improper float levelIntake pipe leaking

BLUE-------------......~. Engine oil leaking; refer to sections9, 10

GRAY-------------..... • Rich mixture• Worn piston rings

BETTER CONDITION-------......~. Lean mixtureIntake pipe leakingImproper carburetor adjustmentClogged jetsImproper float level

BETTER CONDITION-------...,...... • Dirty air cleaner elementRich mixtureClogged carburetor air passagesImproper float level

UNDER THE SPECIFIED------.. • Dirty fuel filterClogged fuel linesFaulty fuel pump or pump relay

LOW COMPRESSION--------1...~. Improper valve and seat contactValve stuck openDamaged cylinder head gasketWorn cylinder and piston rings

ABNORMAL----------_.. • Improper ignition timing(Faulty pulse rotor or generator withferrous burrs)

POSSIBLE CAUSE

TROUBLESHOOTING

[Continued]

I8. Test ride check valve train VALVE SURGING----------· Improper valve clearance (too small)

I Weak valve springNO PROBLEM Worn camshaft

9. Ch!Ck for clutch slippage CLUTCH SLlPS----------... • Improper clutch lever free playI • Faulty clutch lifter system

NO PROBLEM Worn or warped clutch disc/plateI Weak clutch spring

10. Clean the carburetors: air passages BETTER-------------l_~· Clogged air passagesand jets • Clogged jets

IDOES NOT IMPROVE

....1 ----<..~. Seized cylinder and piston

Seized connecting rod bearingDamaged main bearing

20-7

Technische Daten Honda NT650 HAWK GT

Gegenstand Technische Daten

AbmessungenLänge über alles 2.085 mmBreite über alles 750 mmHöhe über alles 1.075 mmRadstand 1.430 mmSitzhöhe 778 mmFußrastenhöhe 355 mmBodenfreiheit 155 mmTrockengewicht 168 kgLeergewicht, fahrfertig 184 kgRahmenTyp Aluminium-Kastenprofilrahmen (�Twin tube diamond�)Vorderradaufhängung TeleskopgabelFederweg 130 mmHinterradaufhängung SchwingarmFederweg 120 mmFahrzeuggesamtgewicht 291 kgMaximale Zuladung 156 kgReifengröße vorne 110/80 - 17 57H, schlauchlosReifengröße hinten 150/70 - 17 69H, schlauchlosReifenluftdruck, (Reifen kalt) bis 90 kg Zuladung:

vorne: 225 kPa / 2,25 barhinten: 225 kPa / 2,25 barbis zur maximale Zuladung:vorne: 225 kPa / 2,25 barhinten: 250 kPa / 2,50 bar

Vorderradbremse Hydraulische EinscheibenbremseBremsscheibenfläche 262 x 2 cm²Hinterradbremse Hydraulische EinscheibenbremseBremsscheibenfläche 200 x 2 cm²Kapazität des Kraftstofftanks 12,0 LiterReservemenge des Kraftstofftanks 2,0 LiterNachlaufwinkel 27 °Nachlauf 111 mmFüllmenge Gabelöl bis Baujahr 1988: 497 ccm

ab Baujahr 1988: 502 ccmFüllstand Gabelöl: bis Baujahr 1988: 133 mm

ab Baujahr 1988: 128 mmMotorTyp wassergekühlter Zweizylinder, Viertaktmotor, SOHC Zylinderanordnung 2 Zylinder, 52 ° VBohrung und Hub 79,0 x 66,0 mmHubraum 647 ccmVerdichtungsverhältnis 9,4 : 1Ventiltrieb leiser Mehrglieder-Kettenantrieb mit obenliegender

Nockenwelle und KipphebelnSchmiersystem Druckumlaufschmierung mit Ölsumpf

1/4

Technische Daten Honda NT650 HAWK GT

Gegenstand Technische Daten

Luftfilter PapierfilterVerdichtungsdruck 1,324 kPa ± 196 kPa (13,5 bar ± 2 bar)Einlaßventil öffnet sich bei einem Hub von 1 mm: 10 ° vor OT

schließt sich bei einem Hub von 1 mm: 40 ° vor UTAuslaßventil öffnet sich bei einem Hub von 1 mm:: 40 vor UT

schließt sich bei einem Hub von 1 mm:10 ° nach OTVentilspiel, Motor kalt Einlaß: 0,15 ± 0,02 mm

Auslaß: 0,20 ± 0,02 mmMotorgewicht (trocken) 80 kgLeerlaufdrehzahl 1.200 ± 100 U/minVergaser Vergasertyp: GleichdruckvergaserBezeichnung VDGKA [VDGLA]Schwimmerstand 9,2 mmAntriebsstrangKupplung Mehrscheiben-Ölbadkupplung mit SeilzugGetriebe 5-Gang-GetriebePrimäruntersetzung 1,888 (36/68)Getriebübersetzung 1. Gang 2,769 (13/36)Getriebübersetzung 2. Gang 1,882 (17/32)Getriebübersetzung 3. Gang 1,450 (20/29)Getriebübersetzung 4. Gang 1,174 (23/27)Getriebübersetzung 5. Gang 0,965 (29/28)

Schaltschema Fußschaltung links, mit Rückführsystem1 - N - 2 - 3 - 4 - 5

EektrikZündung Digitale TransistorzündungZündzeitpunktmarkierung » F « 10 ° vor OT im LeerlaufFrühzündung, voll 31 ° vor OT bei 7.000 U/min ± 200 U/minAnlaßsystem Elektrischer AnlasserWechselstromlichtmaschine 240 W / 5.000 U/minBatteriekapazität 12 V / 8 Ah, MF BatterieZündkerzen Standard:

NGK: DPR8EA-9 Nippon Denso: X24EPR-U9für kaltes Wetter (unter 5°C)NGK: DPR7EA-9 Nippon Denso: X22EPR-U9für längere Hochgeschwindigkeitsfahrten:NGK: DPR9EA-9 Nippon Denso: X27EPR-U9

Elektrodenabstand 0,80 - 0,90 mmZündfolge vorderer Zylinder (232 °) - hinterer Zylinder (488 °)Sicherungen / Hauptsicherung 6 x 10 A , 1 x 15 A / 30 ABeleuchtungScheinwerfer (Fernlicht/Abblendlicht) 12 V - 60/55 WRücklicht / Bremslicht 12 V - 21/5 WBlinker vorne / hinten 12 V - 21 WInstrumentenbeleuchtung 12 V - 1 x 3,4 W, 2 x 1,7 WÖldruckwarnleuchte 12 V - 3,0 WFernlichtanzeige 12 V - 3,0 WBlinkeranzeige 2 x 12 V - 3,0 WLeerlaufanzeige 12 V - 3,0 W

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Drehmomentanzugswerte Honda NT650 HAWK GT

MotorZündkerze 4 12 14 (1,4)Zylinderkopfdeckel-Schraube 4 6 10 (1,0)Nockenwellenhalterungs-Schraube 6 8 23 (2,3)Nockenwellenhalterungs-Mutter 2 8 23 (2,3)Nockenwellenhalterungs-Schraube / 6mm 4 6 10 (1,0)Mutter Zylinderkopf 8 10 48 (4,8)Schraube Zylinderkopf 4 8 23 (2,3)Mutter Zylinderkopf / 8 mm 4 8 23 (2,3)Schraube Zylinderkopf / 6 mm 2 6 10 (1,0)Schraube Nockenwellenantriebsrad 4 7 23 (2,3)Sicherungsmutter der Kupplungsnabe 1 18 130 (13,0)Schraube des Kurbelgehäusedeckels, rechts 15 6 10 (1,0)Schraube des Kurbelgehäusedeckels, links 9 6 10 (1,0)Ölfilter 1 20 10 (1,0)Ölablaßschraube 1 14 35 (3,5)Leerlaufschalter 1 10 12 (1,2)Öldruckschalter 1 �-- 12 (1,2)Schraube des Primärantriebszahnrads 1 12 90 (9,0)Schwungscheibenschraube 1 12 130 (13,0)Schrauben des Anlaßerfreilaufs 6 8 30 (3,0)Ölkontrollschraube 1 10 23 (2,3)Befestigungsschraube der Ölleitung 2 7 10 (1,0)Mutter des Pleuellagerdeckels 4 8 34 (3,4)Kurbelgehäuseschraube 14 8 27 (2,7)Kurbelgehäuseschraube 6 6 12 (1,2)Schraube der Schaltwalzen-Anschlagplatte 1 6 26 (2,6)Zündzeitpunkt-Prüflochkappe 1 14 10 (1,0)Kurbelwellenabdeckappe 1 30 15 (1,5)Schraube des Ölpumpen-Antriebsrads 1 6 15 (1,5)Sicherungsmutter Einstellschraube Ventile 6 7 23 (2,3)Zylinderstehbolze / 8 mm 2 8 20 - 30 (2,0 - 3,0)Zylinderstehbolzen / 10 mm 8 10 30 - 50 (3,0 - 5,0)Halteschraube der vorderen Motoraufhängung 4 8 28 (2,8)Befestigungsschraube der Motoraufhängung 1 10 40 (4,0)Schraube der Motoraufhängung, hinten, oben 1 10 40 (4,0)Sicherungsmutter der Motoraufhängung 1 22 55 (5,5)Einstellschraube der Motoraufhängung 1 22 11 (1,1)Schraube des Schalthebels 1 6 12 (1,2)Thermostatschalter 1 16 18 (1,8)Befestigungsschraube Zündunterbrechungsschalter Seitenständer 2 6 25 (2,5)Auspuff / BenzintankMutter der Krümmerrohrbefestigung am Zylinderkopf 4 8 27 (2,7)Schraube der Auspuff-Klemmschelle 2 8 27 (2,7)Schalldämpfer Halteschraube zu Fußrsten 1 8 27 (2,7)Schraube Benzintankbefestigung /vorn: 1 6 12 (1,2)Schraube Benzintankbefestigung / hinten: 1 8 22 (2,2)Benzinfilter Befestigungs-Schraube 1 6 22 (2,2)

Gegenstand Anzahl Gewinde-Ø Drehmomentmm Nm (kg/m)

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Gegenstand Anzahl Gewinde-Ø Drehmomentmm Nm (kg/m)

BremsenHalter des vorderen Hauptbremszylinders 2 6 12 (1,2)Hohlschraube für Bremsleitungsbefestigung 4 10 30 (3,0)Schraube Deckel des Bremsflüssigkeitsbehälters 4 4 1,5 (0,2)Entlüftungssachraube 2 7 6 (0,6)Bremssattelbefestigungsschraube (vorne) 2 8 27 (2,7)Halterungsschraube des Bremssattels 2 10 28 (2,8)Bremsbelaghaltestift 2 ? 17 (1,7)Abdeckung Bremsbelaghaltestift 2 ? 2,5 (0,25)Befestigungsschraube Bremsscheibe am Vorderrad 6 8 40 (4,0)Befestigungsschraube hinterer Bremsflüssigkeitsbehäter 1 6 9 (0,9)Bremsscheibenbefestigungsschraube, Hinterrad 4 8 35 (3,5)Sicherungsmutter Bremsscheibenbefestigungsschraube, Hinterrad 1 8 9 (0,9)Bremssattelbefestigungsschraube / hinten 2 8 27 (2,7)Schraubbolzen Bremsssattel / hinten 1 8 22 (2,2)Schraube der Bremsmomentabstützung 2 10 35 (3,5)Vorderrad / GabelLenkerklemmschraube 2 8 27 (2,7)Befestigungsschraube des Zündschlosses 2 8 25 (2,5)Klemmschraube der oberen Gabelbrücke 2 7 11 (1,1)Klemmschraube der unteren Gabelbrücke 2 10 50 (5,0)Gabelstopfen 2 �- 23 (2,3)Befestigungsschraube Dämpfer Standrohr 2 8 17 (1,7)Einstellmutter des Lenkkopflagers 1 26 20 (2,0)Lenkschaftmutter 1 24 105 (10,5)Schraube der Vorderradachse 1 14 60 (6,0)Vordere Achsklemmschraube 4 8 22 (2,2)Hinterrad / SchwingeHintere Radmutter 1 18 120 (12,0)Sicherungsmutter des Lagerkäfigs Hinterrad 1 35 165 (16,5)Obere Federbeinbefestigungsschraube 1 12 65 (6,5)Untere Federbeinbefestigungsschraube 1 10 45 (4,5)Sicherungsmutter der Stoßdämpferstange des Federbeins 1 14 62 (6,2)Einstellschraube der Hinterradschwinge 1 26 15 (1,5)Sicherungsmutter Einstellschraube der Hinterradschwinge 1 26 65 (6,5)Hinterradschwinge Schraubbolzen 1 14 65 (6,5)Klemmschraube des Lagerkäfigs der Hinterradschwinge 1 16 75 (7,5)Montageschraube Kettenrad 6 8 43 (4,3)Ritzelbefestigungsschrauben 2 ? 10 (1,0)Halteschraube der Fahrerfußrasten 4 8 27 (2,7)Befestigungsschraube des Heckrahmens 4 10 40 (4,0)Schraube Gelenk des Seitenständers 1 10 38 (3,8)Befestigungsschraube des Seitensänders 2 8 28 (2,8)Befestigungsschraube des Hauptständers 2 10 55 (5,5)

Drehmomentanzugswerte Honda NT650 HAWK GT

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