Honda-CBR150R-Service-Manual-English

NOTE:: AIR SUCTION HO MAINTENNAANNCCEE

If the hoses show any signs of heat damage, inspect the PAIR CONTROL VALVE
PAIR check valves (paggee 5-17).

Check the air suction hose betweeenn the sub-air cleaner
and PAIR control valve for deterioration, damage or loose
connections. Make sure that the hoses are not kinked,
pinchedd or cracked.

For PAIRR control valve inspectioonn,, see page 5-15.

DRIVE CHAIN

DRIlVEE CHAAINN SLACK INSPEECCTTIIOONN

PM;';"',,'

Neverrinssppeeccttand adjust the drriivvee chhaaiinnwwhhiillee the enngginee
is runnniinngg..

Turn off the engine, placee the motorcycle onn its side stanndd
and shift the transmission intoo neutral.

Checkk the drive chainn slack inn the drive chaiinn lower runn
midway betweeeenn the sprockets.

CHAAIINN SLACK: 25 -- 35 mmmm (11.O0 -- 1.4 inn))

ADJUUSSTTMMEENNTT

Looosseenn the rear axlee nut.
Looseenn botthh lock nuts and tuurrnn bothh adjusting nuts unttiill
the correct drive chainn slack is obtained.
Makkee sure the index liness onn the bothh adjusters aree alignneedd
with tthhe rear edges of the axle slots inn the swingarm.

lTigighhtteenn botthh lock nuts.
lTigighhtteen the rear axle nut to the specifiedd torque.

TORQUE: 599 N.'mm (66..00 kkggf'.mm, 43 IbHf4tt))

RReecchheecckk the drive chhaaiinn slacckk andd free wheeeell rotationn.
Chheecckk the drive chhaaiinn wear indicator label.
IIf the arrow mmaarrkk of the chhaaiinn adjuusstteerr reaacchheess the reedd
zonnee onn the label, replace the drive chhaaiinn withh a neww onee
(paaggee 33--1177))..

http://mototh.com 3--1155

MMAIINTTENANCCEE

CLEEAANNIINNGG AND LUUBBRRIICCAATTIIOONN NON-FLAMMAABBLLEE OR HIGH-FFLLAASSHH FT BRUSH
POINT SOLVENTT
Cleeaann the chainn with non-flammable or highh flashh point
solvent and wipe it dry. CLEAANN
Bee sure the chainn hass driedd completely before lubricating.
Inspeecctt the drive chainn for possible damage or wear. WIPE AND DRY
Reppllaaccee any chainn that has damagedd rollers,, loose fitting
links, or otherwise appears unserviceable.
Iinstalling a new chain onn badly wornn sprockets will causee
the new chaiinn to wear quickly.
Inspect andd replace sprocket ass neceessssaarryy..

Lubricate the drive chainn with #800 -- 900 gear oil or drive

chainn lubricant designeedd specifically for use with aO--rriinng
chains. Wipe off the exceessss oill or chainn lubricant.

PRO HONDA CHAIN LUBE

SPROCKETS INSSPPEECCTTIIOONN

Inspect the drive and driven sprocket teeth for wear or
damage, replace iiffneceessssaarryy..
Never usee a new drive chain on worn sprockets.
Botthh chainn andd sprockets must bee inn good conditiioonn,, or
the new replacemmeenntt chaiinn will wear rapidly.

Check the attachingg bolts and nuts on the drive and driven
sprockets.
If any are loose, torque them.

TORRQQUUEE::
Driivvee sprocckkeettfiuxing ppllaatteeboolltt:: 1100 N·.mm (11.O0 kkggff·.mm, 7 Ibff-.ftt)
Driivveenn sspprroocckket nutt:: 64 N·.m (6.5 kkggff·.m, 47 IbfN+tt)

3-116 http://mototh.com

REPLAACCEEMMEENNTT MAINTEENNAANNCCEE

Remove the swingarm (page 15-10\).. OW fI. L!;VE MAR

Remove the two bolts and drive sprocket cover. 3--117
Remoovvee the drive chain.
Instaallll the new drive chain..

REPLLAACCEEMMEENNTTCHAIINN:: DID4288VV1133--112244LLEE

Instaallll the drive sprocket cover and tighten the bolttss..

Instaallll the swingarm (pagee 15-13\)..

BRAKE FLUID

CAUTION::
• Do not mix different tyyppess of fluuiidd, as they are not coomm--

patibblle with each otthheerr..
• Do not allow foorreiiggnnmmateriall to enter thhe syssttem wwhheann

filllliinngg thhe reservvooiirr..
• Avoidd spilling fluid on painted, plastic or rubber parttss.

Place a rag over thhessee parts wwhhennever thhe ssyyssttem is
sserrvviicceedd..

NOTE:
When the fluid levell is low, check the brakkee pads for wear
(paggee 3-20\).. A low fluid leveell may bee due to wear of the
brake padss..Ilftthe brakkee pads are worn, the caliper pistonnss
are pusshheeddout, andd this accounts for a low reservoir level.
If the brakkee pads are not worn and the fluid levell is low,,
check entire syvstemm for leakss (bpaaage 3-20\)..

FRONTT BRAAKKEE

Turn the handlebar to the left side so that the reservoir iss
leveell and check the fluid through the sight glasss..
if the level is near the lower leveell mark, removvee the screws,
cover, set plate and diaphragm, and ffiillllthe reservoir with
DOTT3 or 4 brakee fluid from a sealedd container to the upper
level.

Instaallll the diaphragm, set plate and cover and tighten the
screws.

TORQUE:: 11.55 N·mm (0.155 kkggff·.m, 1.1 l1bbHf.Rt)l

REAARR BRAAKKEE

Placcee the motorcycle on a leveell surface, andd support it
upright.
Check the fluidd level inn the rear brakee reservoir.
If the leveell is near the lower leveell line, removvee the bolt
and reservoir withh the brakee hose connected.
Remove the screws, cover, set platee and diaphragm and
filll the reservoir withh DOT 3 or 4 brake fluid fromm a sealeedd
container to the upper levell line.

Installl the diaphragm, set plate, cover and tighten the
screws to the specifieedd torque.

TORQUUEE:: 1.5 N·.m (0.15 kggff·m, 1.11 I1bbHf.ht\)

Instaallllthe reservooiirr tank onto the stay and tighten the bolt.

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MAINTENANCE

BRAKE PAD WEAR

FRONTT BRAKEE PAD

Check the brake pad for wear.
Replaccee the brake pads if either pad is worn to the bottom
of wear limit groove.

Refer to page 16-55 for front brake pad replacement.

OR

REAR BRAKKEE PAD I WEARININDDIICCAATTOOR I

Check the brake pads for wear. ~
Replaccee the brake pads if the wear limit groove of either
padd is worn out.

Refer to page 166--66for rear brake padd replacement..

BRAKKEE SYSTEEMM LIGHT SWITCH

INSPPEECCTTIIOONN

Firmly apply the brakkee lever or pedal, andd check that no air
hass entereedd the system.
IIff the lever or peddaall feels soft or spongyy whenn operated,
bleeedd the air from the system.

Inspect the braakkee hossee anddfittings for deterioratiioonn,, crackkss
anndd siiggnnss of leaakkaaggee..
Tightenn any looossee fittings.
Reeppllaaccee hosseess anndd fittings ass required.

Reeffeerr too paggee 1166--33for brraakkee bleeeddiinngg procedures.

BRAAKKEE LIGHHTT SWITCCHH

NOTE:
Thee front brakkee lighhtt switchh doeess nnoott reqquuiirree adjustment.

Adjust thhee bbrraakkee lliigghhtt sswwiittcchh ssoo that thee bbrraakkeelliigghht commeess
oonn just pprrior too tthhee bbrraakkee aacctually bbeeiinngg eenngaged.
IIffthhee lliigghhttfaaiillss too ccoommee oon, aaddjust thee sswwiittcchh ssoo that the
lliigghhttccoommeess oonn aatt thhee pprroopper time .
HHoolldd tthhee sswwiittcchh bbooddyy aanndd tuurrnn tthhee aaddjuster.. DDoo nnoott turrnn
thhee sswwiittcchh bbooddyy..

33--1188 http://mototh.com

HEADLIGHT AAIM MMAAIINNTENANCE

''Iii.fi.Jil.J' ADJUSTING SCREW

AAnn iimmpprrooppeerrllyy aaddjjuusstteeddhheeaaddlliigghhtt mmaayy bblliinndd oonn--ccoommiinng 100 -- 20 mmm (0.4 -- 0.8 in)
ddrriivverrss, oorriittmmaayyffaallllttoo lliigghhtttthhee rrooaaddffoorraa ssaaffeeddiistanccee. ADJUSTER

NNOOTE:
AAddjjuusstt tthhe hheeaaddliigghhtt bbeam aas ssppecified bbyy llocal lIaIIWwSs aand
rreeogulations.

PPlace tthhee mmootorcycle oon aa lleevel ggrroouunndd..

AAddjjuusstt tthhee hheeaaddlliigghhtt bbeam vveerrttiiccaallllyy bby llooosening tthhee
screeww and move tthe headligght unit.

CLUTCH SYSTEM

Check the cable and clutch lever ffoorr loose connnneeccttiioonnss,,
excessive play,, or other damagee..
Replace or repair if necessary.
Inspect the clutch cable for kinks or damage, and lubri-
cate the cable.

Measure the free play at the tip of the clutch lever. I

-FREEE PLAAYY: 10 -- 20 mmm (31/88 - 13/166 in)

Adjust as follows:
Minor adjustment can be done with the upper adjuster.
Looseenn the lock nut and turn the adjuster.
After adjustment,, tighten the lock nut.

MMaajoor adjustment aree maade'witthh thee lower adjuussttiinngg nut. 33--1199
IIftthhe maajor adjustmmeenntt iss required, ttuurrnnthee uuppppeerradjuster
allll the way iinnanndd baacckk out 17 turn..
lLoooosseenn the lockk nut anndd adjuussttiinngg nnuutt anndd ttuurrnn thee
adjustingg nuutt too adjust freeee pllaayy..
TTIigghhtteenntthhee uuppppeerr aanndd lloower lloocckk nnuuttss..
CChheecckktthhee cclluuttcchh ooppeerraattiioonn..

IIff thhee ffrreeee ppllaayy ccaannnnoott bbee oobbtained, oor tthhee cclluuttcchh sslliippss
duurriinngg teesstt rriiddee,, ddisassemble aanndd iinnspect thhee cclluuttcchh
((sseeccttiioonn88))..

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MAIINNTTEENANCE

SIDE STANDD

Support the motorcyccllee onn a levveell surfacee..
Checkk the side standd spring for damage or loss oftteennssiion.
Checkk the side stand assembly for freedom of movement
andd lubricatee the side stanndd pivot if necessary.

SUSPENNSSIIOONN

''''.;;''''.LLoooosse, wwoorrnn or ddammagedssuspenssiioonnparts impair mootoorr-

ccyycclleesstability andconnttrrooll..Repair or reppllaacceeanyy damaged
ccoommppoonneennttssbbefoorre riiddiinngg..Ridinnggaa mmoottoorrccyycclleewwiithhfaulty
ssuussppeennssiioonn innccrreeaasseess your risk of an accident and pos-
ssiibbllee innjiuurryv..

FROONNTT SUSSPPEENNSSIIOONN INSSPPEECCTTIIOONN

Check the actionn of the forks by operating the front brake
andd compresssiinngg the front suspension several times.
Checkk the entire assembly for signs of leaks, damage or
lloooosse fasteners.
Replaaccee damaggeedd components which cannot be repaired.
Tighteenn alll nuts andd bolts.
Refer to sectioonn 144 for fork service.

REARR SSUSPENSSIIOON INSPPEECCTTIIOONN

Checkk the action of the rear shock absorber by compressss--
ingg the rear endd severaall times.
Cheecckkthe entireeshhoocckk.aabbsorber assemblyyfor leaks or dam-
age.
Tighten alll nut andd bolts.

Support the motorcycle securely andd raise the rear wheel
off the ground.
Checkk for worn swingarm bushings by grabbing the rear
wheell andd attempting to move the wheell side to side.
Reppllaacceethe swing arm if any looseness iss noted.

33--2200 http://mototh.com

MAIINTENANCCEE

Check for worn wheel bearing by grabbing the rear wheel,,
and attempting to move the wheel side to side.
Replaccee the bearinggss if any looseness is notedd (paggee 15--
61).

NUTS, BOLTS, FASTENERS 33--2211

Check that all chassis nuts and bolts are tightened to their
correct torque values (page 1-13).
Check that all safety clips, hose clamps and cable stays
are in placee and properly secured.

WHEELS/TIRES

NOTE::
Tire pressure should be checked when the tires are COLLDD..
RECOMMMEENNDDEEDD TIRE PRESSUURREE AND TIRE SIZE:

Driver only:
Front: 200 kppa (22..0000 kgflcndt, 29 pssii))
Rear: 200 kpa (22..0000 kggff/lccmd,. 29 psi1)

Driver and passsennggeerr::
Frontt:: 200 kppa (2.0000 kgff/lcmnl,. 29 pssii))
Rear: 225 kpa (2.25 kggff/lccmd. 333 pssii))

Checkk the tires for cuts,. embedded nails, orr other damaggee..
Check the front and rear wheels for trueness (refer to
section 14 and 15))..
Check the tread depth.
Replacee the tires when the tread depth reachheess the fol-
lowingg limits.

MMINNIMMUUMM TREAD DEPTHH:: To the indicator

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MAINTENANNCCEE

STEERIINNGG HEADD BEARINNGGSS

NOTTE::

Checckkthat thhe connttrrooll cablleess do not inntteerrffeerreewith handdllee--
bar roottaattiioonn..

Support thhee moottoorrccyycclleesecurrellyyandd raiisseethhe fronnttwheel
off thhe groouunndd.
Checckk that thhe handdllebbarr moovveessfreely froomm siiddee to siiddee..
If the handllebbar moves unevennllyy,, bindss, or hass vertiiccaall
movvement, insppect the steerriinngg headd beariinnggss (Sectiioonn
14))..

33--2222 http://mototh.com

LUBBRRICAATTION SYSTEM

LUBRIlCAT1IO0NN SYSTEM DIAGRAAMM

44--00 U

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4. LUBRICATION SYSTEM

LUBBRRIICCAATTIIOONN SYSTEM DIAGRAAMM 4--00 TROUBLLEESSHHOOOOTTIINNGG 44--11
SERVICE INFORMAATTIIOONN 4--11 OIL PUMP 4-2

SERVICE INFORRMMAATTIIOONN

GENERAALL

''';.;;'''.. ImI ]a• "Ifththee eennggiinnee musst be runnnniinngg to ddoo ssoomee wwoorrkk., mmaakkeesuree thee areaa is well veennttiillaatteedd..NNeever run the engginee in aan
eenncclosed aarreeaa.. TThhee eexxhhaauusstt ccoonnttaaiinnssppooisonous caarbboonn mmoonnooxxiiddeegas that may caaussee loss off connssccioouussnneessss and
mmay lead to ddeeaatthh.. RRuunn thhee eennggiinnee inn aann open areaa or withh aan exhaust evaaccuuaattiioonn system in enclosed areeaa..
I UUsseedd eennggiinneeoil mmay ccaaussee sskkiinn ccaancer iff repeaateddly left in coonnttaacctt withh the skin for prolongeddpeerriooddss..Although

thhiss is uunnlliikkeellyyuunnlleessss you hhaannddlee uused oil on aa daily basis, it is still addvvissaabbllee to thorougghhlyy wwaasshh yourr hands withh
ssooaapp and wwaatteer aas ssoooonn aas poossssible after haannddlliinngg used oiill.. KKEEP OUT OF RREACH OF CCHHIILLDDRREENN..

* The oill pummpp cann bee serviced with the engine installeedd inn the frame.
* The service proceedduurreess inn this sectiioonn must be performed with the engine oil drained.
* When removing and installinngg the oill pump, use caree not to allow dust or dirt to enter the engine.
* If any porttiioonn of the oill pummpp iss worn beyonndd the specified service limits, replace the oil pumpp as an assembly.
* After the oill pummpp hass beeenn installed, check that there are no oil leaks.

SPECCIIFFIICCAATTIIOONNSS

Unniitt: mmmrn((inii)

ITEEMM STANDAARRDD SERVVIICCEE LLIMMIITT

Engine oill capacittyy At draining 1.0 liter (1.06 US qt, 0O.8.S8SIlmpp qt) ---
Reccoommmmeennddeeddenginnee oill At disassemblyy ---
1.3 liter (1.37 US qt, 1.1441Imp qt)
Oill pummpp rotor lTiipp clearance ---
Bodyy clearancee Honda 4-stroke oil or equivalent
Side clearance motor oill 0.20 (O0.O0O08S)
API service classificattiioonn SE, SF or SG 0.26 (0.010)
Viscosity: SAE 1O0WW--3300 0.15 (0.006)

---

0.150 -- 0.21100 (0.0059 -- 0.00S83)

-0.050 - 0.10000 (0.0020 -- 0.0040)

TORQQUUEE VAALLUUEESS 5.2 N·mm (0.53 kgff.m, 3.S8 I1bbff·.Rft)

Oill pumpp bolt

TROUBLESSHHOOOOTTIINNGG

Engiinnee oill levveell too low
Normall oill consummppttiioonn

-* Exteerrnnaall oill leak
Worn pisttoonn rinngg or incorrect pistonn ringg installation
Worn valve guide or seaall

Oill contamination
* External oill leakk

- Worn pistonn rinngg or incorrect pistoonn rinngg installation
Worn valve guide or seaall
Clogged oill strainer screen

http://mototh.com 44--1I

LUBRICCAATTIIOONN SYSTEM

O01IL1PUMMPP

REMOVAL

Draiinn tthhee eennggiinnee ooiill (paaggee 3-111))..
Remoovvee the righhtt crrannkkccaassee ccoovveer (paaggee 8--33))
Remoovvee thhe thhrreeee bollttss andd oiill pump assseemmbbllyy..

Remoovvee thhe dowwell piinnss..

DISAASSSSEEMMBBLLYY

Remoovvee thhe E-cliipp..

Remoovvee thhe oiill pump shhafftt andd gearr.. 011. PUMP COVER stlAFTIG AI'!
Remoovvee the two boollttss andd oill pump coovveerr..

eOLTS

44--22 http://mototh.com

LUBBRRIICCAATTIIOONN SYSTEM

___ ~ ___~ ~ ~~

Remmoovvee the inner andd outer rotors.

INSSPPEECCTTIIOONN 44--33

Temporarily instaallll the outer andd inner rotors into the oill
pump body.
Instaallll the oil pump shaft.
Measure the tip clearraannccee betwweeeenn the inner and outer
rotors.
SERVICCEE LLIIMMIITT:: 0.2200 mmmm (0..000088 inn))

Measuurree the body clearaannccee betweenn the outer rotor andd
pump body.
SERVICCEE LIMMIITT:: 0.26 mmmm (0.010 in))

Measure the side clearraanncceeusing a straight edge and feeler
gauge.
SERVICEE LIMIT:: 00.15 mmmm (00..000066 inn))

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LUBBRRIICCAATTIIOONN SYSTEEMM -~ ~-

ASSSEEMMBBLLY OUTER ROTOR
INNER ROTOR
E-CLIP

OIL PUMP SHAFT

OIL PUMP BODY

OIL PPUUMMPP DRIIVVEENN GEARR
LOCK PPIINN

Insttallll the oiill pump shaft lockk piinn innttoothhe oill pummpp shhafftt..
Inssttaallllthhe oil pummpp shaft into thhe oil pummpp driivveenn gearr.. Oil PU MP DfirVEN GEAR

OIL PU MP S~!,AFT

Inssttaallllthhe outter rotor andd innnnerr rroottoorr.. LOOK PIN
Fillll thhe oiill pump with enginne oill.
•

44--44 OUTER ROTOR
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Instaallll the oil pump cover onto the oill pump body. LUBRICATION SYSTEM
Temporally installl the dowel pins and tighten the two bolts BOLTS
to the specified torque.
•
TORQUE: 55..22 N·.m ((00..5533kgff·.m, 33..88 Ibf·4ht))

DOWEL PIN S

Instaallll the oil pump shaft into the oil pump body aligning AUGN
the flats betweenn the shaft and inner rotor.

Securee the oil pump shaft with E-clip.

INSTALLLAATTIIOONN 44--55

Installl the dowel pins.

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LUBBRRIICCAATTIIOONN SYSTEM

Insttaallll andd tighhtten the thrreee bollttss secuurreellyy..
Cleann the oil strainer scrreeeenn (paggee 3--1122))..
Insttaallll the right crankkccaassee cover (paggee 88--1144))
After innssttaallllaattiioonn,,filll the crrannkkccaasseewith recommmmeennddeedd oil
(paggee 33--1100))and checkk that there are no oil leakkss..

44--66 http://mototh.com

FUEL SYSTEM

5-20 http://mototh.com

5. FUEL SYSTEM

SERVICE INFORMATION 5-1 CARBURETOR DISASSEMBLY 5-6
TROUBLESHOOTING
FUEL TANK 5-2 CARBURETOR ASSEMBLY 5-9
AIR CLEANER HOUSING
SUB-AIR CLEANER 5-3 CARBURETOR INSTALLATION 5-13
CARBURETOR REMOVAL
5-4 PILOT SCREW ADJUSTMENT 5-14

5-4 SECONDARY AIR SUPPLY SYSTEM 5-15

5-4

SERVICE INFORMATION 5

GENERAL

• Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
• 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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored
can cause a fire or explosion.

CAUTION:
• Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms

might be damaged.
• Do not remove the sub-air cleaner tube joint except the replacement.

• Before disassembling the carburetor, place an approved fuel container under the float chamber, loosen the drain
screw and drain the carburetor.

• After removing the carburetor, cover the intake port of the cylinder head with shop towel to prevent any foreign
material from dropping into the engine.

• When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on
reassembly.

• The float chamber can be serviced with the carburetors combined.

SPECIFICATIONS

ITEM SPECIFICATIONS
Carburetor identification number VK6AA
Main jet #115
Slow jet #35
Pilot screw opening
Float level See page 5-14
Idle speed 13 mm (0.5 in)
Throttle grip free play 1,400 ± 100 min–1 (rpm)
2 – 6 mm (1/12 – 1/4 in)
TORQUE VALUES
5.2 N·m (0.53 kgf·m, 3.8 lbf·ft)
Reed valve cover bolt
07401 – 0010000
TOOL

Float level gauge

http://mototh.com 5-1

FUEL SYSTEM Engine stalls, hard to start, rough idling
• Restricted fuel line
TROUBLESHOOTING • Fuel mixture too lean/rich
• Contaminated/deteriorated fuel
Engine cranks but won’t start • Intake air leak
• No fuel in tank • Misadjusted idle speed
• No fuel to carburetor • Misadjusted pilot screw
• Clogged air cleaner
— Clogged fuel strainer • Clogged slow circuit
— Clogged fuel line • Starting enrichment valve open
• Too much fuel getting to the engine • Faulty ignition system (section 18)
— Clogged air cleaner
— Flooded carburetor Afterburn when engine braking is used
• Intake air leak • Lean mixture in slow circuit
• Contaminated/deteriorated fuel • Faulty ignition system (section 18)
• Improper choke operation
• Improper throttle operation Backfiring or misfiring during acceleration
• No spark at plug (faulty ignition system-section 18) • Lean mixture
• Faulty ignition system (section 18)
Lean mixture
• Clogged fuel jets Poor performance (driveability) and poor fuel
• Faulty float valve economy
• Float level too low • Clogged fuel system
• Restricted fuel line • Faulty ignition system (section 18)
• Clogged carburetor air vent tube
• Intake air leak
• Faulty vacuum piston

Rich mixture
• Starting enrichment valve open
• Clogged air jets
• Faulty float valve
• Float level too high
• Dirty air cleaner
• Faulty vacuum piston

5-2 http://mototh.com

FUEL TANK FUEL TANK FUEL SYSTEM

REMOVAL/INSTALLATION BOLT

Remove the driver seat (page 2-2). COLLAR

Remove the bolt and collar.
Raise the rear of fuel tank while releasing the bosses of
the rear cowl from the grommets of the fuel tank.
Pull the fuel tank backward and support it.

Disconnect the fuel unit 3P connector.

FUEL UNIT 3P CONNECTOR

Disconnect the fuel and vacuum tube from the fuel auto FUEL TUBE FUEL AUTO VALVE
valve.

Installation is in the reverse order of removal.

VACUUM TUBE

FUEL AUTO VALVE INSPECTION VACUUM PUMP

Remove the fuel tank (See above).

Connect a commercially available vacuum pump to the
diaphragm vacuum outlet.
Fuel should flow out from the fuel tube when vacuum is
applied.
If fuel flow is restricted, replace the fuel auto valve.

FUEL AUTO
VALVE

http://mototh.com 5-3

FUEL SYSTEM FUEL OVERFLOW TUBE

AIR CLEANER HOUSING

REMOVAL/INSTALLATION

Remove the fuel tank (page 5-3).

Disconnect the crankcase breather, crankcase breather
drain and fuel overflow tubes.
Loosen the caburetor connecting tube band screw and dis-
connect the connecting tube from the carburetor.

Remove the air cleaner mounting bolts and air cleaner
housing.

Installation is in the reverse order of removal.

CRANKCASE BREATHER CRANKCASE
DRAIN TUBE BREATHER TUBE

SUB-AIR CLEANER SUB-AIR CLEANER
TUBES
REMOVAL/INSTALLATION

Remove the following:
— fuel tank (page 5-3)
— air cleaner housing (See above)

Disconnect the tubes.
Remove the sub-air cleaner from the frame.

Check the element and replace if necessary.

CARBURETOR REMOVAL BOLT

Remove the following:
— fuel tank (page 5-3)
— air cleaner housing (See above)

Remove the mounting bolt and PAIR control valve with
the tubes connected.
Disconnect the air injection hose from the cylinder head
cover.

AIR INJECTION HOSE PAIR CONTROL VALVE

5-4 http://mototh.com

Loosen the throttle cable adjusting nut and disconnect the FUEL SYSTEM
throttle cable end from the throttle drum.
ADJUSTING NUT

Loosen the nut and remove the starting enrichment (SE)
valve and washer from the carburetor body.

NUT VALVE/WASHER

Loosen the insurator band screw.
Remove the carburetor.

INSURATOR BAND
SCREW

Disconnect the fuel, air vent and drain tubes. FUEL TUBE

AIR VENT TUBE DRAIN TUBE
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5-5

FUEL SYSTEM COVER
SPRING
CARBURETOR DISASSEMBLY

VACUUM CHAMBER

Remove the two screws and vacuum chamber cover.

NOTE:
As the compression spring is very long, it will jump out of
the carburetor when the cover is removed.

SCREWS

Remove the compression spring and diaphragm/vacuum DIAPHRAGM/
piston from the carburetor body. VACUUM PISTON

Remove the needle holder. HOLDER
Remove the spring, jet needle and washer from the
vacuum piston.

Check the following: DIAPHRAGM/VACUUM PISTON
— jet needle for stepped wear JET NEEDLE
— vacuum piston for wear or damage HOLDER
— diaphragm for pin holes, deterioration or damage

NOTE:

Air can leak out of the vacuum chamber if the diaphragm
is damaged in any way, even if only a pin hole.

WASHER SPRING

5-6 http://mototh.com

FUEL SYSTEM

Throttle cable stay SCREWS STAY
Remove the two screws and throttle cable stay.

Air cut-off valve SCREWS O-RING

Remove the two screws. COVER DIAPHRAGM SPRING
Remove the valve cover, spring, O-ring and diaphragm.

NOTE:
The air cut-off valve cover is under spring pressure.

Check the following:
— diaphragm for pin holes, deterioration or damage
— spring for deterioration
— needle of diaphragm for wear
— air passages for clogging

Starting enrichment (SE) valve cover COVER

Remove the two screws/wahsers.
Remove the valve cover and O-ring.

SCREWS/WASHERS O-RING
SCREWS
FLOAT CHAMBER

Remove the three screws and float chamber cover.

http://mototh.com COVER

5-7

FUEL SYSTEM PIN FLOAT
MAIN JET
Remove the float pin, float and float valve. FLOAT VALVE
Check the float for damage or fuel in the float. SLOW JET
Check the following:
— valve and valve seat for scoring, scratches, clogging or

damage.
— tip of the float valve, where it contacts the valve seat,

for stepped wear or contamination.
— operation of the float valve.

Remove the main jet, needle jet and slow jet.
CAUTION:
Handle the jets with care. They can easily be scored or
scratched.

Turn the pilot screw in and carefully count the number of PILOT SCREW/
turns until it seats lightly. Make a note of this to use as a SPRING/
reference when reinstalling the pilot screw. WASHER/
O-RING
CAUTION:
Damage to the pilot screw seat will occur if the pilot screw
is tightened against the seat.

Remove the pilot screw, spring, washer and O-ring.

Check each jet for wear or damage.
Check the pilot screw for wear or damage.

O-RING

SPRING NEEDLE JET
SLOW JET
PILOT MAIN JET
SCREW

5-8 WASHER
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FUEL SYSTEM

CARBURETOR CLEANING

Remove the following:
— diaphragm/vacuum piston
— main jet, needle jet and slow jet
— pilot screw
— air cut-off valve

CAUTION:
Cleaning the air and fuel passages with a piece of wire
will damage the carburetor body.

Blow open all air and fuel passages in the carburetor body
with compressed air.

CARBURETOR ASSEMBLY SPRING DIAPHRAGM/
JET NEEDLE VACUUM PISTON
STAY VACUUM
DIAPHRAGM CHAMBER COVER

WASHER

AIR CUT OFF
VALVE COVER

O-RING SPRING SPRING
PIN NEEDLE
FLOAT VALVE HOLDER
FLOAT O-RING
STARTING
O-RING ENRICHMENT(SE)
VALVE COVER
SLOW JET SPRING
PILOT SCREW
FLOAT DRAIN O-RING NEEDLE JET
CHAMBER SCREW MAIN JET WASHER NEEDLE JET

O-RING SLOW JET

FLOAT CHAMBER MAIN JET

Install the pilot screw and return it to its original position O-RING 5-9
as noted during removal.
Perform the pilot screw adjustment if new pilot screw is SPRING
installed (page 5-14). PILOT
SCREW
CAUTION:

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

• Handle the jets with care. They easily be scored or
scratched

WASHER

Install the needle jet, main jet and slow jet.

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FUEL SYSTEM FLOAT

Hang the float valve onto the float arm lip.
Install the float valve, float and float pin.

FLOAT LEVEL INSPECTION PIN FLOAT VALVE
O-RING FLOAT LEVEL GAUGE
NOTE:
Set the float level gauge so that it is perpendicular to the
float chamber face at the highest position of the float.

With the float valve seated and the float arm just touching
the valve, measure the float level with the float level gauge.

TOOL: 07401 – 0010000
Float level gauge

FLOAT LEVEL: 13 mm ( 0.5 in)

The float cannot be adjusted.
Replace the float assembly if the float level is out of
specification.

Install a new O-ring into the groove in the float chamber
cover.

Install the float chamber cover and tighten the three COVER
screws. SCREWS

COVER

5-10 http://mototh.com

Starting enrichment (SE) valve cover FUEL SYSTEM
Install a new O-ring to the valve cover.
Install the valve cover to the carburetor body. COVER

Install and tighten the two screws/washers securely. O-RING

SCREWS

Air cut-off valve SCREWS

Install the diaphragm to the carburetor body. COVER
Install a new O-ring, spring and cover.
Tighten the screws securery. O-RING

DIAPHRAGM SPRING COVER

Throttle cable stay SCREWS STAY

Install the throttle cable stay and tighten the two screws
securely.

http://mototh.com 5-11

FUEL SYSTEM DIAPHRAGM/VACUUM PISTON
JET NEEDLE
VACUUM CHAMBER HOLDER

Install the jet needle with washer into the vacuum piston.
Install the spring onto the needle holder and set the needle
holder into the vacuum piston.

WASHER SPRING

Install the needle holder by aligning the cut-out of the DIAPHRAGM/ ALIGN
holder and boss of the vacuum piston. VACUUM
PISTON

ALIGN HOLDER
COVER
Install the diaphragm/vacuum piston into the carburetor DIAPHRAGM/VACUUM PISTON
body.

Lift the bottom of the piston with your finger to set the
diaphragm rib in the groove in the carburetor body, and
install the spring and vacuum chamber cover.

CAUTION:
Be careful not to pinch the diaphragm under the chamber
cover.

SPRING SET

Install and tighten the two screws securely.

5-12 SCREWS
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CARBURETOR INSTALLATION FUEL SYSTEM

Connect the fuel, air vent and fuel drain tubes. FUEL TUBE

AIR VENT TUBE DRAIN TUBE

Install the carburetor into the insulator by aligning the ALIGN
carburetor boss with insulator boss.
Tighten the insulator band screw.

Check the starting enrichment (SE) valve for scoring, WASHER SCREW
scratches or wear.
Check the seat at the tip of the SE valve for stepped wear. NUT
Replace the SE valve set if necessary. ADJUSTING NUT

Installation is in the reverse order of removal.

After the installation, check for the smooth operation of
the choke lever (page 3-5).

VALVE

Connect the throttle cable end to the throttle drum and
tighten the adjusting nut.

http://mototh.com 5-13

FUEL SYSTEM BOLT

Connect the air injection hose to the cylinder head cover.
Install the PAIR control valve and tighten the bolt.

Install the following:
— air cleaner housing (page 5-4)
— fuel tank (page 5-3)

Adjust the throttle grip free-play (page 3-4).

AIR INJECTION HOSE PAIR CONTROL VALVE

PILOT SCREW ADJUSTMENT PILOT SCREW

IDLE DROP PROCEDURE VACUUM TUBE VACUUM
PUMP
NOTE:
• The pilot screw is factory pre-set and no adjustment is

necessary unless the carburetor is overhauled or the
pilot screw is replaced.
• Use a tachometer with graduations of 50 min-1 (rpm) or
smaller that will accurately indicate a 50 min-1 (rpm)
change.

1. Turn the pilot screw until it seats lightly, then back it
out to the specification given.
This is an initial setting prior to the final pilot screw
adjustment .

CAUTION:
Damage to the pilot screw seat will occur if the pilot screw
is tighten against the seat.

INITIAL OPENING: 2-1/8 turns out

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

3. Stop the engine and connect the tachometer, accord-
ing to the manufacturer's instructions.

4. Disconnect the vacuum tube of PAIR control valve, then
it connect the vacuum pump and plug the vacuum port.

5. Apply the specified vacuum to the PAIR control valve
vacuum tube more than 37 kPa (280 mmHg).

PLUG

5-14 http://mototh.com

6. Start the engine and adjust the idle speed with the FUEL SYSTEM
throttle stop screw.
THROTTLE STOP SCREW
TENTATIVE IDLE SPEED: 1,400 ± 100 min–1 (rpm)

7. Turn the pilot screw in or out slowly to obtain the high-
est engine speed.

8. Lightly open the throttle 2 or 3 times, then adjust the
idle speed with the throttle stop screw.

9. Turn the pilot screw in until the engine speed drops by
50 min-1 (rpm)

FINAL OPENING: 3/4 turns out

10. Disconnect the plug from the vacuum port, then
remove the vacuum pump and connect the vacuum
tube of PAIR control valve.

11. Readjust the idle speed with the throttle stop screw.

IDLE SPEED: 1,400 ± 100 min–1 (rpm)

SECONDARY AIR SUPPLY SYSTEM

SYSTEM INSPECTION AIR INTAKE PORT

Start the engine and warm it up to normal operating PAIR CONTROL VALVE
temperature. VACUUM PUMP
Remove the fuel tank (page 5-3).
Check that the secondary air intake port is clean and free 5-15
of carbon deposits.
Check the pulse secondary air injection (PAIR) check valves
if the port is carbon fouled.

Disconnect the PAIR control valve vacuum tube from the
cylinder head.
Connect the vacuum pump to the PAIR control valve
vacuum tube.

Start the engine and open the throttle slightly to be cer-
tain that air is sucked in through the air supply hose.
If the air is not drawn in, check the air supply hose for
clogging.

With the engine running, gradually apply vacuum to the
PAIR control vale vacuum tube.
Check that the air supply hose stops drawing air, and that
the vacuum does not bleed.

SPECIFIED VACUUM: 37 kPa (280 mmHg)

If the air is drawn in or if the specified vacuum is not main-
tained, install a new PAIR control valve.
If afterburn occurs on deceleration, even when the sec-
ondary air supply system is normal, check the air cut-off
valve.

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FUEL SYSTEM BOLT

PAIR CHECK VALVE INSPECTION

Remove the following:
— fuel tank (page 5-3)
— air cleaner housing (page 5-4)

Remove the bolt and PAIR control valve with the tubes
connected.
Disconnect the air injection hose from PAIR check valve
cover.

AIR INJECTION HOSE PAIR CONTROL VALVE

Remove the two bolts and PAIR check vale cover from the COVER
cylinder head.
REED VALVE
Check the reed for damage or fatigue. Replace if neces-
sary.
Replace the PAIR check valve if the seat rubber is cracked,
deteriorated or damaged, or if there is clearance between
the reed and seat.

Install the PAIR check valve and cover onto the cylinder BOLTS COVER
head cover. REED VALVE

Install and tighten the two bolts to the specified torque.

TORQUE: 5.2 N·m (0.53 kgf·m, 3.8 lbf·ft)

Install the removed parts in the reverse order of removal.

BOLTS

5-16 http://mototh.com

COOLING SYSTEM

SYSTEM FLOW PATTERN

6--00 http://mototh.com

6. COOLING SYSTEM

SYSTEM FLOW PATTEERRNN 6-0 THHEERRMMOOSSTTAATT 6-6
SERVICE INFORMATION 6-11 RADIATOR/COOLLIINNGG FAN 6-8
TROUBLESHOOTING 6-2 RADIATOR RESERVE TAANNKK 66-12
SYSTEM TESTING 6-3 WATER PUMP 66-12
COOLANT REPLAACCEEMMEENNTT 6-44

SERVICE INFORMAATTIIOONN

GENERALL

"!. ....iiN E
• Waaiittuntil the engine is cool before slowly removing the radiaattoorr cap. Removing the cap while the engine is hot andd

the coolant is under pressure may cause serious scaldinngg..

-• Radiatoorr coolant is toxic.. Keep it away from eyes, mouthh,, skin andd clothes.
-IIff any coolant gets in your eyes, rinse them with water andd consultt a doctoorr immediately.

---IIf f any coolant is swalloowweedd,, inducee vomiting, garglee andd consult a physician immeddiaateelyy.

-IIff any coolant gets on your skin or clothes, rinse thoroughly with plentyy off wateerr..
• KEEP OUT OF REACH OOF CHHIILLDDRREENN..

CAUTION:

Usinngg Coolant with silicatee inhibitors may caussee premature wear off water pump seals or blockage off radiaattoorr pas-
saaggeess..
Usinngg tap water may cause engine dammaaggee..

* Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
* All cooling system services can be done with the engine in the frame.
* Avoid spilling coolant on painted surfaceess..

After servicing the system, check for leaks with a cooling system tester.
* Refer to Sectiioonn 20 for fann motor switch andd thermosensor inspection.

SPECCIIFFIICCAATTIIOONNSS

ITEEMM SPECIFICATTIIOONNSS

Coolant capacittyy Radiator andd engine 0.766 liter (0.20 US qt, 0.17 Imp qt)
Reseerrvvee tank 0.24 liter (0.06 USS qt, 0.05 Impp qt)
Radiator cap relief presssuurree 108 kPaa (11..11 kgf/cm2',, 16 psi))
Thermostat Beggiinn to openn
Fully openn 69.55 --7722..55"C (15577..11 --116622.5.5""FF))
Valve lift
80°C (176°°FF))
3.5 mm (0.14 in)) minimum

http://mototh.com 66--11

CCOOOOLLING SSYYSSTTEEMM 1100 NN.·mm ((1100 kkggfm.m,, 77IIbbff..fftt))
TTOORRQQUE VVAALLUUEESS

WWaatteerr ppuummpp iimmppeellleerr

TTOOOOLS 0077774499 -- 000011000000
00779945 -- 44115500440000
DDrriivveerr
AAttttaacchhmmeenntt,, 336 mmm

TROUBLESHOOTIINNGG

EEnngine tteemmpperature ttoooo hhigh

- Faulty tteemmppeerraattuurree innddiiccaattoorr oorr tthheerrmmoo sswwiittcch ((ssection 2200)
- Faulty radiator cap
- Insufficient cooolaanntt

Passages bblocked in raaddiiaattoorr,, hoses oorr wwaatteerr jjaacckkeett
Airr in system
* Faulty water pump
* Thermostat stuck closed
Faulty cooling fan motor
* Faulty fan motor switch

Engine temperature too low
Faulty temperature indicator or thermoo switch (sectionn 20)
Thermostat stuck open
Faulty cooling fan motor switch

Coolant leaks
Faulty water pump mechaanniiccaall seal

-* Deteerriioorraatteedd O-rinngg
Dammaaggeedd or deteriorated gasket
* Looossee hose connection or clamp
•* Daammaaggeeddor deteriorated hoossee
• FFaauullttyy raaddiiaattoorr ccaapp

66--22 http://mototh.com

COOLING SYSTEM

SYSTEM TESTING HVDflO' ETIER

COOLANT (HYDROMMEETTEERR TEST)

F!5'·'ijd~;

Be sure the enngine is cool before remmoving the capp orr you
mayy be sevverreellvy scalddedd.

Remove the follloowwiinngg::
-rigrihgtht middle cowl (page 2-4))
-upuppeprer cowl (page 2-51)

Remove the radiator cap.

Check the coolant gravity using a hydroommeetteerr..

STANDAARRDD COOLAANNTT CONCENTRRAATTIIOONN:: 50%

Look for contamination and replace the coolant if neces-
sary.

Cooolaanntt grraavviittyy chhaarrtt

\Coolant temperature OC(O 5 10 15 20 25 30 35 40 45 50

Coolant ratio % (32) (41) (50) (59) (68) (77) (86) (95) (104) (113) (122)

I5 I 1.009 I 1.009 I 1.008 I 1.008 1 1.007 I 1.006 I 1.005 I 1.003 1 1.001 I 0.999 I 0.997 I

I 10 I I I I I I I 1 I I I1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005

I 15 I 1.028 I 1.027 I 1.026 I 1.025 I 1.024 I 1.022 I 1.020 I 1.018 I 1.016 I 1.014 I 1.012 I

I 20 I I 1 I I I I I I I[ 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.026 1.023 1.021 1.019

I 35 I 1.063 I 1.062 I 1.060 I 1.058 I 1.056 I 1.054 I 1.052 I 1.049 I 1.046 I 1.043 I 1.040 I

I 1 I I I I 1 1 1}40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047

I 5_ 5_ I 1.095 I 1.093 I 1.0.9.1 I 1.088 I 1.085 I 1.082 I 1.079 I 1.076 I 1.073 I 1.070 I 1.067 1
I I I I I I 1 I I 1[60 11.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071

http://mototh.com 66--33

COOLING SYSTEM

RAADDIAATTOORR CAAPP/ESYSTEMM PRESSUURREE
INSPEECCTTIIOONN

NOTEE:
Beforree installinngg the cap inn the tester,, wet the sealing sur-
faces.

Pressuurree test the radiator capp usingg the tester.
Repllaaccee the radiator cap if it does not hold pressure, or if
relief pressure is too highh or too low, it must holdd speci-
fied pressure for at least 6 seconds.

RADDIAATTOORR CAPP REELLIIEEFF PRREESSSSUURREE::
110088 kPa ((11..11 kgff/lccrdri,, 1166 psi))

Pressuurree the radiator, engine and hoses usingg the tester,
and check for leaks.

CAUTION:
Excessssiivveepressuree cann dammaaggee the cooling system comm--
ponents. Do not exceed 113377 kPa (1.44 kgff//ccmnZr, 20 psi))..

Repair or replace components if the system will not holdd
specifiedd pressure for at least 6 seconds.

COOLANT REPLACEEMMENTT

PREPAARRAATTIIOONN

,!§WiIIi"

• Radiatorr coolant is toxic. Keep it away fromm eyes,

-mouth, skin and clothheess..

- iff any coolant gets in your eyes, rinse them withh wa--
ter and consult a doctor immmeeddiiaatteellyy..

-If"aanny coolant is swallowed, induce vommiitinngg,, garglee
and consult a physician immeddiaately.

-- "Ifaanny coolant gets on your skin or clothes, rinsee thor-

oughly withh plenty of waatteerr..
• KEEP OUT OF REACH OF CHHIILLDDRREENN..

CAUTION:

Using coolant witthh silicate inhibitors may causee prema-
ture wear off water pump seals or blockage of radiator
passage. Usingg tap water may caussee engine dammaaggee..

NOOTTEE: ANTIFRREEEEZZEE LOW MINERAL OR
* The effectiveness of coolant decreaseess with the accu- SOLLUUTTIlOONN DISTILLED WATER

mulation of rust or if there is a changee inn the mixinngg (ETHHYYLLEENNEE GLYYCCOOLL
proportionn during usage.. Therefoorree,, for best perfor- BASSEE SOOLLUUTTIIOONN))
mancee change the coolant regularly as specified inn the
maintenannccee schedule.
Mix only distilleedd,, low mineraall water with the antifreeeezzee..

RECOOMMMMEENNDDEEDD MMIXTURREE:

500 -- 50 (Distilled water andd antifreezee))

I COOOLLAANNTT

66--44 http://mototh.com

COOLIINNGG SYSTEM

REPLACEMENT/AIR BLEEDING

p",.""",

Thhee enginne must be cool before serviicciinnggthhe cooolliinnggsys-
tem, or severree scalding may resuulltt..

NOTE::
When fillingg the system or reservee tank with a coolant
(cheecckkiinnggthe coolant level), place the motorcycle upright
on a flat, leveell surface.

Removee the following:
-unudnedrer cowl (paaggee 22--33))
- rigrihgtht middle ccoowwll (paaggee 22--44))

Removvee the radiator cap..

Removee the drain bolt andd sealing washer on the water
pump and drain the coolant fromm the system.

Removvee the reserrvvee tank cap. SIPHON TUBE

Disconnect the siphon tube fromm the radiator andd drain
the coolant fromm the reservee tank.

Connect the siphon tube.
Insttaallll the drain bolt with new sealing washer.

Fillll the systemm with the recommeennddeedd coolant through
the filler opening up to filler neck.
Fillll the reservee tank to the upper leveell line.

Bleeedd air fromm the system as follows:
11.. Shift the transmission into neutrraall..

Start the engine and let it idlee for 22--33minutes.
22.. Snap the throttle 3-4 times to bleeedd air fromm the sys--

tem.

33.. Stop the engine and add coolant up to the filler neck.
Reinstaall the radiator cap.

4. Check the leveell of coolant inn the reserve tank and filll to
the upper leveell if it is low.

Insttaallll the following:

-- right midddlee ccoowwll (paaggee 22--44))
-- under cowll (pagee 2-5)

http://mototh.com 6-55

COOLIINNGG SYSTEM

THERMOSTAT

REMOVAL
Draiinn the coolant (paaggee 6--55)). .

Remove the following:
-fufeulel tank (pagee 5-33))
-aiar ir cleaner housing (paggee 5-4))
Remove the two bolts and thermostat housing cover.

Remove the thermostat from the housinngg..
NOOTTEE::
The thermostat, may bee damagedd if droppeedd or conflicted
to shocckk..
IIf dropped or conflicted, inspect the thermostat andd re--
placcee if neceessssaarryy..

INSPPEECCTTIIOONN

• Wear innssuullaatteedd gglloovveess and adeqquuaatteeeye prrootteeccttiioonn..
• KKeepp fllammmmaabblleemmatterriiaallssawayfromm thhee electricchheatt-

ingeelleemmeenntt..

NOTTEE::
Doo not let the thermostat or thermometer touchh the pan,
or you will get falsee readings.

* Reppllaaccee the thermostat if valve stayss openn at rooomm tem-
perature, or if iitt resppoonnddss at temperatures other thaann
thoossee specified.

Visuuaallllyy insppeecctt the thermostat for daammaaggee.. THHEERRMMOOSSTTAATT

HHeeaattthe water withh ann electric hheeaattiinngg elemmeennttto oppeerraatt--
inngg temppeerature for 5 mmiinnuutteess..
SSuuspendedd thee thermostat inn hheeaatteedd water too check ittss
operation.

THERMOSTATT BEEGGIINNSS TO OPEN::

69.5 -- 722..'!S£ (115577..11 -- 116622~%6))

VALVVEE LIIFFTT:
3.5 mmm (0.14 iinn)) miiniimmum at 80B'CC (117768FF))

6--66 http://mototh.com

COOLING SYSTEM

INSTALLAATTIIOONN t:I! SEA.L RUBS IA

Apply coolant to the new seal rubbber and insttalll it ttoo tthe
thermostat flangge.

THERMOSTAT

Inssttaallllthe thermosttat inttoothe hoouussiinnggwith itss hoollee facinngg
uUpP..

Inssttaalll the thhermmoossttaatt hhoouussiinngg coovver andd two bboollttss.
lTightn thhe bboollttss seccuurreellyy..

Fillll andd bblleeeedd thhee ccoooolliinnggssyysstteemm (ppaaggee 6-55)).

http://mototh.com 6-77

COOOLLIINNGG SYSTEEMM "n,AT·""'" HOS

RADIlATOR/COOLLIINNGG FANN

REEMMOOVVAALL

Draaiinn tthhee ccoooollaanntt(paaggee 6-5).
Reemmoovvee the following:
- fufeulel tank (ppaaggee 5--33))
--left midddllee cowwll (paaggee 2--44))
Disconnect the fann motor 3PP connectoorr.
Disconnect the siphon tube froomm the radiator.
Looosseenn the hose baanndd screw andd disconnect the lower raa--
diator hose.

Loosseenn the hose bandd screw and disconnect the upper
radiator hose.

Removvee the radiator mounting bolts and collars.
Slide the radiator to the right side, then releaassee the upper
grommet from the frame boss.
Remoovveethe radiator assemblyy..

DOISASSEMBBLLY BOLTS

Disconnecctt the fan motor switch connneeccttoorr.. ml A CONNECTOR
Remove the two bolts and ground terminal.
Remove the cooling fan assembly from the radiattoorr..

- T ICOOLING FAN ASSEMBLY ~~-~ h

6-8 http://mototh.com

COOLINGG SYSTEMM

Remoovvee the nut and coolliinngg fann.

Releassee the motor wire froomm the clampp. .....SCREWs,MlAS Efl.!>
Remoovvee the scrrewwss andd washheerrss..
Remoovvee the fan motor from the shrroouudd.. FAN MOTOR

ASSEMBLY

RADIAATTOORR

COOLLIINNGG FAANN \
http://mototh.com
FANN SHROUUDD

6--99

CCOOOOLLIING SSYYSTEM SCREW5lNA5 ~ [RS

IInnstall tthhee ffaann mmoottoorr ttoo tthhee sshhrroouudd.. COOLI G AN
IInnstall aannd ttiigghhtteenn tthhee wwaasshheerrss//ssccrreewwss sseeccurely.
lInnssatll tthhe moottoorr wwiirreess ttoo tthhee ccllaammpp..

Apply locking agenntt to the motor shaft threads..
Install the cooling fan onto the motor shaft byy aligning
the flat surfaces.

Inssttaalll andd tighten thhee nnuutt secuurreellyy..

IInnssttaalll tthhee ccoooolliinngg faann aasssseemmbbllyy too thee rraaddiiaattoorr.. rm BOLTS CONNECTOR

IIInnssttaalll aannddtigghhtteennthhee bboollttss aanndd ggrroouunnddtteerrmmiinnaall aasssshhown.

CCoonnnneecctt thhee faann mmoottoorr sswwiitch ccoonnnneector.

1 -CCOOOOLLININGGFFAANNAASSSSEEMMBBLLYY ~-~-9 h

66--1100 http://mototh.com

INSTALLATTIOONN COOLING SYSTEM

Instaallll the radiator assembly by aligning its grommet with ,.... n lll'Tr,,, HOSiE
the frame boss.
Install the collars and mountingg bolts.

Installll the upper radiator hose and tighten the bandd screw
securely.

Install the lower radiator hose and tighten the bandd screw •
securely.
Connect the siphon tube.

Connect the fan motor 3P connector,. 6--111I
Filll and bleed the cooling system(lpage 6-5).
Install the following:

-- left middle cowl (pagee 2-4)

-fufeulel tank (page 5-33))

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COOLINNGG SYSTEM BOLT

RADIATOORR RESEERRVVEETANK SIPHON TUBE

REEMMOOVVALI/INST ALLATION

Remmoovvee the rear cowwll (paaggee 2-22))..
Draaiinn the coolant fromm the reserve tank (paggee 6--55))..

Disconnect the over flow andd siphon tubes.
Remmoovvee the bolt andd radiator reseerrvvee tank fromm the frame.

Installation iss inn the reversee order of removvaall..

NOTTEE::
Rouuttee the tubes pDrroopDeerrllyv (bpaasgee 1-1199,.11-20).

Fillll the reseerrvvee tank with recommennddeedd coolant to the
upper leveell line (paggee 6-5))..

WATER PPUUMMPP

MECCHHAANNICCAALL SEALL INSSPPEECCTTIIOONN

Remmoovvee the under cowwll (paaggee 2-3)..

Checkk the inspection hose for signs of coolant leakage. If
there iss leakage, the mechanical seaall is defectivvee and it
should be replaced (pagee 6-133))..

Installl the under cowl (paggee 2-33))..

WATER PUMP COVER REMMOOVVALI/
INSTALLAATTIIOONN

Drainn the coolant (paggee 6-5))..

Remove the three bolts, sealingg washer andd water pump
cover.

Apply coolant to the new O-rinngg and install it to the water
pump cover.

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COOLING SYSTEM

Install tthe wwaatteerr pump ccoovveerr,, ssealing wwaasshheerr aand tthhree
bolts..
TTiigghten the three bolts securely.
Fill and bleed the cooling system (page 6--55))..

DOISSAASSSSEEMMBBLl Y

Removee the right crankcasee cover (pagee 8-3).
Hold the water pump shaft and remove the impeller and
washer.

Removee the water pummppshaft, washer,, gear and pinn from
the right crankcassee cover..

Remmoovvee the mechanical seall andd oill seeaal fromm the right
crankcaassee cover.

MECHANICAL SEAL OIL SEA L

http://mototh.com 66--1133

COOLING SYSTEM WATER PUMP GEAR PI1v
ASSEMBLY WASHERR
k
WATER PUMP IMPEELLLLEERR

\ MECHANICAL SEAL

~ SHAFT

\ -O'LIL SEAL
WASHEERR
"I'

Install the new oil seall into the right crankccaassee cover.
Apply sealant to the new mechanical seal flange and drive
it into the right crankcaassee cover usingg the speciaall tools.

TOOLS: 07774499 -- 001000000
Driver
Attacchhmmeenntt,, 36 mm 079455-- 415040000

INSTALLAATTIIOONN

Check the water pump shaft for damage.
Check the water pump gear for damage of the teeth.

Installl the pin to the water pump shaft.
Installllthe water pump gear and washer to the water pump
shaft.

Apply engine oil to the water pump shaft.
Installl the water pump shaft to the right crankcassee cover.

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COOLING SYSTEM

~ ~~

Inssttaallll the washer and impeller to the shaftt.

Holdd the water pump shaft and tighhttenn the impeller to the
specifiiedd torqquuee.

TORQUE: 1100 N·.mm (11..00 kkggff·.mm•, 7lIbbff-.ffttl)

Inssttaalllthe folllloowwiinngg::
-rigrihgtht crraannkkccaassee coovveerr (paggee 8--11441)
-wwaateter r pump coovver (ppaaggee 6--11221)

Fiillll andd blleeedd the coooolliinngg ssyysstteemm (paggee 6--551)..
Fillll thhee engiinnee oiill (paggee 33--11001)..

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7. ENGINEE REMOOVVAAUUIlNNSSTTAALLLLAATIO0N

SERVICE INFORMATION 7-11 ENGINE INST ALLATION I7-4
ENGINE REMOOVVAAL 7-2
7-4

SERVICE INFORMMAATTIIOONN

GENERAL

- During engine removal and installation, support the motorcycle secureellyy using a hoist.
- Support the engine using a jack or other adjustablee support to ease of engine hanger bolts removal.

* The following components can be serviced with the engine installed i n the frame:

-OiOl il pump (sectioonn 4)

-- Clutch/geeaarrsshhiifftt linkage (sectionn 8)

-AlAteltrenrantaotro/sr/tastratertrer clutch (sectionn 9)
-CyCliynldinedrer head/valves (sectiioonn 10))

-- Cylinder/ppiissttoonn (sectiioonn 11))

-StSartatertrer motor (sectiioonn 19))

* The following components require engine removvaall for service.
-TrTarnasnmsmisissisoinon (sectiioonn 12))
-- CrankshafWt/bbaallaanncceerr (sectionn 133))

SPECIFICATIONS

~~ I SPECIFICATIONS
~~
ITEMM

Engine dry weight I At draining 26.11 kg (57..5555Ibbss))
Engine oil capacity I At disassembly
1.0 liter (1.06 US qt,, 0.88 Imp qt))
Recommended engine oil
1.3 liter (1.3377 US qt,, 1.141Imp qt))

Honda 4-stroke oil or equivalent motor oil
API service classification SE,, SF or SG
Viscosity: SAE 1O0WW--3300

TORQUE VALUES 9.8 N·.m (1..00 kggff.mm, 7 Ibf·.ft) Apply a locking agent to the threads
599 N·.m (6.0 kggff·m, 43 Ibf·.ft)
Drivvee sprocket fixing platee bolt 599 N·mm ((66..00kgf.m, 43 Ibhf·.ft) U-nut
Engine hanger nut
Reaarr axle nut

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ENGINNEE REMOV AL/INSTAALlLlAATTIION

ENGGIINNEE REMOVVAALL

Draaiinn the coolant (paaggee 66--55))..
Draaiinn the engine oill (paggee 3-1111))..
Remmoovvee the following:
-exehxahuasutst systemm (paaggee 2-55))
-spsaprakrk plug cap (paggee 3-6)1
--lleeftft middle cowwll (paggee 2-44))
-ffuueel l tank (paaggee 5-33))
-airair cleaner housinngg (paaggee 5-44))
-cacrabrubruerteotror (paaggee 5-44))
-stastratertrer motor terminal andd ground cable (paggee 19--44))
Disconnect the vacuum tube fromm the PAAIIRR control valve
andd air injection hosee fromm the PAAIIRR check valve coveerr..
Disconnect the neutral switch andd alternator 4P
connectors.

Remmoovvee the pinncchh bolt andd gearshift arm from the gear
shift spindle.

Looosseenn the hose banndd screws and disconnect the radiator
hosess.

77--22 http://mototh.com