Honda-CBR150R-Service-Manual-English

HOWTO USE THIS MANUAL CONTENTS

This service manuuaall describes the service procedures IIIGENERAL INFORMA TIlON

for the CBRR1150R.. ~::::::::::::::::::::::;::;:::;;:::;:;:::::::::::::::::::::::~

Follow the Maintenannccee Schedule (Seccttiioonn 3)) recom- -=-FRAMMEE/lBBOODDYY PANELLSS/lEXHAAUUSST
mendations to ensuree that the vehicle iss inn peak oper-
ating condition and the emission levels are within the ~SS=YYS=TSE=MT=EM==================~~
standards.
MAINTENANCE ..
Performing the first scheduled maintenaannccee is very
important. IItt compeennssaatteess for the initiaall wear that oc- LUBRICATION SYSTEM
curs duringg the breaakk--iinn period.
FUELL SYSTEM
Sections 11 andd 3 apply to the whole motorccyyccllee..
Secttiioonn 2 illustrates proceedduurreess for removal/installa- «Zz COOLLIINNGG SYSTEM
tion of components that may be requiredd to perforrmm ~====================iiii;;;
service describbeedd inn the following sections. 0:: ~=E=N=G=IINN=EE==RE=M=O=OV=V=A=LLI=lIN=S=T=AA=L=L=AA=TTIl=OO=NN=~
Secttiioonn 4 through 211 describe parttss of the motorcycle,
grouped according to location. >~Lku CLUUTTCCHH/lGGEEAARRSSHHIlFFTT LINKKAAGGEE
a2:n
Finndd the sectionn you want on this page, then turn to
the table of contents on the first page of the section. ~I ALLTTEERRNNAATTOORR/lSSTTARTERR CLUTCH
E~W Ir=CC=YY=LLI=NIND=EDR=EH=RE=AHD=ElV=AA=LDV=E/VS==A=LV=E=S========;;;;;
Most sections start with an assembly or systemm illus- 0
tration, service information and troubleshooting for the
sectionn.. The subsequent pageess give detailed procedduurree.. Zw\.I~TCC~YYRALL~IlNNN~DDSEE~RMR~/lPIPSIlS~SSTT~OOIN~NO~N~============~II'==~.:~='=
TRANSMISSION
If you don’'tt know the source of the troubllee,, go to sec-
tion 22 TROUBLESSHHOOOOTTIINNGG.. CRANKKSSHHAAFFTT/lBBAALLAANNCCEERR

ALL INFORMATIOONN,, ILLUSTRATIONS, DIRREECCTTIIOONNSS FRONNTT WHEELL/lSSUUSSPPEENNSSIIOONN/I
AND SPECCIIFFIICCAATTIIOONNSSINCLUUDDEEDDINN THISS PUBLLIICCAA--
TIONN ARE BASEEDD ONN THEE LATEESSTT PROODDUUCCTT IN-- eV8v~Urn),i~~R:~SRE:T~EA:EA~E:RRR~:WWI:N~HH:G~EE:~E:ELL:~lS=/~U=SS~=UP=~ES=~N=PSE=~ION=~N=S~=I=~O=~N============:=:=:===
FORMATIONN AVAILABLE AT THE TIME OFF AP-
PROVVAALL FORR PRINTINGG.. Honda Motor Co... lLttdd. BRAAKKEE SYSTEM
RESSEERRVVEESSTHEE RIGHHTTTO MAKEE CHANNGGEESSAT ANY
TIMEE WITHOUT NOTTIICCEEAND WITHOUT INCCUURRRRININGG CHAARRGGIINNGG SYSTEM
ANY OBLIGGAATTIIOONN WHATEVEERR.. NOO PARRTT OFF THISS
PUBLICATION MAY BBEE REPRROODDUUCCEEDD WITHOUT ..111:10~2~r. ~~IG~N~IT~I~O~N~S=Y=ST=E=MM==========~,::=.~::
WRRITITTENN PERMISSSSIIOONN.. THISS MANUAL ISS WRRITITTENN ..., ELEECCTTRRIICC STARTER _~!!!
FORR PERSOONNSS WHO HAVEE ACQUIRED BASIC
KNOWWLLEEDDGGEE OF MAINTENNAANNCCEE ONN Honddaa MO--
TORCYCLES, MOTOORR SCOOOTTEERRSS OR ATVS.

Honda Motor Co.,, lLttdd..
SERVVIICCEE PUBBLLIICCAATTIOIONNOFFFIICCEE

2w.... LIGHTS/lMETTEERRSS/lSSWWIITTCCHHEESS

w

WIRING DIAGRAAMM til
TROUBBLLEESSHHOOOOTTIINNGG
INDEX tU

Daattee of Issue: February, 2002 http://mototh.com
©Q Honda Motor Co., Ltd.

.--------IMPORIMTPOARTNANTTSAFETY NOTIICCEE - - - - - - - - ,
"'4'¥iii!N Indiiccaatteess a strong possibility of sevveerree personal injury or ddeatthh if innssttrruuccttiioonnssare not foolllloowweedd..

CAUTION:: Indiiccaatteess a possibility of equipment damage if inssttrruuccttiioonnssare not foolllloowweedd..

NOTEE:: Gives helpfuull information.

Detailed descriptions of standdaarrdd workshop procedures, safety princiipplleess andd service operraattiioonnss aree not
included. IItt iss important to note that this manuuaall containnss some warnings and cautionss against some specific
service methods which couldd caussee PERSONAL INJURY to service persoonnnneell or couldd damage a vehicle or
render it unsafe. Pleaassee underssttaanndd that those warnings couldd not cover alll conceivable ways inn which service,
whether or not recommennddeedd by Honda, might bee done or of the possibly hazardouuss consequences of eachh
conceivable way, nor could Honda investiggaattee alll such ways. Anyone using service procedures or tools,
whether or not recommennddeedd by Honda,, must satisfy himself thoroughly that neither personal safety nor
vehicle safety will bee jeopardiizzeedd by the service methods or tools selectedd..

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SYMBOLSS

The symbols usedd throughout this manuuaall show specific service procedures. If supplementary information is required
pertaining to these symbols,, it would bee explaineedd specificallyy inn the text without the usee of the symbols.

.-",3 Reppllaacceethe parrtt((ss))with new onee((ss)) beforee assembly.

~ ~~

---Ii Usee recommmeennddeedd engine oil, unleessss otherwise specified.

~ Usee molybdenum oill solution (mixturree of the engine oill andd molybdenum grease in a
ratio of 1::1l))
~
Usee multi-purpose greasee (lLitithhiiuumm baseedd mUulti-purpose greasee NLGGIl #2 or equivalent)
~
Usee molybdenum disulfide greasee (connttaaiinniinngg more than 3%% molybdenum disulfide,
LW NLLGGIl#2 or equivalent.

Example: Molykote'" BRR--22pluss manufactureedd by Dow Corninngg U.S.A.

Multi-purppoossee M-22 manufaccttuurreedd by Mitsubishi Oil, Japan
Usee molybdenum disulfide paste (containinngg more than 40%% molybdenum disulffiiddee,,
NLLGGIl#22 or equivalent.
Example: Molykote'" G-nn Passttee manufaaccttuurreedd by Dow Corningg U.S.AA..

Honda Moly 60 (U.S.A. only)
Roccooll ASP manufactured by Roccooll lLimimiitted, U.K.
Roccooll Passttee manufactured by Sumicoo Lubricant, Japan

Ussee siliconnee grease.

~

Apply a lockinngg agent. Ussee a middle strengthh lockinngg agent unless otherwise specified.

J1tmru Apply sealant..
Usee DOTT 4 brake fluid. Usee the recommeennddeedd brakee fluid unlessss otherwise specifiedd..
.I. Usee Fork or Suspeennssiioonn Fluiidd..

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1.. GENERAL INFORRMMAATTIOONN

GENERALL SAFETY 1--11 TOOLS 1-14
SERVIICCEE RULLEESS 1-22 LLUBBRRIICCAATTIIOONN & SEAL POINTSS
MODELL IDENTIFICATION 1-3 CABBLLEE & HAARRNNEESSSS ROUTTIINNGG III1-15
SPECIFICAATTIIOONNSS 1-4 EMISSIIOONN CONTROLL SYSTEMS
TORQUUEE VALLUES 1-12 1-17

I1-24

1-24

GENERAL SAFETY USEDD ENGGIINNEE OIL

CAARBBOONN MONOXIDE UUsed engine oil may cauusseeskin cancer if repeatedly left
If the engine must bee runnniinngg to ddo some work, makee in contact witthhtheeskinn for prolonged periooddss.. Although
sure the area iss well ventilated. Never runn the engine inn thiss is unlikely unless you handle used oil on a daily ba-
ann enclosed areaa.. sis, it is still advviissaabbllee to thoroughly wwaasshh your hands
withh soap and water as sooonn as possible after handling
'!i.§Uiiii" used oil.. KEEP OOUT OF REACH OF CCHHIILLDDRREENN..

TThheeexhaust contains poisonous caarrbboonn monoxide gas BBRAAKKEE FLLUUIIDD
that cann cauussee loss of consciousness and may lead to
deeaatthh.. CAUTION:
Spilling fluid on painted, plastic or rubber parts wwiilllldamm--
RRuunnthe engine inn ann openn areaa or withh ann exhaust evaccuu-- age theemm.. Plaaccee aa cleaann shoopp towel over thesee parts
ationn systeemm inn ann enclosseedd area. wheenneevveer thee system is servvicceedd.. KKEEEEP OUT OF REACH
OF CHHIILLDDRREENN..
GAASSOOLLIINNEE
Work inn a well ventilated area.. Keeepp cigarettes, flames ~
or sparkss away from the work areaa or where gasoline iss
stored. BBAATTTTEERRYY HYDDRROOGGEENN GAASS && ELLEECCTTRROOLLYYTTEE

,,,,.;ad''' • TThhee battery givess off expplloossiivvee gasess; keeepp sparks,
flameess and cigareettteess awwaayy.. Proovviiddee adeqquuaattee veennttii--
GGaassoolliinnee is extremely flammabble and is exploossiivvee un- lation whheenn chaarrggiinngg..
der certain condditions. KEEP OUT OF REACHH OOF CHHIILL--
DRREENN.. • TThheebattery containss sulfuric acid (felectrolyyttee)).. Coonn--

HOT COMPONENTS tact witthh skin or eyeess may cauusseesevere burnnss.. WWeeaarr
protective clothingg and a faccee shieelldd..
Engine and exhaust system parts becommee very hot and --IIf f electrolyte gets on your skin, flusshh witthh waatteerr..
remmaaiinn hot for some timee after thee engginnee is ruunn.. WWeeaarr --IIf f eleccttrroollyyttee gets in your eyeess,, flusshh witthh water
insulated gloves or wait until thee engginee and exhaust
system havvee cooled before handling theesseeparts. for at least 1155minutes and call aa physician imme-
diaatteellyy..

-• Electrolyte is poisonnoouuss..
- Ifswalloowwed, drink larggeequanntities ofwater or milk
and follow withh milk of maaggnneessiiaaor veggeettaabbllee oil
and call aaphysician. KKEEEP OOUTOFREACHHOFCHHIILL--
DRREENN..

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GENERAL INFORMA lTiIOONN

SERVICE RULESS

11.. Use genuine Honda or Hondaa--rreeccoommmmeennddeeddparrttssandd lubricaannttss ortthheir equivalents. Parrttssthat don't meet HONDA's
design specificatioonnss may causee damaggee to the motoorrccyyccllee..

2. Usee the special tools designed for this product to avoid damaaggee andd incorrect assembbllyy..
3. Usee only metric tools when servicing the motorcyyccllee.. Metric bolts, nutss andd screws aree not interchaannggeeaabbllee with

Engglliisshh fasteners.
4. Insttaalll new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Thenn tighten to the specifiedd torque

diagonally inn incremental steps unless a particular sequencee is specified.
6. Cleeaann partss inn cleaningg solvent uponn disassembly. Lubricate any sliddiinngg surfacceess befoorree reeaasssseemmbbllyy..
7.. After reassembly, check alll parts for proper installationn andd operation.
88.. Rouuttee alll electrriiccaall wires ass show onn pageess 1--1177 through 1-23, Cabbllee andd Harnneessss Routing.

1-22 http://mototh.com

GENERAL INFORMA TIlON

MMOODDEEL IDENTIFIICCAATTIIOONN

FRRAAMMEESERIAL NUMMBBEERR ” ENNGGIINNEE SERRIIAALL NUMMBBEERR I/ /

The frame seriaall number is stampedd onn the right side of The engine serial number is stampedd onn the lower left side

the steerinngg heaadd.. of the craannkkccaassee..

CCAARRBBUURREETTOORR IDDEENNTTIIFFIlCCAT1IOONN NNUUMMBBEERR 11--33
The carburetor identification number iss stammppeedd onn the
left side of the carbuureetoorr booddyy..

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GENERAL INFORMA TlilOON

SPECIFFICAT1IO0NS

-r- GENERAL ITEM SPECIFICATIOONNSS

DIMENSIONSS Overall length 1,91100 m m (75.2 in)
FRAMEE Overall width 6552 mm (25.77 in)
Overall height 1,06655 mm (411..99 inn))
ENGINEE Wheelbase 1,28866 mm (50.6 in)
Seat height 776 mm (30.6 in)
Footpeg height 312 mm (12.3 in)
Ground clearance 172 mm (6.8 in)
Dry weight 115 kg (253.53 Ibs))
Curb weight 123 kg (27711..1177lIbs)

Frame type Diamond type
Front suspension Telescopic fork
Front axle travel 190 mm (4.29 in)
Rear suspension Swingarm
Rear axle travel 120 mm (4.72in)
Rear damper Single effected tube type
Front tire size 80/!90-17M/C 44P
Rear tire size 100/80-17M/C 52P
Tire brand FronVt/RReeaar: IRCC
Front brake Hydraulic disc brake
Rear brake Hydraulic disc brake
Caster angle 25°"
Trail length 88 mrmn (3.46 inn))
Fueell tank capacity
10.0 liter (2.64 US gal,, 2.2 Imp gal)
Bore and stroke
63.55 x 47.2 mmm (2.50 x 1.86 in))
Displacemeenntt 149.4 cm3' (9.1 cu-in)
11.00:: 1
Compressssiioonn ratio Multi link chainn drive and DOHHCC
5"° BTDCC
Valve train ope"'r"closes 35°" ABDC
Intake valve 30°" BBDC
00°"ATDC
(0.014minm) lift Forcceedd presssuurree andd wet sump
Trochoid
Exhaust valve opens Liquiidd cooleedd
Paper filter
closes Assembled type
26.1 kgg (57.55 Ibss))
Lubriccaattiioonn system Singalee cyvlinder inclined 40°" from vertical

Oill pump type

Coolinngg system

Air filtration

Crankshaft type

Engine dry weight

Cyvlinder arrangaement

11--44 http://mototh.com

r GENERAALL (CCoont''dd)) GENERAL INFORMA TIlONN

ITEEMM ~~ ~

CZARBBUURREETTOORR CEaarburetor type SPEECCIIFFIICCAATTIIOONNSS
D3RRIIVVEETRAAIINN VVeennttuurrii dia.
CCV (Connssttaannttvelocity) type
CClluuttcchh system 25 mrnmm (0.9988 in)) or equivalent
Clutcchh operation systeemm
TTrraannsmission Multi-plate, wet
Primaarryy reducttiioonn Mechanical type
Finaall reductionn Constant mesh, 6-speeeedd
Gear ratio 3.260 (755//2233))
2.933 (444//1155))
EZLLEECCTRICAL Gearshift pattern 1st 3.0833 (37/1122))
2ndd 1.94411 (333//1177))
Ignition systeemm 3rd 1.500 (300//2200))
Starting system 4th 1.227 (277//2222))
Charggiinngg systemm 5thh 1.004411 (255//2244))
Regulatoorr//rreeccttiiffiieerr 6thh 0.923 (244//2266))
Lighting system Left foot operaatteedd retuurrnn system 1-N--22--33--44--55--66

Condenser Discharged Ignition (CODlI))
Electric starter motor
Single phassee output alternator
SCR shorted/single phase, half wave recttiiffiiccaattiioonn
Alternator

http://mototh.com 1-5

GENERRAALL INFORMA TIlOONN

r- LUBRICATION SYSTEM Unit: mm(in)

ITEEMM STANDARDD SERVICE LIMITT

Engine oill capacity At draining 1.0 liter (1.06 USS qt, 0.88 Imp qt) --
Recommended engine oil At disassembly 1.3 liter (1.37 USS qt, 1.14 Imp qt)
--

Honda 4-stroke oill or equivalent

motor oil --
API service classification SE, SF or SG

Oill pump rotor TIip clearance Viscosityv: SAE 1IO0W-3300 1 00..2200((00..00080)8)
Body clearance 1 0.26 (0.001100))
Side clearance ---
1 0.15 (0.006)
1 -0.150 -- 0.210 (0.00599 - 0.0083)
1 -0.050 -- 0.100 (0.00200 - 0.0040)

r FUEL SYSTEM SPECIFICATIONS

ITEM VK6AA
#1I 115
Carburetor identificcaattiioonn number #35
Maaiinn jet
Slow jiet See page 5-14
Pilot screw opening 133 mmm (0.5 in))
Float leveell
Idllee speeeedd +1,4000 ± 1000 min-'' (rppmm))
Throttle grip free play
2 -- 6 mrnmm (1/122 -- 1/4 in)

- COOLING SYSTEM Radiaattoorr and engine SPECIFICATIONS
Reseerrvvee tank
ITEM 1 0.766 liter (0.20 USS qt, 0.17 Impp qt)
Beggiinn to open
I Coolant capacity Fully open I 0.244 liter (0.06 USS aqt,, 0.05 Iimpp aqt)
Valve lift
Radiator capp relief pressure 1088 kPPaa (11..11 kgf/cmm2',, 16 psii))

Thermostat nsc69.5--72.5"C (1577..11 --116622S5°FF))

80°C (176°F))

3.55 mmm (0.14 in) minimum

r- CLUTTCCHH/GGEARSHIFT LINKAGE Unit: mm (in)

ITEEMM STANDARDD SERVICE LIMIT -
---
Clutch Lever free play 100-2200(3(3/I8B-1- 31/31/166))
Sprinngg free length
Disscc thickness 37.66 (1.4488)) 36.6 (1.4444))

I AA - -3.5 - 3.6 (0.1388 - 0.1421) 3.11 (0.121)
I BB
2.92 -33.0.088 (0.115 -00.1.12211)) 2.60 (0.110022))
10O.D0..
Plaattee warpage -__- 10.2 (0.00088)) I
11 1I.D0.
Outer guide 1 22.959 -- 22.998800 (0.9039 -- 0.9047) I 22.93 (0.90033))

I 1 16.999911 -- 17.009 (0.6689 -- 0.6696) 1 17.04 (0.67711))

I Outer 1I..D0.. I 23.000 -- 23.001133 (0.9055 -- 0.9060) I 23.06 (0.90088))

Mainshaft 00..00. .at clutcchh outer gwuiidde 1 16.996 --1166..9984 (0.6680 -- 0.6687) I 16.935 (0.6666677))

11--66 http://mototh.com

GENERAL INFORMA TION

- CYLINDER HEAD/V ALVES STAANNDDAARRDD Unit· mm (in)

ITEEMM SEERRVVIICCEE LIMMIITT

Cylinder compressionn 11,,337700kppaa ((1133..99kgf/cm2',, 119977..77pssii)) ---
at 668800 minn·-'’(rppmm))
Cylinder heaadd warpage 00..0055((00..00022) )
--- ---
Valve, I Valve clearannccee I INN 00..1166±f 00..0033((00..00066±f 00..000011)) ---
00..2255±f 00..0033((00..001100±f 00..000011))
valve guide EXX 33..777755-- 33..779900((00..11448866-- 00..11449922)) 33..77 ((00.1.51)5)
33..776655--3..778800((00..11448822-- 00..11448888)) 33..77 ((00..115)5)
Valve stem 0O.D0. INN 33..880000 --33..881122((00.1.4194696- -00.1.510510)1) 33..8899((00..11553)3)
00..001100-- 00..003377((00..00000404- -00..00001155)) 00..007755((00..000229)9)
EX 00..002200-- 00..004477((00..000088-- 00..00001199)) 00..008855 ((00..00033)3)

Valve guide 1I..D0. IN/EXX 115..55((00..616)1) ---
---
Stem-to-guuiiddee clearance INN 113..11 ((00..525)2) 11..99((00..007)7)
11.22 --11..66 (100..0055-- 00..0066)) 3388..55((11.5.25)2)
EX 3399..77((11.5.65)6) 222..4477 ((00..8858)5)
2222..447788-- 222..44993 ((00..8885500-- 00..88885555)) 222..55((00..8899))
Valve guide projection INN 2222..551100-- 2222..552266((00..8886622-- 00..88886699)) 335..007733((11..3388008)8)
above cylinder heaadd EEX 3355..1122--3355..2200((11.3.8338-3-11..338866)) 3344..666622((11..3634664)6)
334..711-- 334..7799 ((11..336677--11.3.37700)) 00..0022 ((00..00010)1)
Valvee seaatt width IN/EX 1177..0022((00..66770033) )
Valvvee spring free lenggtthh --- 116..996600 ((00..6667677)7)
I INN//EEXX 1177..000000--1177..001188((00..66669933--00..66770000)) 00..006677((00..000226)6)
1166..996666--1166..998844((00..6668800-- 00..66668877))
Valve lifter 0O..D0.
00..001166--00..005522 ((00..00000066--00..00002200))
Boree 1I.D.0..

Camshaft Camm lobee height INN

EXX

Runout

Camshaft holder 1I..D0. IN/EXX

Camshaft 0O.D0. INN/EXX

Camshaft-to-caammsshhaafftt IlN/EX

holder clearancee (rigghhtt side))

- CYLINDER PISTON Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder 1.0. 63.50 - 63.51 (2.5000 - 2.5004) 63.55 (2.502)

Out of round -- 0.10 (0.004)

Taper -- 0.10 (0.004)

Warpage -- 0.05 (0.002)

Piston, piston Piston mark direction "IN" mark facing toward the intake side --

rings Piston 0.0. 63.47 - 63.49 (2.4988 - 2.4996) 63.40 (2.496)

Piston 0.0. measurement point 6.5 (0.36) from bottom of skirt --

Piston pin bore 1.0. 15.002 - 15.008 (0.5960 - 0.5909) 15.055 (0.5927)

Piston pin 0.0. 14.994 - 15.000 (0.5903 - 0.5906) 14.98 (0.590)

Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.04 (0.0016)

Piston ring-to-ring Top 0.045 - 0.075 (0.0018 - 0.0030) 0.10 (0.004)
groove clearance Second
0.015 - 0.050 (0.0006 - 0.0020) 0.08 (0.003)

Piston ring end gap Top 0.05 - 0.20 (0.002 - 0.008) 0.3 (0.01)

Second 0.15 - 0.30 (0.004 - 0.010) 0.7 (0.030)

Oil (side rail) 0.20 - 0.70 (0.008 - 0.028) 1.1 (0.04)

Cyliinnddeerr--ttoo--ppiissttoonncleaarraannccee 00..0011-- 00..0044((00..000044-- 00..00001166)) 00..9900((00.0.3053)5)

Connecting roodd smaallll enndd 1I..D0. 1155..001100--1155..002288((00..55990099-- 00..55991177)) 1155..0099((00..59549)4)

Connecting roodd small end-to-pistonn pinn clearannccee 00..001100-- 00..003344((00..000044-- 00..00001133)) 00..007755((00..0003003)0)

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GENERAL INFORMA TION

r7 TRANNSSMMIISSSSIIOONN I Unit·: rmnmrn (inn))
STANNDDAARRDD I1
ITEEMM
SERVVIICCEE LIMIT

Transsmmiissssiioonn Gear 1.0. M5,M6 17.016 -17.034 (0.6699 - 0.6706) 17.08 (6.724)
SShhiift fork
Cc11 18.0000 -- 18..002211 (0.70877 -- 0.7009955)) 18.07 (0.7111))

Cc2 23.020 -- 23.004411 (0.9006633-- 0.907711)) 23.09 (0.990099))
22..11 (0.877))
C3.,CC4 22.020 -- 22.004411 (0.8669 -- 0.86788)
155..11 (0.5599))
Busshhiingg 1I..D0. Cc11 155..000000- 15.018 (0.59900--00.5.59911))
20.10 (0.79911))
Cc2 20.020 -- 20.004411 (0.78822 -- 0.789900)) 17.9 (0.700))
22.9 (0.9900))
Busshhiingg 0O..0D. Cc11 17.9699 -- 17.980 (0.77007744- 0.707799))
0.100 (0.00044))
Cc22 22.984 -- 23.005 (0.9004499-- 0.905577))
Geeaarr--ttoo--bbuusshhiinngg clearance CC11 I 0.100 (0.004)
1 0.020 -- 0.052 (0.0008 -- 0.002200)
ICc2 0.036 -- 0.057 (0.0001144-- 0.00222) I 16.93 (0.666677))
I M55 I 16.966 -- 16.984 (0.6680 -- 0.668877)) I 14.90 (0.558877))
Mainshaafft 0O..0D. I 19.92 (0.78844)) ]
I ICounteerrsshhaafftt 0O.D0.. C11 geaar busshhiingg 14.966 --1144..998844 (0.58922 -- 0.5899)
I 1C22 gaeaar busshhiingo 19.978 -- 19.989 (0.786666-- 0.78700)) 1 0.1100 (0.004) 1
I I
0.10 (0.00044))
Geeaarr--ttoo--sshhaafftt cleearance I M5 \ 0.032 -- 0.068 (0.0012 -- 0.0027) 0.1100 (0.004)

Bushhing-to-shhaafft cleearance CC11 0.016 -- 0.052 (0.00000011-- 0.0020) 9.93 (0.391)

Cc2 0.0311 -- 0.063 (0.0012 -- 0.0025) 10.03 1(00..3395)

SShhaafft O0.D0. 9.986 -- 9.999955 (0.3931 -- 0.3935) 1 4.9900 (0.193)

Forrkk It.oD.. 10.000 -- 10.018 (0.3937 -- 0.3944) 25.90 (1.020)

Fork claw thicckknneess 4..9933--55..00 (0..119944--00..119977) I 25.0088 (0.987)

Shift drum 0.0. at right end 25.959 - 25.980 (1.0220 -1.0228)
Shhiift drum journal (R.crankcaassee))
I 26.000 -- 26.021 (1.0236 -- 1.024444))

- CRANKSHAFT/BARANCER STANDARD Unit· mm (in)

ITEM --- SERVICE LIMIT

Conneecctting rodd I Big end sside cleearance --- 0.6 (0.0022))
--- 0.05 (0.002)
I Bigg end raddiiaall clearance 0.03 (0.001)

Crankshhaafft runout

11--88 http://mototh.com

GENERAL INFORMA TION

r- FRONT WHEEL/SUSPENSION/STEERING STANDAARRDD Unit: mm (in)
SERVVIICCEE LIMIT
ITEEMM

Minimum tire treadd depthh --- To the indicator

Cold tire pressure Driver only 2000 kPPaa (2.0000 kgf/cm2',,29 psii)) ---
-__-
Driver andd passenger 200 kPPaa (2.0000 kgf/cm2',,29 psii))
0.20 ((0a..0a0o8a)
Axle runout ---
2.0 (0.08))
Wheel rimm runout Raddiiaall -_ _-
-__- 2..00 (0.08))
Axial
--- 6600 g (2.1 o02z)l max..
Wheel balancer weight

Forkk Springg free lengthh 412.4 (16.2244)) 404.1 (15.911))
Springg direction
With the tightly wound endd facing ---
Pippee runout
down
I Recommended fork fluidd
--- I 00..2200(0.0088))
Fluuiidd leveell
Fluiidd capacity I Honda Ultraa Cushion Oill No.10 I -- - I

13311 (5.22)) ---
---
206 ±f 2.5 crmn3' (7.0 ±? 0.08 USS oz,77..33 ±f

0.09 Impp ozz))

r- REAR WHEEL/SUSPENSION STAANNDDAARRDD Unit: mm (in)

ItTlEEM --- SERVIICCEE LLIIMMIITT

Miniimmuumm tire tread depthh 200 kPaa (2.0000 kgf/ccmm2',, 29 psii)) To the indicator

Coldd tire presssuurree I Driver only 2255 kPPaa ((22..2255kgf/cm2',,33 psii)) ---
---
I Driver and passenger -__-
--- 0.20 (0.00088))
Axle runout I Raddiiaall ---
Wheel rimm runnout I AAxxiiaall --- 2.0 (0.08)
22..00 ((00..0088) )
Wheel balancer weiaght 1Size/link 1 DIDD442288VV1133--112244LLEE
Drivee chaaiinn 6600gII (2..11 o02z)l maxx..
I Slack 255--3355(1(.10.0-1-.14.)4)
---
---

http://mototh.com 11--99

GENERAL INFORMA liON

, BRAKE SYSTEM STANDARD Unit: mm (in)

ITEM SERVICE LIMIT

Front Specciiffiieedd brakee fluid DOT 3 or DOT 4 ---
Rearr Brake pad wear indicator
Braakkee disc thickness -- To groove
Braakkee disc ruunout 3.0 (0.12))
Master cyvlinder LI.D. 3..88--44..2 (0.15--00..1177)) 0.1 (0.004))
Master piston O.D. 12.755 (0.50222))
Caliper cylinder lI.D. --- 12.640 (0.4976)
CaliDper pDiissttoonn O.D. 25.450 (1.0020)
Specciiffiieedd brake fluid 12.700 --1122.7.74433 (0.500000 -- 0.501177)) 25.300 (100..99996600))
Brakkee paadd wear indicator
Braakkee disc thickness 12.657 --1122..668844 (0.4983 -- 0.4994) ---

I BBrraakkee ddiisscc rruunnoouutt 25.400 -- 25.405 (1.0000 -- 1.000022)) To groove
3.0 (0.12))
Master cylinder LI.D. 25.318 -- 25.368 (0.9968 -- 0.9987)
Master pistonn O.DD.. I 0.1 (100..00004)
Calipoer cyvlinder LI.D. DOT 3 or DOT 4
12.755 (0.5022))
1 Caliper pistonn O0.D0.. --- 12.645 (0.4978)
32.090 (1.2634))
3.8.8--44..2 (0..1155--00..117)
1 31.94 (1.257))
I ---
-12.700 --1122..774433 (0.5000 - 0.5017)

12.657 -- 12.684 (0.4983 -- 0.4994)

32.030 -- 32.080 (1.2610 --11.2.2663300)

I 31.948--313.19.9898 (1.2578--11.2.2559988)

- CHARGING SYSTEM/AL TERNATOR SPECIFICATIONS

ITEM 122VV--S5AAh

Battery Capacity 0.11 mAmmaax
Alternator Current leakaagnee 13.0 --1133..2 V
Specific gravity Fuully chargeedd
Below 12..33VV
Neeeddss charging
Chargiinngg current Normal 0.5 AAxX 5 --1100 h
2.55 AAx 11h
Quick
Capacity 155 WII5,5O,O00O0 rmnin-' (rpm))

Charrggiinngg coiill resistancee ((220O°oCC/6/86°8F")F) 0.2.2--11..0Qn
Lignhtinga coil resistannccee (20O°oCC/6/688°F"F))
0.1 -- 0.88 CQ2

1-1100 http://mototh.com

GENERAL INFORMA liON

- IGNITION SYSTEM SPECIFICATIONS

ITEM

Spark pluugg NGK DENNSSO0

I SStannddaarrdd CCRR88EE U2244EESSRR--NN
I OOpDttiioonnaall
CCRR99EE U27ESR -- NN

Sppaark pluugg gap 0.7 -- 0.8 mmmm (0.02288 -00.0.03322 in))

Ignnition cooiil peaakk voltaggee 10000 V minimmuumm

Ignniittiioonn puullssee generator peak voltage 0.7 V minimuumm

I Iggnniittiioonntiming 120° BTTDDCCat 1,4000 ±f 10000 min'~(’rppmm)) I

I" ELECTRIC STARTER Unit: mm (in)

I ITEM STANDARD ISERVICE LIMIT

I Starter motor bruusshh lenngatthh I 10.00 -- 10.05 (0.339933-- 0.396) I 3.5 (0.144)) I

- L I GH T S / M E T ERS/SWIT CHES SPECIFICATIONS

ITEM 122 V -1188//1188 W x 2

BBuullbbss HHeeaaddlliigghhtt(HHi/loww bbeeaamm)) 122 Vv -1100//55Ww x 2
BBraake/tailI light
Fuussee Licceennssee lIiQghhtt 1122VV-- 55WW
Theermmoosseennssoorr FFroonntt turn siggnnaall light
ressissttaannccee RReeaarr turnn siggnnaall light 122vV--1100 wWxx2
Instrummeenntt ligaht 122vV--1100 wWxx2
Tuurnn siggnnaall indicaattoorr
HHiigghh--bbeeaammindicatoor 122VV--11.77WWXx44
NNeeuuttrraall indiccaattoorr
MMaaiinn 1 2 VV--11..77WW
12Vv --11. 7Ww
Sub
12V - 11..77WW
50°C (1222°°FF))
112200°0Cc(248°0FF)l 200A

10AAxx 2

-133.9 - 1788..99 Q
-14.9 -1177..33 Q

http://mototh.com 1-1111

GENERALL INFORMA TlION

TORQUE VALUES TTORQUE FASTENER TTYPE TORQUE
N.'m (kkggffv'mn., IbbfH.ft)) N.'m ( kkggf'fmm, Ibf.-ft)
-- STANDARRDD 5 mm screw
5 ((00..55, .33.6.)6) 6 mm screw 4 ((00..44, ,22.9.)9)
FASTENNEERR TYPE 10 (1.0,.77)) 6 mmm fllaange bolt and nut (Include 9 ((00..99,,6..55))
NSHFF)) 12 ((11..22,,99) )
5 m m bolt and nut 22 ((22..22,,1166)) 8 mm flange bolt and nut
6 m m bolt and nut (Include SH 34 ((33..55, .2255)) 10 rmnm flange bolt and nut 26 ((22..77,.2200))
flange bolt) 54 ((55..55, .4400)) 39 ((44..0,02,92)9)
8 mm bolt and nut
10 mm bolt and nut
12 mrmn bolt and nut

• Torque specifications listed below are for important fasteners.
• Others should be tightened to standard torque values listed above.

NOTES: 1. Apply engine oil to the threads and flange surface.
2. Apply molybdenum disulfide oil to the threads and flange surface.
3. Apply locking agent to the threads.
4. Apply sealant to the threads.
5. Stake.
6. UBS bolt.
7. U-nut.
8. ALOC bolt.

r-- EENNGGIINNEE THREADD TORQUUEE
NU'.m (kkggf'fmm, IbbfH.ftl
ITEMM -Q'TTY DIAA..((mrnmrnll REMARKKSS

MAINTENNAANNCCEE:: 1 10 12 ((11..22, ,99))
Spark plug 1 300 7..9 ((00..88,,5..88))
Crankshaft hole cap 1 14 5..9 ((00..66,,4..33))
TIiming hole cap 1 12 25 ((22..55, ’1188))
Oil drain bolt
35 5..2 ((00..5533, ,33.8.)8)
LUBBRRIICCAATTIIOONN SYSTEM::
Oil pumpp bolt 11 7 110((11..00,7,7) )

COOLLIINNGG SYSTEM: 26 1100 (1.00,,77) NOOTTEE 11
Water pummpp impeller 48 300 ((33..11, ,222) ) NOTTEE 3
2 1122 322 ((33..33, .2244) ) NOTTEE 1
CYLLIINNDDEERR HEAADD/lVVALLVE:: 25 8..88((00..99,.6..55))
Cylinder heaadd cover boltt 11 6 4..22((00..4433, ,33.1.)1)
Cylinder heaadd nut 88 66 1122 ((11..22,.99) )
Cylinder heaadd bolt
Camm sprocket bolt 11 1144 744 ((77..55, ,5544) ) NOTTEE 11
Camm chaiinn tensioner plugg 11 1144 644 ((66..55,,4477) ) NOTTEE 11
Camshaft holder boltt 11 6 112((11..22,.99) ) NOTEE 3
11 6 112((11..22,.99) )
CLLUUTTCCHH/lGGEEAARRSSHHIlFFTT LLIINKKAAGGEE::
Clutch center lock nut 11 1122 6644((66.5.,54,74)7) NOOTTEE 11
33 66 1100 ((11..00,7,7) ) NOOTTEE 33
Primary drive gearr llockk nnuutt 33 55 55..22((00.5.35,3,33..88)) NOOTTEE 33
Gearshift camm platee bolt 33 88 3300 ((33..11,2,22)2) NOOTTEE 33
Shift drum stopper armm bolt
ALCTTEERRNNAATTOORRISlSTTAARRTTEERR CLLUUTTCCHH:: -22 5 55..22((00..5533, .33.8.)8)
FFllyywwhheeeell nuutt
Stator boolltt
Iggnniittiioonn puullssee generator boltt
SStaarrtteerr cluuttcchh boltt
OTTHHEERR FAASSTTEENNEERRSS::
RReeeedd valve cover bolltt

11--1122 http://mototh.com

GENNEERRAALL IINNFFOORRMMAATTIlOONN

r-. FFRRAAMMEE THREAD TORRQQUUEE
DIA.(mm) NN'.mm (kkgaff'mm,, IIbbfoffWt)
IITTEEMM Q'TY REMAARRKKSS

FFRRAAMMEE/IBBOODDYY PAANNEELLSS/IEEXXHHAAUUSSTT SYSTEM: 11 66 1133(11..33,, 99))
MMuufffler mmoouunntting nnuutt 33 66 1133 (11..33,,99)
EExxhhaauusst ppiippee ccover volt
33 1100 5599 (6.0, 4433)) NOOTTEE 33
EENNGGIINNEE REEMMOOVV AlL/IINNSSTALllLAATTIOIONN:: 22 66 1100 (11..00,,7)
EEnnggiinnee hhanger nnuutt
Driivvee sprocket fixinngg plaattee bolt 11 244 8888 (99,.65))

FFRROONNTT WHEElL/SISUUSSPPEENNSSIOlONN/SISTTEEEERRINI"G: : 11 266 Seeee pagee 1144--2222
Steeeerriinngg stemm nutt
Topp thread 22 88 2277 (2.8, 200))
Haannddlleebbaarr pinncchh bolt
Top bridgee pinncchh bolt 22 88 233 (2..33,,1177))
Bottomm briddggee pinncchh bolt
Froonntt axlee nutt 22 88 266 (2.77,,2200))
Foorrkk bolt
Foorrkk socket bolt 11 1122 5599 (66..00,,443) NOOTTEE 77
Froonntt braakkee disk bolt
Grip enndd screww 22 2277 233 (2.33,,1177))

RREEAARR WHEELl/SISUUSSPPEENNSSION: 22 88 200 (2..00,,1144)) NOOTTEE 33
Reaar axle nnuutt
Drivenn sprocket nut 88 66 42 (4.3,31) NOOTTEE 88
Rear brakee disc bolt
Shock absorber upper mounting bolt 22 66 88.8 (0.9,66..55))
Shock absorber lower mounting nut
Swingarm pivot nut 11 1122 5599 (6.0, 4433)) NOOTTEE 77
4 100 64 (6.5, 477)) NOTTEE 7
BRRAAKKEE SYSTEM: 48 42 (4.3,3311)) NOTTEE 8
Brakkee hose bolt 11 100 39 (4.00,.2299))
Front master cylinder cover screw 11 100 44 (4.5,3333)) NOTTEE 7
1 1122 88 (9.0,.6655)) NOTTEE 7
Front brake light switch screw
Brakkee lever pivot nut 1 100 34 (3.55,,2255))
Front brakee caliper mounting bolt
Braakkee caliper padd pinn 2 4 1.55 (0.1155,,11..11)
Bleedd valve
Rearr brake reservoir cover screw 11 4 1.22/(00.12., 0.9)
Rear master cylinder mounting bolts
Rear master cylinder push rodd nut 16 5.99 (0.6,, 4.3)
Mainn step holder mounting bolt
OTHER FASTENERS: 28 30 (3.1,2222)) NOTTEE 8
Chain slider screw
18 1177 /(1.7, 122))

28 5.44 (0..66,,44)

2 4 1.55 (0..1155,,11..11)

26 12 (1..22,,99))

18 17 (11..77,,1122))

48 27 (2.8,20)

26 5.9 (0.6, 4.3)

http://mototh.com 1-13

GENEERRAALL INFOORRMMAATIlONN TOOL NUMMBER REMARKS REF. SEC.

TOOLS 07440011 -- 0010000 NVOTE 1 5
07663311 -- 0010000 133
NOTTEESS:: 11.. Eqauivalent commmmeerrCciallvy available. 07716 -00002200110000 NOOTTEE 2: 8
2. Alternative tooil. 07772255-0004400000000 Ilmrie diagnostic tester 9
([mooddeell 6255)) 122
DESCRIPTIOONN -0774411-00001100220011 12,13
12,,13,,114,,115
Float levveell gauge 07746 -- 001010000 12,144
Univveerrssaall bearingg puller 07746 -- 0010200 133
Lockk nut wrench,, 20 x 24 mmmm 07746 -- 001030000 13,,14,,1155
Flywwhheeeell holder 07746 -- 001060000 122
Beaarriinngg remover weight 077746 -- 0040200 12
Attachment, 322 x 35 mmmm 077746 -- 0040300 122
Attachment, 377 x 40 mrnmm 077746 -- 0040400 133
Attachmmeenntt,, 42 x 447 mmmm 0777466--0004400550000 14,1155
Attachmmeenntt,, 722 x 755 mrnmm 077746 -- 0040800 14,155
Pilot, 1122 mmm 0774466--0005500110000 144
Pilot, 155 mmmm 077746 -- 00503000 14
Pilot, 1177 mmmm 07747 -00001100110000 144
Pilot, 20 mmmm 122,,13,,114,,115
Pilot, 35 mmmm -07747 -00001100330000 100
Bearing remover shaft 100
Bearriinngg remover head, 122 mmmm 07774488-0001100000011
Forrkk seaall driver 07774499-0001100000000 166
Forkk seaall driver attachment 07775577-0001100000000 144
Oill seaall remover 122
Driver 0778800-0001100220000 122
Valvee spring compressor 07778800-0001100660000 122
Valve seat cutter 0778800--0001122550000 122
07778800-0001133330000 6
Seat cutter, 27.5 mmmm (44550" IINN)) 07778800-0001144000000 14
Seat cutter, 24 mmmm (44550" EXX)) 0778800--0001144550000 133
Flat cutter, 24 mmmm (33220" INN)) 07JMH -- KYV20220000 133
Flaatt cutter, 27 mmmm (33220" EXX)) 8
Interior cutter, 300 mmm (66000" INN)) -07914 - SA5500000011 144
Interior cutter, 266 mmm (6000"EEXX)) 100
Cutter holder, 3.8 mmm 07991166-33771100110011 18
Snap rinngg plierrss 07993366-11666600111100 100
Steerriinngg stem socket 0793366--11666600112200 10
Beaarriinngg remover head, 122 mmmm 100
Bearing remover shaft -07936 - KC1lO0l1O0O0 9
Beaarriinngg remover shaft -07936 - KC1100220000
Beaarriinngg remover head, 155 mmmm
Attachmentt,, 366 mmmm 0794455-41415500440000
Steeerriinngg stem driver 0794466--43430000110011
Assembly collar 07965 -VVMMO0O0lO10O0
Assembly shaft
Clutcchh center holder -07965 - VM00200
Baalll racee remover
Valve guide driver 07GMBB -- KT7700110011
Peeaakk voltage adaptor 07GMD -- KS400110000
Valve spring compressor attachmenntt 07GMDD -- KT700110000
Tapeett holee protector
Valvee guide reameer -07HGGJJ - 0020100
Rotor puller -07JMMEE - KYV200110000
-07JMG - KYV200110000

07JMH --KVKY2020110000

-07KMC - HEO0O01IO0O0

1-1144 http://mototh.com

GENERAL INFORMA TlION

LUBRICATIIOONN&&SEAL POINTS

.- ENGINE

LOCATION MATERIAL REMARKS

Vlaallve stem (valve guide sliding surface) Molybdenum oil solution
C:lulutctchh outer guide outeerr surfaces (a mixture off 1/2 engine oil
P'isisttoonn pin outer surface annnd 1/2 molybdenum
C:oonnnneeccttiningg rod small end inner surface djiissuullffiiddee grease)
Sjhhiifftt fork shaft
Trransmissioonn gear rotating surfaces Engine oil
Trransmissssiioonn gear shift fork grooves
C:11, , C2 gear bushing MUullti-purpose grease
B3alancer driven gear inner surface lLoocckkiinng agent
CZlutch lifter arm spindle lLiqiquuiidd sealant
G;eeaarsrshhiftift spindle outer surface
Sjhhiifft drum journal outer surface
C:aammsshhaafftt

C:aamm chain
C:aammsshhaaftft holder bolt threads and seating surface
P'isistotonn outerr surface
P'isistotonn rings
Czylinnddeerr head nut threads and seating surface
VJalve lifter sliding surfaces
C3lutch disc lining surface
C3lutch center lock nut threads and seatingg surface
CZlutch lifter piece
C:rarnankshaft thrust surfaces
P'rirmimaaryry drive gear nut threads and seatingg surface
F'lylywwhheeeel l nut threads and seating surface
SShhiift drum grooves
SSttaarrtter clutch rolling surface
SSttaarrter reduction gear
O3ill pump inner and outer rotor
EEaacchh bearing rotating area
EEaacchh O-ring whole surface
EEaacchh oill seal lipp
WWaatter pumpp shaft

EEaacchh oill seaall lipp
(cluuttcchh lifter arm spindle, gearshift spinddllee))

Tliimming hole capp threads

CCrraannkksshhaafft hole capp threads

Gearshift cam plate bolt threads
Ignition pulsee generator bolt threads
Mainshaft bearing setting platee bolt threads
Starter clutch bolt threads
Camsprocket bolt threads

Alternator/ignition pulssee generator wire grommet
seaattiinngg suurfacee
R./L. Crankcase mattiinngg surface
except the oill passsaaggee area.

http://mototh.com 1-1155

GENEERRAALL INFORMA TlIONN

-- FFRRAAMMEE LOOCCAATTIIOONN MATERIAL REMARKS
Multi-purpose grease
Steerriinngg heaadd bearinngg sliding surface
I
Steering head bearinngg dust seaall lips
Front fork oill seall lips ---Siliconneegreasee
Frontt wheel dust seaall lips
Rearr wheel duat seaall lips
Rearr wheel hubb O-rinngg
Clutchh lever pivot bolt sliding surface
Speedometer gear andd pinion gear teeth
Speedometer gear/pinion sliding surface
Sidee stand pivot surfaccee
Throttle grip sliding surface
Speedometer outer cable inside
Seat lock sliding surface
Braakkee padd pinn sliding surfaccee

Braakkee caliper pinn bolt
Braakkee lever pivot bolt sliding surface
Braakkee lever-to-mmaasstteerr pisttoonn contacting area
RReeaarr braakkeemasterr piston-to-push rodd contactinngg areaa
Throttle cable inside

Clutch inner cable surface Molybdenum compounndd oill I
Chookkee inner cable surface I
Lockkiing agent
Forkk socket bolt threadss I
Coolinngg fann motor shaft threads Honddaa Bonndd A or eqauivalent

Handdllee grip rubber inside DOOTT 3 or 4 brakkee fluidd

Braakkee master pistonn andd cups

Braakkee caliper piston andd pistonn seallss

Braakkee caalibpeer dust seaall

~~ 1Honda Ultra Cushion Oill Noo..1100

Fork inside Sealant

Air cleaner housinngg tube jioint

1-1166 http://mototh.com

GENERAALL INFORMA TIlON

CABLE &HARNESS ROUTIINNGG

FRONT BRAKE HOSE CLUTCCHH CABBLLEE

I

THROOTTTILLE CAABBLE LEFT HANDLEBAR SWITCH WIRE
CHOKE CABLE
RIGHT HANDLE6
SWITCH WIRE

IGNNIITTIIOONN SWWITCCHH WIRE

MAIN WIRE HARRNNEESSSS

HOORRNN WIREE

TACHOMETER 2P COONNNNEECCTTOORR

I

http://mototh.com COMBINATION
METER 9P
CONNECTOR

HEAD LlGHTfTURN SIGNAL
LIGHT 6P CONNECTOR

1-177

GENERAALL INFORMA TIlOONN

CLUTTCCHH CABLLEE

CHOKE CABLE

SPEEDOMETER CABLE FRONT BRAKE HOSE

THROTTLE CABLE
RIGHT HANDLEBAR
SWITCH WIRE

MAIN WIRE HARNESS

1-1188 http://mototh.com

GENERAL INFORMA TlION

IGGNNIITTIIOONN CCOONNTTRROOLL MMOODDUULLEE (IICMM))

IGNNIITTIIOONN COOIL FUUEELLTUBBEE FUUEELL UNNIITT 3P COONNNNEECCTTOORR

\ I

ALTERNATOR ”\ \
4P CONNECTOR
RADIATOR OVERFLOW TUBE
NNEEUUTTRRAALL SSWWIITTCCHH
COONNNNEECCTTOORR

CAARRBBUURREETTOORR DDRRAAIINN TUUBBEE

http://mototh.com 1-19

GENERAL INFORMA TION

SUB-AIR CLEANER
REAR BRAKE LIGHT
SWITCH 2P CONNECTOR

THERMO SWITCH
SPARK PLUG WIRE
STARTER MOTOR CABLE

FUEL TANK CLUTCH CABLE
OVERFLOW TUBE

CRANKCASE
BREATHER TUBE

1-20 http://mototh.com

GENERAALL INFORMA lTilOONN

LLEEFFTT HHAANNDDLLEEBBAARR SWWIITTCCHH RRIGGHHTT HHAANNDDLLEEBBAARR SWWITCCHH
2P CCOONNNNEECCTTOORR 3P CCOONNNNEECCTTOORR

LEFT HANDLEBAR COOLING FAN MOTOR
SWITCH 9P CONNECTOR 2P CONNECTOR
I
\
PAIR CONTROL VALVE
CCHHOOKKE CCAABBLLEE
FFUUEELL AUTO VALVEE /

-VACUUUUMMTTUUBE -~~tf'i;4--f1~L_ TTHHRROOTlTILE CCAABBLLEE

1FFUUEELL TTUUBBEE \
THERMO SENSOR
CCAARRBBUURREETTOORR AIR / WIRE

VENT TUUBBEE \
SUUBB--AAIRR CCLEANER

http://mototh.com b.

RREEAARR BBRRAAKKEELLIIGGHHTT
SSWWIITTCCHH 2P CCOONNNNEECCTOR

J

11--2211

GENERAL INFORMA TIlON

RREEGGUULLAATTOORR//RREECCTTIFIFIEIERR DIODE RREEAARR BBRRAAKKEELLIIGGHHTT SWWIITTCCHH
2P COONNNNEECCTTOORR
I
I

o

TURN SIGNAL RELAY

REAR BRAKE HOSE

REAR BRAKE REAR BRAKE
RESERVOIR HOSE LIGHT SWITCH

1-222 http://mototh.com

GENERAL INFORMA TIlON

SPARE FUUSSEE 10A
SPARE FUSE 20A

/ STARTER RREELAY SWWITCHH/
RADDIATOR RESSEERRVVEE TANK CAP MAINN FUUSSEE 20A

http://mototh.com 1-233

GENERAL INFORMAA TIlON

EMISSIIOONN CONTROL SYSTEMMSS

SOUURRCCEE OF EMISSIOONNSS

The combustion process prodduucceess carbboonn monoxide andd hydrocarbons. Controlling hydrocarbon emission is very
important because, under certaaiinn conditions, they reacctt to formm photocheemmiiccaall smog when subjecteedd to sunlight.
Carbboonn monoxide does not react inn the same way, but it is toxic.
Honnddaa Moter Co., Ltdd.. utilizes leaann carburetor settings as well as other systems, to reduccee carbon monoxide and
hydrocarbonnss..

CRANNKKCCAASSEE EMISSSSIIOONN CONTTRROOLL SYSTEM

The enginee is equippppeeddwith a closed crankccaassee system to prevent discharrggiinnggcrankcaassee emissionss into the atmospher.
Blow-by gas iss returrnneedd to the combustion chamber through the air cleaner and carburetor.

a¢:::J ::FREESSH AIR

1.... :: BLOWW--BBYY GAS

1-2244 http://mototh.com

GENERAALL INFORMA lTilOONN

EXHAUST EMISSIOONN CONTROL SYSTEM (PULSEE SECONDAR Y AIR INJECTION SYSTEM)

The exhaust emission control system consissttss of a secondary air supply system which introduces filtered air into the
exhaust gasess inn the exhaust port. Freesshh air is drawn into the exhaust port whenever there is a negative pressure pulsee
innthe exhaust system. This charge offfrreesh air promotes burning oftthe unburnedd exhaust gasess and changes a consid-
erable amount of hydrocarbons and carbonn monoxide into relatively harmless carbonn dioxide and water vapor.
This model has the pulse secondary air injection (PAAIIRR)) control valve and PAIRR checkk valve. Pair check valve preventss
reverse air flow through the system. The PAIR control valve reactss to high intake manifold vacuum and will cut off the
supply of the fresh air during engine deceleratioonn,, thereby preventing afterburn inn the exhaust system.

No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the com-
ponents is recommended.

PULLSSEE SECONDAARRYY
AIR INJECTION (PAIR)
CONTROL VALVE

http://mototh.com 1-2255

FRAME/lBODY PANELSl/EXHAUUSSTT SYSTEM

BODY PANEL LOCATIOONNSS

DRIVER SEAT

GRAB RAIL

UPPER COWL
FRONT FENDER

REAR COWL

UNDER COWL

2-0 http://mototh.com

2. FRAME/BODY PANELS/EXHAUST SYSTEM

BBOODDY PAANNEELL LLOOCCAATTIIOONNSS 2-00 REAR FENDER I2-3
SERVICE INFORMAATTION 2-11 UNDERR COWL
TROUBBLLEESSHHOOOOTTIINNGG 2-11 MIDDLLEE COWL 22--333
PAASSSSEENNGGEERR SEAAT 2-2 FRONTT FENDEERR 2-4
DRIVEERR SEAT 2-2 UPPER COWL
GRABB RAAIILL 2-22 EXHAUST SYSTEM lIhIIJ122--44
REAARR COWL 2-22
2-5

I2-5

2-5

SERVICE INFOORRMMAATTIIOONN

GENERALL

'!i.'Wiiih

Seriouuss burns may result iif thhee exhaust syyssttem is not allowed to cool beforre compoonnentss are removed or servviicceedd..

* This section covers remmoovvaall andd installation of the body panels and exhaust system.
* Always replaccee the exhaust pippee gaskkeettss after removing the exhaust pipee fromm the engine.

Always inspecct the exhaust systeemm for leakkss after installation.

TORQUUEE VALLUUEESS 13 N·mm (1.3 kgff·mm, 9ILbbf·f.fftt)

Muffler mounnttiinngg nnuut 133 N·mm (1.3 kggff.mm, 9IIbbff·.fftt))
Exhaust pipee cover bolt

TROUBLESHOOTING

Excceessssiivvee exhaust noisee

-•* Brokeenn exhaust system

• Exhaust gas leakk
Pooorr peerrformannccee

- Deformmeedd exhaust system
- Exhaust gas leakk

•* Cloggggeedd muffler

http://mototh.com 22--1I

FFRAMEl/BODY PPANELSl/EXHAUST SSYYSTEM IGNITION KEY

PASSENGER SEAT -j

REMOVAALLA/INSTALLATION ~

Unlock tthhee ppaassenger sseeaatt wwith tthhe iiggnnittiioonn key.
RRemove tthhee ppassenger sseeat.
Installation is in the reverse order ooff removal.

DRIVER SEAT ~

REMOV ALl/lINST ALLATTIOONN DRIVER SEAT

Removee the driver seat (Seee above).
Removvee the mounting bolt and collars.
Raissee the rear of the seat and remove the seat backward.
Installation is inn the reversee order of removal.

GRAB RAIL ~ BOLT
LTS
RREEMMOOVVAALL//INNSSTTAALLLLAATTIIOONN

Reemmoovvee the four boollttss anndd grabb raaiill..
Inssttaallllaattiioonn iss inn the revveerrssee order of remmoovvaall..

REAARR COWLL

RREEMMOOVVAALL/AINNSSTTAALLLLAATTIIOONN

RReemmoovvee tthhee ggrraabb rraaiill ((SSeeeeaabboovvee))..

RReemmoovveetthhee ttwwoossccrreewwss aanndd bbooddyy cceenntteerrccoovveerr..
RReemmoovveetthhee bboollttss aanndd ccoolllaarrss..
RReemmoovveetthhee ssccrreewwss..
SSpprreeaadd tthhee ffrroonntt ooff tthhee rreeaarr ccoowwllss ccaarreeffuullllyy aanndd rreelleeaassee
tthhee rreeaarrccoowwll bboosssseessffrroommtthhee ffuueell ttaannkk ggrroommmmeettss..
RReemmoovveetthhee rreeaarrccoowwllss aass aann aasseeeemmbbllyv..

22--22 http://mototh.com

FRAME/BODY PANELWS/EEXXHHAAUUSSTT SSYYSTEM

RReemove tthhee ffoouurr ssccrreewwss aand rreeaarr cceenntteerr ccoowl ffrrom tthhee
rreeaarr ccoowwls.

Installation is i n the reverse orddeerr ooff removal.

REAR CENTER
/ REAR COWL COWL

REAR FENDER -

SCREWW//CCOOLLLLAARR ------o~

REMOVALAIINNSSTTALLATIOONN REAR COMMBBIINNAATTIIOONN
LIGHHTl
Remove the following:
-babttaetrteyry (page 17-41) -

-- rear cowl (page 2-2)

-stasrttaerrter relay switch and fuses

Disconnect the rear combination light 6P connector.
Remove the screw and collar.
Release the rear combination light bosses from frame
grommets, then remove the rear combination light.

Removee the two bolts and rear fender.
Installatioonn iss inn the reversee order of removaal.

I BOLTS

UNDER COOWWLL 22--33

RREEMMOOVVAALLIlIlNST AALLLLAATTIIOONN

Hoolldd thee lower ccoowwll securely anndd rreemmoovvee thee sixx screws
frroomm tthhee bbootthh ssiiddeess..
RReemmoovvee thhee uunnddeerr ccoowwllss aass aann aasssseemmbbllyy..

http://mototh.com

FRAME/BODY PANELSW/EXHAUST SYSTEEMM

Removee the three screws andd under cowl center coveerr.. UNDER COWL
Remove the screw and separate the right and left under CENTER COVER
cowls.

Installation is inn the reverse order of removvaall..

SCREWWSS SCREEWW
RIGHTT MIDDDDLLEE COWWLL
MIDDDLEE COWL

REMMOOVVAL/AINNSSTTALLAATTIIOONN SCREWWSS

At first, remove the screws and then releeaasseethe bossseess of
the middlee cowll from the grommets of the frame and
radiator.
Releeaasseethe speedometer cable from the guide (leftt middle
cowl only) and remove the middle cowl.

NOTEE:
Doo not damage the tabs of the upper cowl and speedom-
eter cable guide of the left middle cowl.

Installationn is inn the reverse order of removal.

I SCREWS LEFT MIDDLE

FRONT FENDER SPEEDOMETER CABLE
COLLLLAARRSS
REMMOOVVAL/AINNSSTTALLAATTIIOONN

Removee the bolts, collars, front fender and stay.
Installatioonn is inn the reverse order of removvaall..

STAY BOLTS
http://mototh.com
22--44

UPPER COWL FRAME/lBODY PAANNEELLSW/EXHAUST SYSTEEMM

REEMMOOVVAALL/hINNSSTTAALLLLAATTIIOONN BOLTS

RReemmoovvee the mmiiddddllee ccoowwl (ppaaggee 2-4).
Discoonnnneeccttthe commbbiinnaattionn mmeeter 9Pp', heeaaddlliigghhtv/ttuurrnnsignnaall
light 6P anndd tachometer 2P conneecctoors.

Remmoovvee the booltss anndd upper cowwll as ann assemmbbllyy..

DISASSEMBLYI/ASSEMBL YIl
INSTALLLLAATTIIOONN

Reemmoovvee the rear view mirroorss..
RReemmoovvee the screwwss andd upper cowwl lids.
Reemmoovveethe two boollttss andd commbbiinnaattiioonn mmeetteerr..

Remmoovvee the stay.
Remmoovvee the three screws and headd light assembly.

Assemmbblee iss inn the revveerrssee order of removaal.

Inssttaallll the remmoovveedd parts inn the reverssee order of remmoovvaall.

HEADLIGHT
ASSEMBLY

EXHAUST SYSTEM

"M"'''D0o0 not service the exlthhaauusst system while it is hot.

REMOVALL

Remmoovvee the under cowl (paaggee 2-3).
Remoovvee the exhaust pipe joinnt nuts.

http://mototh.com 2--55

FRAME/BODY PANELSW/EXHAUST SYSSTTEEMM

RReemmoovvee thhee mmuuffffleer mmoouunntting bboollt, ccoollllaarr aanndd mmoouunnttiinngg
rrubber.

Remmoovvee the exhaauusstt pipe mouunnttinngg bolt, nut, washer,
collarr andd moouunnting rubbeerrss..
Reemmoovvee the mmuufffler anndd exhaust pippee as asssseemmbbllyy..
RReemmoovveethe exhhaauusst pippee gasket.

DIlSASSEMBLYY//AASSSSEEMMBBLLY

MOUNTING RUB

MUFFLER EXHAUST PIPEE 13 N·.mm (11.3 kgf..mm,, 9IIbbff·.ft) WASHER MOUNTING EXHAUST JOINTT NUTS
PIPEE
GUARD COVER RUBBERRSS

2-6 http://mototh.com

FRAMMEE/lBBOODDYY PAANNEELLSS/lEEXXHHAAUUSSTT SYSTEEMM

INSTALLLAATTIIOONN

Instaallll the new gasket.
install the muffler and exhaust pipe assembly, thenn
temporarily instaallll the all mounting fastners.

Tighten the exhaust pipe joint nuts.

Tighten the exhaust pipe mounting bolt.

Tighten the muffler mounting bolt to the specified torque.
TORQUE:: 1133 N·.m 1(11.3 kgf·.m, 99IbI bf-ffWt)

http://mototh.com 2-7

3. MAINNTEENANCE

SERVICE INFORRMMAATTIIOONN 3--11 SECONDDAARRYY AIR SUPPLY SYSTEM 3-144
MAINTENNAANNCCEE SCHEDULE 3-33 DRIVE CHAIN 3-15
FUEL LINEE 3-4 BRAKEE FLUIDD 3-117
THROTTLE OPERATIOONN 3-4 BRAKEE PAD WEAR 3-18
CARBUREETTOORR CHOKE 3-55 BRAKE SYSTEMM
AIR CLEANEERR 3-55 BRAKKEE LIGHTT SWITCCHH III3-18
CRANNKKCCAASSEE BREATTHHEERR 3-66 HEADDLLIIGGHHTT AIM
SPARK PLUGG 3-66 CLUUTTCCHH SYSTTEEMM 3-118
VALVE CLEARAANNCCEE 3-88 SIDE STAND 3-119
ENGINE OIL 3-110 SUSPEENNSSIIOONN 3-119
ENGGIINNEE OIL STRAINER SCREENN 3-12 NUTS,,BBOOLLTTSS,,FFAASSTTEENNEERRSS 3-2200
ENGINEE IDLE SPEED 3-12 WHEELSS/lTIlRES 3-2200
RADIATOR COOLANT 3-13 STEERING HEAD BEARINNGGSS 3--2211
COOLINNGG SYSTEMM 3-144 3-2211
3-22

SERVICE INFORMMAATTIIOONN

GENERALL

'¥lM....i

• GGaassoolliinneeis extremmeellyyflammmaabblleeand is explosivee under ceerrttaaiinncoonnddiittiioonnss.. WWoorrkk in aa well vennttiilaatteeddareeaa.. Smmookk--
ing or allowing flameess or sparks in the work area or whheerree the gasooline is stored can causee aa fire or expplloossiioonn..

• If the engginee must be running to do sommee woorrkk,, maake ssure the areaa is well veennttiillaatteedd..Never run the engine in aan
enncclosed areeaa.. TThhee exhaauusst coonntaains poisonous caarrbboonn mmoonnooxxiiddeegas that may caaussee losss of coonnsscciioouussnneessss and
mavy lead to deeaatthh.. RRuun the enngginee in aan opwen areaa or witthh aan exhaauusst eevvaaccuuaattiioonn systemm in ennccloseeddareeaa..

Placcee the motorcycle onn a level ground before startinngg any work.

SPPEECCIIFFIICCAATTIIOONNSS

ITEMM SPECIFICCAATTIIOONNSS

Throttle grip free play I Standard 2 -- 6 mmmm (1/1122 -- 1/4 inn)) DENNSSO0
Spark plug U24EESSRR--NN
I Optional NGK U277EESSRR--NN
Spark plugg gap CRRS8EE

CRS9EE

-0.77 - O0.8S mmm (0.00228S-- 0.032 inn))

http://mototh.com 33--11

MAAINNTTEENNAANNCCEE

I ITEEMM I SPECIFICATIONS I

Engine oill capacittyy At draining 1.0 liter (1.06 USS qt, 0.88 Impp qt) -
At disassembly 1.3 liter (1.377 USS qt, 1.141Imp qt)
Honda 4-strokee oil or equivalent motor oil I
Recommmmeennddeedd engine oill
API service classificaattiioonn SE, SF or SG
Engine idle speed
Viscosity: SAE 10OWW--3300
Valve clearance INN 1,.4000 f± 10000 min-’1 (rpmm))
0.16 f± 0.03 mmm (0.006 ±k 0.001 in))
EXX 0.25 ±f 0.03 mmm (0.010 f± 0.000011 in))
25 -- 35 mmmm (1.00 --11..44 in))
Drivvee chaiinn slack DID428VV1I33-- 1244LLEE
DOT33o0r DOT44
Drivee chaiinn size/link 100 -- 20 mmmm (3/88 -- 13/16 inn))
80/!90-17M/C 44P
Braakkee fluid
[ 100//8800--1177MM//CC522PP
Clutch lever free play I Front
Tl iiree size 1 Rear I 200 kPa (2.00 kg/cmm2',,29 psii))
1 200 kPaa (2.00 kg/cmm2',, 29 psii))
Tl iiree air pressssuurree Driver only Front
Rear 200 kPa (2.00 kg/cemm2',, 29 psii))

Driver andd passeenn-- Front 225 kPaa (2.25 kgl/ccmm’,', 33 psi))
ggeerr Rear To the indicator
To the indicator
Miniimmuumm tire treadd depth Front
Rear

TORQUE VALUES 25 N·.mm (2.5 kgf·mm,, 18 Ibbff·4ftt))
122 N·m (1.2 kgff·m, 9IIbbff·.ft)
Oill drainn bolt
Spark pluugg 59 N·mm (6.0 kgff·mm, 43 Ibf·3ft))
Reaarr axlee nnuut
Crankshaft hollee capp 7.9 NN·.mm 1(00.8 kgff·mm, 5.88IIbbf·.ft)
Timing hole cap 5.99 N·.m (0.6 kgff·mm, 4.33 Ibbff·Wft)
Drivee sprocket fixing plattee bolt 100 N·.m (1.0 kgff·m., 7IIbbff·dftt)
Drivveenn sprocket nnuut 64 N·.m (6.5 kgff·mm, 47 Ibf·.ft) U-nut
Front master cylinder cover sccrew 1.5 N·.m (0.1155 kgf.·m,, 11..11 Ibbff·fWt)
Reaarr brake reservoir cover screw 1.5 NN·mm (0.15 kgff·mm, 11.1IIbf·.ft)

33--22 http://mototh.com

MAINTTEENNAANNCCEE

MMAIINTTENANCE SCHEDULLE

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. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may
require more technical information and tools. Consult their authorized HONDA dealer.

~ '*WHICHEVER ODOMETER READING (NOTE 1)

ITEM COMES X1l,,OOOOOOkkmm 1 4 8 122 REFER
7.5 TO
* FUEL LINE aFIRST X1l,OOOOO mmii 0.66 2.5 5 18 PPAAGGEE

.* THROTTLE OPERATION ~ MONTTHH 6 122 3-4
CHOKE OPERATION 3-4
AIR CLEANER II I 3-5
CRANKCASE BREATHER 3-5
SPARK PLUG I I .1 3-6
3-6
* VALVE CLEARANCE II I 3-8
3-10
ENGINE OIL NOTE 2 CC R 3-12
H' ENGINE OIL STRAINER SCREEN 3-12
NOTE 3 CC C 3-13
* ENGINE IDLE SPEED 3-14
IRI 3-14
RADIATOR COOLANT 3-15
I EVERY 24,000 km (16.000 mil: , 3-17
.* COOLING SYSTEM 3-18
SECONDARY AIR SUPPLY SYSTEM RR 3-18
DRIVE CHAIN 3-18
BRAKE FLUID C 3-19
BRAKE PADS WEAR 3-19
BRAKE SYSTEM III I 3-20
3-20
.* BRAKE LIGHT SWITCH NOTE4 I 3-21
HEADLIGHT AIM 3-21
CLUTCH SYSTEM I 3-22
SIDE STAND
NOTE5 I
* SUSPENSION
* NUTS,BOLTS,FASTENERS EVERY 1,000 km (600 mil: I, L
** WHEELSfT/RES
** STEERING HEAD BEARINGS NOTE 4 II I

II I

IIII

III

III

III I

II I

II I

II

II I

II

* Should bee serviced by ann authoriizzeedd Honda dealer, unless the owner has proper tools and service data and is

mechanically qualified.
**IIn the interest of safety, we recommend these items be serviced only by an authoriizzeedd Honda dealer.

NOTEESS:: 1. For higher odometer readings, repeat at the frequencyy interval established here.
2. Service more frequently when riding inn unusually wet or dusty areass..
33.. Service more frequently when riding inn rainn at full throttle.
4. Reppllaaccee every 2 years. Replacement requiirreess mechanical skill.

5. Reppllaaccee every 3 years or 24,000 km. Replacement requires mechanical skill.

http://mototh.com 33--33

MAINTENANCE

FUEL LINNEE

Remove the fuel tank (paggee 5--33)). .

Check the fuell liness for deterioration, damage or leakage..
Reppllaacceethe fuell line if necessary.

THROTTLE OPERATIOONN

Checckkfor smootthh throttle grip fulll operatiinngg and automatic
full closing inn alll steeriinngg posiittiioonnss..
Checckkthe throttle cable andd replace iitt if it is deterioorraatteedd,,
kinkkeedd or damaged.
Lubricaattee the throttle cable, if throttle operation is not
smooth.

Measuurree the free play at the throttle grip flange.

-FRREEEE PPLLAAYY:: 22 - 66 mmmm (11/1122 -- 11/4 inn))

Throttle grip free play cann bee adjusteedd at either end of the
throttle cable.

Minor adjustment aree made with the upper adjuster.
Adjust the free play by looseniinngg the lock nut and turning
the adjuster.

LOCK NUT \’

Major adjustments are made with the lower adjuster.
Remove the fuell tank (paaggee 55--331)..
Remoovvee the boltt andd PAIIRR contrrooll valve w ith tubes
connected.
Disconnect the air injection hose fromm the cylinder head
coverr..

33--44 http://mototh.com

MAINTTEENNAANNCCEE

Adjust the free play by looseninngg the lock nut and turning
the adjusting nut.
After adjustment, tighten the lock nut securely..
Recheckk the throttle operation.
Replaccee any damaged parts, if necessary.

CARBURETOR CHOKE

This model’'s choke system uses a fuel enriching circuit
controlledd by a starting enrichment (SEE)) valve.
The SE valve opens the enriching circuit via a cable when
the choke knob on the fork top bridge is pulled..
Check for smooth choke knob operation and lubricate the
choke cable if required..
Inspect the cable for cracks which could allow moisture to
enterr..
Repllaacceethe cable if necessaarryy..

AIR CLEANER

Removvee the fuel tank (paggee 5--33)). .

Remove the five screws and air cleaner housing cover.

Remove and cleann the air cleaner element inn accordance
with the maintenaannccee schedule.
Also replace the air cleaner element any time it is exces-
sively ddirty or damage.

http://mototh.com 3-5

MAINTENANCE

Iftthe surface oftthhe element is dirty, remove the dust first
by tapping the element gently. Then, blow away any
remaininngg dust onn the surface oftthe filterrwith compressed
air from the inside towardd outside.
Reppllaaccee the element, if the surface of it is still dirty after
cleaning.
Instaallll the air cleaner element and removeedd parts inn the
reverse order of removal..
lTigighhtteenn the air cleaner cover screws.
Install the fuel tank (page 5-33))..

CRANKCASE BREATHERR

Remoovvee the cap fromm the crankcassee breather tube and
drain depositteess into a suitable container. Installll the cap to
the tube securely.
NOTE:
Service more frequently when riddeenn innrain, at full throtttllee,,
or after the motorcycle is washed or over turned. Service
if the depositeess level cann bee seenn inn the transparent sec-
tion oftthhe breather tube.

SPARK PLUGG

REMMOOVVAALL

Remoovvee the right middle cowl (pagee 2-4)..
Remove the radiator lower monting bolt and movee the
bottom of radiator forward.

Disconnect the spark plug cap.

33--66 http://mototh.com

MAINNTTEENNAANNCCEE

Removvee the spark plugg usingg a equipppeedd spark plugg
wrench or ann equivaleenntt..

Inspect or replace as described inn the maintenance sched--
ule (paggee 3--33)). .

INSPPEECCTTIIOONN I

Checkk the followinngg and replaccee if necessary (recomm-- INSULLAATTOORR
mendeedd spark plug: page 33--11))
1
-•* Insulator for damage
Electrodes for wear T
Burninngg condition, coloration;
-dadrakrk to light browwnn indicaatteess good condition. 0..77--00..8 mmmm
-execxecsessivseive lightness indicates malfunctioning ignition ((00..002288-- 00..003322inn)) ~§~
system or leaann mixture.
--wweet t or black sooty deposit indicatteess over--rriicchh mix-
ture.

REUUSSIINNGG A SPARK PLUUGG

Cleann the spark plugg electrodes with a wire brushh or spe-
cial plugg cleaneerr..
Check the gap betweeeenn the center andd side electrodes.
If necessary, adjust the gap by bendingg the side electrode
carefully.

SPARKK PLLUUGG GAAPP:: 0.7 -- 0..88 mmmm (0.002288 -- 0.032 inn))

CAUTIONN:: 33--77
TTooprevenntt ddammaaggee to thhee cylinder headd, hand tiigghhtteennthhe
spark plug before usinngg a wrench to tighhtten to thhe
specified toorrqquuee..
Reinnssttaalll the spark plugg inn the cylinder heaadd andd hanndd
tighteenn,, then torque to specification..
TORQUE: 12 N·.m 11.2 kggff·.mm, 9IIbbff-.fftt))

http://mototh.com

MAINTENANCE

REEPPLLAACCIINNGG A SPARK PLLUUGG

CAAUUTTIIOONN::
Do not ovvertightten thhee spark pluugg.
Inssttaalll andd hanndd tighten the new spark plug, then tighten
it about 1/2 of a turnn after the sealiinngg washer contacts the
seat of the pluugg hole.
Connect the sprak plugg cap andd insttaallll the removeedd partss
inn the reveerrssee order of removal.

VALVE CLEARAANNCCEE

INSSPPEECCTTIIOONN

NOTE:
Inspect andd adjust the valve clearance while the engine is
cold (below 35°"C/95"°FF))..

Remove the cylinder heeaadd ccoovveerr(paggee 10-4).
Remove the timinngg hollee capp andd crankshhaafftt hole caapp_.

Rottaatteethe crankshaft counterclockwise andd align the index
line of the "T" mark onn the flywheel with the index notch
onn left crankkccaassee cover.

The index liness oonn the cam sprockets must be flush with
the cylinder headd surface as shown.

Makee sure the pistoonn iss at TDC (Toopp dead centeerr)) on the
compression stroke.

If the index liness are not flush, rotaattee the crankshaft
counterclockwise 36600°" ((11full turn) andd align the index lines
off the "TT"" mark with the index notch.

33--88 http://mototh.com

MAINTENANCEE

Measure the cylinnddeerr valve clearance by inserting a feeeleer
gauge between the valve lifter and cam lobe.

VALVE CLEARANCE:
IN: 0.1166+± 0..03 mm (0.006et: 0.00011 in)
EX: 0..225s± 00..0033mm 1(00.,018lt 0.000011 in)

ADJUSTMEENNTT Sl'tl

Remove the camshafftt (page 10--55)),. 0O 0O 0O0Q

Removee the valve lifters and shims. 11.80 mmmm 11..882255 mmmm 11.85 mmmm 11.875 mmm

Cleann the valve shim contact area in the valve lifter with
compresseedd airr.

NOTE:

*• Shim may stick to the inside of the valve lifter. Do not

allow the shims to fall into the crankccaassee..
* Mark all valve lifters and shims to ensure correct

reassembly inn their original locations.
* The valve lifter cann be easily removedd with a valve

lapping tool or magneett..

* The shims cann bee easily removedd with a tweezers or
magnet..

Measure the shim thickness and recoorrdd it..

NOTTEE::
Sixty-nine different thickness shims are available fromm the
thinnest 1(11.2000 mmmm thickness) shim to the thickest (22.990000
mmmm thickness) inn intervals of 0.025 mmm.

Calculaattee the new shimm thickness usinngg the equation
below.

AA == I(BB--CCI)++DD

A: Neww shim thickness
B: Reccoorrddeedd valve clearanccee
C: Speecciiffiieedd valvee clearancee
D0: Oldd shim thickness

NNOOTE:
* MMaakkee suree of thee correcctt shimm thickness byy mmeeaassuurriinngg

thee shim with the mmiiccrroommeetteerr..
• RReeffaaccee thee valvee seeaatt iif carbon deposits result iinn a

caallccuullaatteedddimension of over 2.990000 mmmm..

http://mototh.com 33--99

MMAAIINNTTEENNAANCE

IInnsstall tthhee nneewwllyy sseelleecctteedd sshhiimmss oon tthhee vvaallvvee rreettaaiinneerrss..

IInnstall tthhee vvaallvvee lliifftteerrss aannd ccaammshafts ((ppage 1100-19).

RRotate tthhe ccaammsshhaaffttss bby rroottaat i n g tthhee ccrraannkksshhaafftt
ccoounterclockwise sseevveeral ttiimmes.
RRecheck tthhee vvaallvvee cclleearance.

IInstall tthhee ccyylliinnddeerr hhead ccoovveerr ((ppaage 1100-22).

Coat a new O-ring with oil and install it onto the crankshaft
hole cap.
Apply grease the crankshaft hole cap threads.
Install and tighten the crankshaft hole cap.

TORQUE: 7.99 N.'rmn 1100.8 kgtt·mm,. 5.88 IbHtWt)

Coat a new O-ring with oil and install it onto the timing
hole cap.
Apply grease the timing hole cap threads.
Install and tighten the timing hole cap.

TORQUE: 5.9 N.'rmn (0.66 kgff·mm,. 4.3 I bHf Wt)

ENGGIINEEO01i1l

OIL LEVVEELL INSPPEECCTTIIOONN

Start the enginnee and let iit idle for a few minutes.

Stopp the engine, support the motorcycle uprighhttoonn a leveell
surfaccee..
Wait for a few minutes.

Remoovvee thee oill filler capl/ddiippssttiicckk andd wipe oofff the oiill froomm
thee dipsstick withh a clleeaann cloth.

With thhee mmoottoorrccyyccllee uprriigghhtt oonn leevveell ground,. iinnsseerrtt thhee I
oiill filler capl/ddiippssttiicckk inttoothee sticckk hhoollee without screewwiinngg
iitt iinn..
RReemmoovvee the oiill filler cap/dipstick anndd cheecckk the oiill level.

~ IIIfftthheeooiilllleevveelliissbbeelloowwoor nneeaarrtthhee lloowweerr lleevveellmmaarrkk., rreemmoovveeI

tthhee ooiill ffiiller ccaapp aanndd tthhee rreeccoommmmeennddeedd eennggiinnee ooiill uupp ttoo
UPPER
LEVEL LINE

tthhee uuppppeerr lleevveell mmaarrkk.. LOWER

LLEEVVEELL LLI1NNEE'--_---'

RREECCOOMMMMEENNDDEEDDEENNGGIINNEE OOILL::

HHoonnddaa44--ssttrrookkee ooiill oorr eeqquuiivvaalleenntt mmoottoorr ooiill

AAPPII sseerrvviiccee ccllaassssiiffiiccaattiioonn:: SSEE., SSFF oorr SSGG

VViissccoossiittyy;: 1IO0W-30

33--1100 http://mototh.com

NOTE:: MAAINNTTEENNAANNCCEE
Other viscosities shown inn the chart may be used when
the average temperature inn youurr ridinngg area is within the • •~
indicatteedd range.. ~
.-•
Reinstall the oill filler cap/dipstick.
-II ,. 20 ]I We
ENGINNEE OIL CHANGGEE I tI
21 .. Sa 81 ,WF
iiN'hdH'

If thee ennggine must be running to do some work, make
sure the area is wellll--vveennttiillaatteedd.,Never run the engine in
an enclosed areaa.. Thhee exhaust containss poisonous car-
bon monooxxiiddeegas that may causee loss off consciousness
and mavylleead to deaatthh.. Run the enginee in an oDpeenn area or
with an-eexxhhaauussttevacuuaattioonn system in encclloosse'kd areaa..

Warm up the engine.

Stop the engine and remove the oil filler cap/dipstiicckk and
drain bolt.
Drainn the oil completeellyy..

1!l9M"1

Used enginee oil may caussee sskin cancer iff repeatedly left
in contact withh the skin for prolongedperiooddss..Although
this is unlikely unleessss you handle used oil on a daily ba-
sis, it is still advisaabbllee to thoroughly waasshh your hands
withh soap and water as soon as possible after handling
used oil. KEEP OUT OF REACH OF CHHILLDDRREENN..

Check that the sealingg washer on the drain bolt is inn good

condition, replace if necesssaarryy..
Instaallll and tighten the drain bolt.

TORQUE: 25 N.'m (2..55 kggff'.mm, 181I bHf Wt)

Filll the crankcaassee with recommended engine oil.

OOIL CAPAACCIITTYY::
1.0 liter (11.0066 USS qt., 0.88 Imp qtlJat ddrrainniinngg

Installl the oil filler cap/dipstick.

Start the engine and let it idle for a few minutes.
Stop the engine and recheck the oill level.
Make sure there are no oil leaks.

http://mototh.com 33--111I

MAINTENANCE

ENGINEE OIL STRAINER SCREEN

Remmovee the right crankcaassee cover (paggee 88--33))..

Remmoovvee the oil strainer screen and cleaann itt..

Reinstall the oil strainer screenn and right crankccaassee cover
(pagee 8-14).
Fillll the crankkccaassee with recommended enginee oill (paaggee 3-
1111))..

ENGINEE IDLE SPEED

"If the ennggine must be runnniinngg to ddoo ssome wwoorrkk,, mmaakkee
sure thee areeaa is wwellll veennttiillaatteedd.. NNeevver runn the eennggiinnee in
aan enclosed areeaa.. TThhee exhaust coonnttaaihns poisonous caarr--
bon mmoonnooxxiiddeegas that may cmausee loss off coonnsscciioouussnneessss
and may lead to deeaatthh.. RRuun the ennggine in aan open area or
withh aan exhhaauusst eevvaaccuuaattiioonn syyssteemm in ennccloseeddareeaa..

NOTE:
Inspeecctt and adjust the idle speed after all other engine
maintenance items have beeenn performed and are within
specificatioonnss..
The engine must bee warm for accurate idle speed in-
speccttioonn and adjustment. Tenn minutes of stop-anndd--ggoo
riding is sufficieenntt..

Warm up the engine for about ten minutes.
Turn the throttle stop screw as requireedd to obtain the speci-
fied idle speed.

IDLLEE SPEED:: 11.40ook± 110000 mimrr'' (rppmm))

3-122 http://mototh.com

RADIATORR COOLANT UUPPPPEERR -MMAAIINNTTEENNAANNCCEE

LEVVEELL CHECK I LLEEVVEELL RESERVEE TANK

'''''. .....;• WWaaiitt uunnttiill tthhee eennggiinnee iiss ccooooll bbeeffoorree rreemmoovviinngg tthhee rraa-- I LOWERR
ddiator ccaapp.. RReemmoovveetthheeccaappwwhhiilleetthheeeennggiinneeiss hot and LEEVVEELL

coolant is under preessssuurreemay caauusseeseerriioouuss sccaallddiinngg..
• RRaaddiiaattoorr ccoooollaanntt iiss ppOoiissoonnoouuss.. TTaakkeeccaarree too aavvooiidd ggeett--

tingg coolannt in your eeyyeess,, on your skin, or on your
clootthheess..
• "If ccoooollaanntt ggeettss iinn yyoouurr eeyyeess,, fflluusshh rreeppeeaatteeddllyy wwiitthh wwaa--
ter and conntaacct a doctor immmmeeddialatetelylr.
• "Ifccoooollaanntt iiss aacccciiddeennttaallllyy sswwaalllloowweedd,, iinndduuccee vvoommiittiinngg
and contact aa doctor immmmeeddiiaatteellyy..
• KEEP OUTRREACCHHOFF CCHHIILLDDRREENN..

Checkk the coolant leveell of the reserve tank with the en- RESERVE TANK CAP . \\ ,
gine runnnniinngg at normal operating temperature.
The levveell shouldd bee betweeeenn the "UPPER" andd "LOWER"
leveell lines with the motorcycle inn a vertical positioonn onn a
flat, level surface.

If necessary, removvee the driver seat (pagee 2-2),. then
remove the reserve tank cap and fill to the "UPPER" level
line w ith a 50-50 solutioonn of d istillleedd water and
recommennddeedd antifreeze (coolanntt mixture preparatiioonn;;
page 6-4).

CAUTION::

Using coolant with silicatee inhibitors may causseeprema-
ture wear of water pump saels off blockagee off radiator
passaggeess..
Using tap water may cause engine dammaaggee..

Check to see ifthere are any coolant leaks when the coolant
level decreases very rapidly.

IIffthe reserve tank becomes completely empty, there is a
possibility of air getting into the cCoOoOlilinng system.
Be sure to remove all air from the cooling system as de-
scribed on page 6-5.

http://mototh.com 3-13

MAINTEENNAANNCCEE

COOLING SYSTEMM

cii'iiW,,"'

Tooprevenntt innjjuurryy,, keep yourr hands and ccllootthhiinnggaway fromm

thhe cooolingfann.. Iht may start auttoommaattiiccaalllyy,,without warnn-

innga..

Check the radiator air passagee for clogging or damage.
Straighten bent fins with a small, flat blade screwdriver
and removvee insectss,, mudd or other obstructions with com-
pressedd air or low pressuurree water.
Replacee the radiator if the air flows is restriicctteedd over more
than 20% of the radiating surface.

For radiator replacemenntt,, refer to pagee 6-8..

Removee the right mmiiddddlleeccoowwl (paggee 2-4)..

Checkkfor any coolant leakagee fromm the water pump (pagee
6-122)),, water hosee andd hossee joints.
Makkee suurree the hosseess are iinn goodd condition; they should
not show any signs of deterioration.
Reeppllaacceeany hosee that shows any signn of deterioration.
Check that alll hosee clampss are tight.

Inssttaalll the right mmiiddddlleeccoowwll (paaggee 2-44))..

SEtCCUONNUDAAKRY AIRK SUPPLY SYSTEM

NNOOTTEE:
Thiss moddeell iss equipped builltt--iinn secondary air supply
system. The pulssee secondary air supply system is lo-
cated onn the cylinder headd cover.

* Thee secondary air supply system introduceess filtered air
into exhausstt gaseess inn the exhaust port.Thee secondary
air iss drawnn inttoo the exhaust port whenever there is
negattiivvee pressssuurree pulsee inn the exhaust system. This
chaarrggeedd secondary air promotes buurrnniinngg of the un-
burrnneedd exhaust gases anndd chaarrggeess a considerable
amount of hydrooccaarrbboonnss anndd carbboonn monoxide into
relativelyy haarrmmlleessss carrbboonn dioxiddee anndd watteerr..

RReemmoovvee thee fueell tank (ppaaggee 55--33))..

Chheecckkthee air injeccttiioonn hoosseess aanndd piippeess bbeettwweeeennthe pullssee
secondary air injeccttiioonn (PPAAIIRR)) connttrrooll valvvee anndd exhaust
ppoorrttfor deterioratioonn,, daammaaggeeoor loooosseeconnections. Makkee
surree that thee hoses aree nott craacckkeedd..

33-1144 http://mototh.com