Honda Cbr150r 2002-2009

CCYYLLININDDEERRHHEEAADDIIVVAALLVVEESS

InInsstatalllltthheeccaammsshhaaftftininttootthheerrigighhttccaammsshhaaftfthhooldldeerrinintthheeiirr
pprrooppeerrloloccaattioionnss..

NNOOTTEE: :
TThhee ccaammsshhaaftfthhooldldeerrss hhaavveetthhee ffoollolowwiningg idideenntitfiifcicaatitoionn
mmaarrkkss::
ININ: :InIntatakkeeccaammsshhaaftfthhooldldeerr
EEXX: :EExxhhaauussttccaammsshhaaftfthhooldldeerr

InInsstatalllltthheessnnaapprriningg. .

RIGH CA SI9AFHIOLDER S AP RING

InInsstatalllltthheeddoowweel lppininss,,ccaammsshhaafftthhooldldeerrssaannddccaammsshhaaffttssinin DOWEL PINS
tthheeiirrpprrooppeerrloloccaatitoionnss. .

AApppplylyooililttooththeetthhrreeaaddssaannddssaaeetitninggssuurrfafacceeoofftthheeccaammsshhaaftft
hhooldldeerrbbooltltss..
InInsstatalllltthheebbooltlstsaannddttigighhtteenntthheemmininaaccrrisisssccrroossssppaattteternrninin
22oorr33ssteteppss..

TTOORRQQUUEE: 1122NN·mm((11.2.2kkggf·fmm,,99I1bbf·ff.thl )

TTuurrnntthheeccaammsshhaaffttbbyyyyoouurrhhaannddwwitithhtthheeccaammlolobbeeffaacciningg
uUpP..
TThheeccaammsshhaaftfstssshhoouuldldttuurrnnssmmooootthhllyy..

RReemmoovveetthheebbooltltss,, ccaammsshhaafftt hhooldldeerrssaannddccaammsshhaaftfstsi fi ftthhee
ccaammsshhaaftfstsddoonnoottttuurrnnssmmooootthhllyy..
RReeininsstatalllltthhee ccaammsshhaaftft,, ccaammsshhaaftfthhooldldeerrss aanndd bbooltlstsaanndd
rreetitgighhtetennththeebbooltlsts((sseeeeaabboovvee).).
RReecchheecckktthheeccaammsshhaaffttrrootatatitoionn. .

TTOORRQQUUEE: 1122NN·mm ((11.2.2kkggf·fmm,,99lb1bf·f.thl )

1100--2200 http://www.motorcycle.in.th

IInnssttaalllthhee ccaamm cchhaaiinn gguuiiddee. CCYYLLIINNDDEERR HHEEAADDIIVVAALLVVEESS
TTiigghhtteenn thhee twwoo bboollttss.
BOLTS

Turnn the crankshaft counterrcclloocckkwwiissee andd align the index
linee of the "T"" mark onn the flywheeell with the index notch
onn the leftt crankccaassee coveerr..
Makkee sure the pistonn iss at TDOCe (Toopp Deaadd Center)) on the
compressssiioonn stroke.

Attach the cam sprockets to the cam chain by aligning the C AM S~OC H
cam sprocket marks with the cylinder headd surface as
shown.
Temporarily align the index line on the sprockets with the
surfaccee of the cylinder headdwithout moving the cam chain.

Install the cam sprockets onto the camshafts.. 10-2211

NOTE:
Be sure that the index lines on the cam sprocket align with
the surface of the cylinder head when the index line offthe
"TT"" mark on the flywheel is aligned with the index notch
on the crankcase cover.

Apply locking agent to the cam sprocket bolt thrreeaaddss..
Align the bolt holes in the cam sprockeett with camshaft
flange..
Install the cam sprocket bolts and tighten them to tthe
specified torque..

TORQQUUEE: 8S.8S N·mm (0.9 kgff·mm,. 6..55Ibbff.dftt)

http://www.motorcycle.in.th

CYLINDER HEADIVALVES

Instaallll the timing hole cap and crankshaft hole cap (pagee
3-10))..

Installll the followinngg::
-exehxahuasutst system (page 2-7)
-unudnedrer cowl (page 2--33))
-cacrabrubruerteotror assembly (page 5-1133))

CYLINDER HEAD COVER INSTALLATIIOONN CYLl DER HEAD COVE~

Install the gasket, new O-ringg and dowel pin to the cylinder
head coverr..
Insttaalll the cylinder head cover onto the cylinder head.

Instaallll the rubber washers withh the ·"UUP" markss facing up. WA.$HE~S!B.o LTS
Insttaalll and tighten the headd cover bolts to the specified
torque..

TORRQQUUEE: 10 N·.m (11..00kgff·.m, 7 Ibf·4ttt)

Connect the air injection hose into the PAIR check valve
coveerr..
Connect the vacuum tube.
Instaallll the PAIR control valve and bolt.

10-2222 http://www.motorcycle.in.th

CYLINNDDEERR HEADIVAALLVVEESS

Connecctt the upper radiator hosee to the cylinder head.
Insttaalll the radiator andd two bolts.
lTigighhtteen the boltss..

Insttaalll the followingg::
-rigrihgtht andd left middle cowll (paaggee 2-4)

--air cleaner housinngg (paaggee 5-4))
-fufeulel tank (paggee 5--33))

Filll the coolingg systemm with coolant (paggee 6-5)..

http://www.motorcycle.in.th 10-23

CYLINDER/PISTON

111--00 http://www.motorcycle.in.th

11. CY1L1INDER/PISTON

SERVICE INFORMATIIOONN 11--11 PISTONN REMOVAL 11-4
TROUBLESHOOOTTIINNGG 11-2 PISTONN INSTALLATTIIOONN 11-7
CYLINDER REMOVALL 11-3 CYLINDER INSTALLATTIIOONN 11-8

SERVICE INFORMAATTIIOONN

GENERAL

- The service procedures in this section can be performed with the engine installed inthe frame.

* Take care not to damage the cylinder wall and piston.
*• Be careful not to damage the mating surfaces by using the screeww drivveerr when removing the cylinder.

When disaasssseemmbblliinngg,, mark and store the disasseemmbleedd parts to ensure that they are reinstalled in their original
locations.

SPECIFICATIIOONNSS

Unit: mm (inn))

ITEM STANDARD I ISERRVVIlCCEEUMIlT

Cylinder 1.0. 63.50 -- 63.51 (2.500000 -- 2.5004) I 63.55 (2.50022))

Out of round -- - I 0-.10.(,0..0.0.4)\. wm
---
Taper 0.10 (0.0044))
-__- 0.05 (0.0022))
I WarDpagae

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

rings Piston O0.D0.. 63.47 -- 63.49 (2.4988 -- 2.4996) 63.40 (2.449966))

I Pistonn O0.D0. measurement opoint 6.5 1(00..3366))from bottom of skirt ---

Piston pin bore 1.0. 15.0022-- 15.008 (0.59600 -- 0.5909)) 15.055 (0.5992277))

Piston pin 0.0. 14.9944 -- 15.000 (0.5990033 -- 0.5906) 14.98 (0.559900))

Piston-to-piston pin clearance -0.002 - 0.014 (0.00000011 -- 0.0006)) 0.04 (0.0001166))
-0.045 - 0.075 (0.001188 -- 0.0030))
Piston ring-to--rriinngg TToopp -0.015 - 0.050 (0.0006 -- 0.0020) I O0.1.l0O(0.00044)) I
groove clearance Second
0.08 (0.00033))

Pistoonn ring end gap TToopp 0.05 -- 0.20 (0.002 -- 0.008)) 0.3 (0..0011))

Second 0.15 -- 0.30 (0.00044 -- 0.010)) 0.7 (0.003300))

Oil (sidee raill)) 0.20 -- 0.70 (0.000088-- 0.028)) 1..11 (0..0044))

Cylinder-to-piston clearance 0.01 -- 0.04 (0.00000044-- 0.0016) 0.90 (0.0355))
15.09 (0..559944))
Connecting rod small end 1.0. -15.010 -- 15.02288 (0.55990099 - 0.5917)) I
-0.010 - 0.034 (0.000044 -- 0.0013)) I 0.07755((0.003300))
Conneeccttiinngg rodd small end-to-piston pin clearance

http://www.motorcycle.in.th 1111--11

CYLINDER/PISTON

TROUBLESHOOTTIINNGG

CCoommpprreessssiioonn too loww, haarrdd staarrttiinngg or ppoooorr peerrffoorr--
mmaannccee at low sppeeeedd
* Leeaakkiinngg cylindeerr hheeaadd gaasskkeett
* WWorn, stuck or brookkeenn pissttoonn rinngg

WWoorrnn or daammaaggeedd cylinder anndd ppiissttoonn

-CCoommpprreessssiioonn too high, ovveerrhheeaattiinngg or knnoocckkiinngg
EExxcceessssiivvee caarbboonn buuiilltt--uupp onn pissttoonn or commbbuussttiioonn
chammbbeerr..

EExxcceessssiivveesmmooke
* WWoorn cylinder, pissttoonn or ppisstoonn ringgss

Immpprrooppeerr inssttaallllaattiioonn of ppisstoonn rinnggss
* SSccoorreedd or sccrraattcchheedd ppisstoonn or cylinddeerr waall

Abnnoorrmmaall nnooiissee (ppissttoonn))

-- WWoorrnn ppisstoonn ppiinn or ppisstoonn ppiinn hoollee
WWoorn cylindeer, pissttoonn or pissttoonn rinngg
WWoorn coonnnneeccttiinnggroodd smmaalll enndd

111--22 http://www.motorcycle.in.th

CYLINDER/PISTOONN

CYLUINDER REMOVALL

Remoovvee the cyylliinnddeerr headd (paggee 10-4).
Loooosseenn thhe banndd screw andd disccoonnnneecctt thhe water hoossee..
Remoovvee the camm chhaiinn guuiiddee..

Remoovvee thhe cyylliinnddeerr..
Clleean the top of the cylinder thoorroouugghhllyy..
CAUUTTIION::
Avoidd dammaaggiinngg thee gasket surfaceess..

Remoovvee thhe dowwel piinnss andd gasskkeett..

http://www.motorcycle.in.th 11-3

CYLINDER/PISTON

INSPPEECCTTIIOONN

Inspeecctt the cylinder walll for scratchheess andd wear..
Meaassuurree andd recoorrdd the cylinder 1I..D0. at three levels in both
the X andd Y axis. Takee the maximum readdiinngg to determine
the cylinder wear.

SERVIICCEE LLIIMMIITT::63.555 mm (2.550022 inn))

Calccuullaattee the cylinder for out of roundd at the three levels
inn ann X andd Y axis.. Take the maximuumm readdiinngg to deter-
minee the out of roundd..

SERVICE LLIIMMIITT::00.1100 mmmm (100..000044in)

Calccuullaatteethe cylinder for taper at three levels inn ann XX and I
Y axiss.. Take the maximmuumm readdiinngg to determine the taper.

SERVIICCEE LLIIMMIITT::00.100 mmmm (0.00044 in)

TOP XX

MIDDLE

/---

BOoTnTOOMM

Checkk the cylinder for warpage by placingg a straight edge
andd a feeler gaugee acrosss the bolt holess as shown.

SERVICE LLIIMMIITT::00.05 mmmm (0.000022in)

PISTTOONN REMOVAALL

NOTE:

~

Placcee a cleaann shop towel over the crankkccaassee opening to
prevenntt pistoonn pinn clips from falling intoo the crankccaassee..

Remmoovvee the pistoonn pinn clip using the pliers.

Remmoovvee the pistonn pinn out andd remove the piston.

Inspect the piston rings for movement by pressinngg the
rings. The ringss should bee able to move inn itss groove with-
out catching.

11-4 http://www.motorcycle.in.th

CYLINDER/PISTONN

Spread eacchh pistoonn rinngg andd remove it by liftinngg iit up at a
point just opposite the gap.
CAAUUTTIIOONN::
• Do not dammagge tthhe piston ringg by sspprreading thhe ends

toooo faarr..
• BBe ccareful not to ddammaggee thhe piston wwhheenn tthhe piston

riinngo remmoovvaall..

Cleeaann carbboonn deposits from the piston.
NOTE:
Cleeaann carbboonn deposittss fromm the pistonn rinngg grooves with
a rinngg that willl bee discarded. Never usee a wire brush; it
willl scratcchh the grooves.

INSPPEECCTTIIOONN 11-5

Inspect the pistonn for crackkss or other damage.
Inspect the rinngg grooves for excessive wear and carboonn
build-up.
Measuree eacchh pistonn 0O..D0.
NOOTTEE::
Take measuurreemmeennttss 6.5 mmm (0..3366 inn)) fromm the bottom,
andd 900" to the pistoonn pinn hole.
SERRVVIICCEE LLIIMMIITT: 63.40 mmmm (2.49966 iinn))
Calculattee the cylinder-to-piston clearanccee.. Take the maxi-
mumm readinngg to determine the clearance (Cylindeerr 1ID.0..::
paggee 11-44))..
SERVICE LLIIMMIITT::0.9900 mmmm (0.03355 iinn))
Measure eacchh pistonn pinn boree 1I..D0. inn ann X andd Yaaxxiiss.
Take the maximmuumm readdiinngg to determine 1I..D0.
SERRVVIICCEE LLIIMMITIT: 15.05555 mmmm (0.55992277 iinn))

http://www.motorcycle.in.th

CYLINDER/PISTTOONN

Measure the piston pin O0.D0. at three points.
SERVICE LLIIMMIITT::63.40 mmm (2.49966 inn))
Calculate the piston-to-ppiissttoonn ppinn clearance.
SERVICE LLIIMMIITT::0.04 mmm (0.001166 inn))

Measure the connecting rodd small end 1I..D0.
SERVICE LLIIMMIITT:: 15.09 mmm (0.59944 inn))
Calcullaatteethe connectingg rodd small end-to-piston ppiinnclearr--
ance.
SERVICCEE LLIIMMIITT::0.0755 mmm (0.00300 inn))

NOTE::
Always replace the piston rings as a set.
Inspect the piston ring, and replace them if they are worn.
Temporarily install the piston rings (page 11--77)) into the
piston grooves.
Pusshh inn the ring untill the outer surface ofthe piston ring is
nearly flush with the piston and measure the clearance
using a feeler gauge.
SERVICCEE LLIIMMIITT::

Topp:: 0.10 mm (0.0004s inn))
Seconndd:: 0.08 mm (0.03 inn))
Using a piston, pushh the ring securely into the cylinder
and measuurree the end gap usingg a feeler gauge.
SERVICE LLIIMMIITT::
Top: 0.3 mm (0.0011 inn))
Secoonndd:: 0.7 mm (0.0033 inn))
Oil: 1..11 mm (0.04 inn))

11-66 http://www.motorcycle.in.th

PIISSTTOONN IINNSSTTAALLLLAATIIO0NN CCYYLLIINNDDEERR/PISTON

CClleeaanntthhee ppiissttoonn hheeaaddss,, rriinngg llaannddssaanndd sskkiirrttss. MARK
CCaarreeffuullly iinnssttaallltthhee ppiissttoonnrriinnggssoonnttoo tthhee ppiissttoonnwwiitthh tthheeiir
mmaarrkkiinnggssffaacciinngg uupp. '9\ -.TOOPP RRIINNGG

CCAAUUTTIIOONN:: SSEECCOONNDD RRIINNGG
• DDoo nnoott ddaammaaggee tthhee ppiissttoonn rriinngg bby sspprreeaaddiinngg tthhee eennddss SIDDEE RAILL

ttooooffaarr.. PISTON

• BBee ccaarreeffuullnnoott ttoo ddaammaaggeetthhee ppiissttoonn wwhheenn tthhee ppiissttoonn

rriinngg iinnssttaallllaattiioonn.

NNOOTTEE::
* DDoo nnoott ccoonnffuussee tthhee ttoopp aanndd sseeccoonndd rriinnggss..

After innssttaalllliinnggthee rinnggssthey shhoouulldd roottaatteefreely, withh--

- ouutt sticking.
SSppaaccee tthhee rriinngg eenndd ggaappss 112200 ddeeggrreeeess aappaarrtt..

PPIISSTTOONN

TOPRING
SPACER

SEECCOONNDDRRINGG

OIL RINNGG

NOTTEE::
When cleaninngg the cylinder mating surface, place a shop
towel over the cylinder and cam chain openings to prevent
dust or dirt enter the engine.

Cleann any gasket material from the cylinddeerr mating sur-
face of the crankcase..

Cleann the oil orifices of the right crankcase.

http://www.motorcycle.in.th 11-7

CYLINDER/PISTOONN

Apply molybdeennuumm solutioonn to the piston pinn outer
surfaces and connecting rodd small end inner surfaces.
Apply engine oil to the pistonn ppiinn hole..
Instaallll the pistonn with its "INN"" markkfacinngg the intake side.
Installl the pistonn pin.

Instaallll the new pistonn pinn clips..

CAUTION:
Always uusse new piston pin cclliippss.. Reinstallinnggusseddpissttoonn
pin clips may lead to seriouss enggiinnee ddaammaaggee..

-NOTE::
Plaaccee a shop towell over the crankccaassee opening to pre--
vent pistonn pin clips from falling into the crankccaassee..
Set the pistonn pinn clip inn the groove properly.
* Doo not align the clip's end gap with the piston cut-out.

CYLINDER INSTALLATION

-NOTE:

• Do not reusee the gasket, replace with new one.
Instaallll the dowel pins and a new gasket.

CAUTIONN::
BBe careful not to ddammaaggee thhe piston rinnggss and ccyyllindder
wwaallll..

Apply enginee oil to the cylinder and piston.
Route the cam chain through the cylinder and instaallll the
cylinder over the pistoonnwhile compressssiinnggthe piston ringss
with your fingers.

111-88 http://www.motorcycle.in.th

CYLINDER/PISTON

IInnsseerrtt tthhee ccaamm cchhaaiinn gguuiidde iinnttoo ccyylliinndder anndd ccrraannkkccaassee.
Innssttaallll iitt bbyy aliiggnniinngg tthhee iittss bboosssseess wwiitthh tthhee ggrroooovves iinn tthhee
ccyylliinnddeerr anndd ccrraannkkccaassee ssecurely.

Innssttaallll tthhe ccyylliinnddeerr hheeaadd (ppaaggee 100--1199).).

http://www.motorcycle.in.th 11-9

TRANSMISSION

122--00 http://www.motorcycle.in.th

12.. TRANSMISSSIIOONN

SSEERRVVIICCEE I NNFFOORRMMAATTIIOONN 1122--11 INNSSPPEECCTTIIOONN 1122--55
TTRROOUUBBLLEESSHHOOOOTTIINNGG 1122--22 TRANSMISSION ASSSSEEMMBBLLYY 1122--1100
TTRRAANNSSMMIISSSSIOONN DDIISSAASSSSEEMMBBLLYY 1122--33 CCRRAANNKKCCAASSEEAASSSSEEMMBBLLYY 1122--1133

SERVICE INFOORRMMAATTIIOONN

GENERRAALL

This section covers service of the transmission (incclluuddiinngg the shift fork andd shift drumm))..

- For crankshaft andd balancer service, refer to section 133..
TThhee ccrraannkkccaassee hhaallvveess mmuusstt bbee sseeppaarraatteedd ttoo sseerrvviiccee tthhee ttrraannssmmiissssiioonn.. TToo sseerrvviiccee tthheessee ppaarrttss,, tthhee eennggiinnee mmuusstt bbee

remoovveedd fromm the frame (seeccttiioonn 7).

Thee following paarrttss must bee remmoovveedd befoorree disasseemmbblliinngg the crannkkccaassee..

--Cylinder heeaadd (seeccttiioonn 100))

-CyCliynldinedrer anndd pissttoonn (seeccttiioonn 1111))
--CClluuttcchh,, primary drive gear, ggeeaarrsshhift linnkkaaggee (sseeccttiioonn8))

- OOil il puummpp (sseeccttiioonn 44))

- --FFllyywwhheeeell (sseeccttiioonn9))
BBee ccaarreeffuull nnoott ttoo ddaammaaggee tthhee ccrraannkkccaassee mmaattiinngg ssuurrffaacceess wwhheenn sseerrvviicciinngg..

SPECIFFIICCAATTIIOONNSS

ITEEMM STANDARRDD UUnniitt:: mm (iinn))

I 1SEERRVVICICEELIMIT

Transmission Gear 1I..D0. M55,,MM66 17.016 --1177.0.0334 (0.6699 -- 0.6770066)) 17.08 (6..772244))
Shift fork
Cc11 18.000 -- 18..002211 (0.7087 -- 0.7009955)) 18.07 (0..771111)) If)

Cc22 23.020 -- 23.041 (0.9063 -- 0.9007711)) 23.09 (0..990099)) I
I
Cc33,,Cc44 22.020 -- 22.0411 1(00..886669 -- 0.8678) I 22..11 (100..8877) I
I
Busshhiinngg 1I.D.0.. Cc11 15.000 --1155.0.011881(00..5590 -- 0.5911)) 1 155..11 (0..5599))
1
Cc2 20.020 -- 20.041 (0.7882 -- 0.789900)) I 20.10 (0.79911))

Bushinngg 0O.D0. Cc11 17.969 --1177..99880 (0.7074 -- 0.707799)) I 17.9 (0.7700))

C2 22.984 -- 23.005 (0.9049 -- 0.905577)) 22.9 (0.90)

kGeaarr--ttoo--bbuusshhiinnggclearance C1 0.020 -- 0.052 (0.0008 -- 0.0020) 0.10 (0.004)
C2 0.D036 -- 0.057 (0.0014 -- 0.0022)
I 0.10 (0.00044))
Mainshaft 0.0. M5 16.966 -- 16.984 (0.6680 -- 0.668877))
Countershaft 0O.D0. 14.966 --1144..99884 (0.58922 -- 0.589999)) 16.93 (0.666677))
I CC11 gear bushing 19.978 -- 19.989 1(00..7866 -- 0.787700))
I C2 gear bushing 14.90 (0.558877))

GGeeaarr-to-shaft clearance M55 0.032 --0.068 (100..00001122-- 0.0027) 19.92 (0.778844))

Busshhiinngg--ttoo--sshhaaffttclearannccee CC11 0.016 -- 0.052 (0.00000011 -- 0.00200)) 1 0.101(0.004)
Cc2 0.003311 -- 0.063 (0.0012 -- 0.00255))
9.986 -- 9.995 (100..33993311 -- 0.3935) 0.10 (0.000044))
Shaft 0.0. 10.000 -- 10.018 (0.3937 -- 0.394444))
Fork 1.0. 4..9933-- 5.00 (0.194 -- 0.197) 0.10 (0.004)
Fork claw thickness 25.959 -- 25.980 (1.0220 -- 1.0222288))
Shift drum O0.D0. at right end 26.000 -- 26.021 (1.0236 --11.0.0224444)) 9.93 (0.39911))
Shift drum journal (R.crankcase)
I 10.03 (0.339955))

1 4.90 (0.193)

I 25.90 (1.002200))

I 25.08 (0.998877))

http://www.motorcycle.in.th 122--11

TTRRAANNSSMMIISSSSIIOONN 0077993366-- KKC10220000
0077993366-- KKCl1O0ll0O0O
TTOOOOLLSS 0077774411--001100220011

BBeeaarriinngg rreemmoovveerr hheeaadd,, 1155 mmmm 0077774499--001100000000
BBeeaarriinngg rreemmoovveerr sshaft
BBeeaarriinngg rreemmoovveerr weight 0077774466--001100220000
DDrriivveerr 0077774466-- 00001100330000
AAttachment, 3377xx 4400 mmmm 0077774466--000100110000
AAttachment, 4422xx 4477 mmmm
Attachment, 3322 x 3355 mmmm 0077774466--000400440000
Pilot,1177 mmmm 0077774466--000400330000
Pilot, 1155 mmmm 0077774466-- 00004400550000
PPiilot, 2200 mmmm 0077774466--000400220000
PPiilloott,, 1122 mmmm 0077993366--1?666600111100
BBeeaarriinngg remover heeaadd,, 1122 mmmm 0077993366--11666012200
BBeeaarriinngg remmoovveerr shaft 0077774411 -- 00001100220011
BBeeaarriinngg remmoovveerr weigh?t

TROUBLLEESSHHOOOOTTININGG

-Exxcceessssiivveennooiissee

• Worn, sizeedd or chipped transmission gear
• Wornn or damaggeedd transmission bearriinngg

Hardd to shift
Bentt shift fork

Bent shift fork shaft

- Dammaaggeedd shift drum guide groove
DDaammaaggeedd sshhiifftt ffoorrkk gguuiiddee ppiinn

Transmiissssiioonnjumps out of gear
* WWoorrnn ggeeaarr ddooggss oorr sslloottss
* WWoorrnn sshhiifftt ddrruumm gguuiiddee ggrroooovvee
* WWoorrnn sshhiifftt ffoorrkk gguuiiddee ppiinn
* WWoorrnn sshhiifftt ffoorrkk ggrroooovvee iinn ggeeaarr

12-2 http://www.motorcycle.in.th

TRANSMISSION

TRANSMISSION DISASSEMBLY

Refer to Service Information (page 12-1) for removal of
necessary parts before disassembling the crankcase.

Remove the cam chain.
Remove the cam chain tensioner plate bolt, plate and
tensioner guide.

Remove the circlip, washer, spring and bearing push plug CIRCLIP WASHER BEARING
from the left crankcase. ~/
PUSH PLUG
Check for the bearing push plug for wear or damage and
replace if necessary.

SPRING

Remove the left crankcase bolts and clamp.

Remove the right crankcase bolts and washer.

http://www.motorcycle.in.th 12-3

TRANSMISSION TRANSMISSION

Placcee the crankccaassee assembly with the right side down.
Carefully separate the left crankcase fromm the right
crankccaassee while tapping them at several locations with a
soft hammer. Doo not ply the crankcassee halves..

Removvee the dowel pins.

Pullll the fork shaft and remove it from the shift forks. S IFTDRUM
Removee the shift drum and shift forks.

Remove the mainshaft and countershaft as an assembly.

12-4 http://www.motorcycle.in.th

Disassemble the mrnaaiinnsshhaafftt andd counteerrsshhaafftt.. TRANSMMIISSSSIIOONN

.tAII'< HA · I

coumfRSHAI'T

INSSPPEECCTTIlO0NN

Gearrss

Check the gear dogs, dogg holes andd teethh for damage or
excessivee wear.
Measure the 1I.D.0. of eacchh gearr..

SERRVVICCEE LIMMIITTSS::

M5, M66: 17.08 mm (6.724 in)
18.07 mm (0.71111 in)
Cc11:: 23.09 mm (0.990099 inn))
Ccz2::

Bushinnggss

Checkk the bushinnggss for wear or damage.
Measure the 0O..D0. of eacchh bushinngg..

SERRVVICCEE LIMMIITTSS::
C1: 17.9 mm (0.70 in)
C22: 22.99 mm (0.90 inn))

Measure the 1I..0D..of eacchh bushinngg..

SERRVVICCEE LIMMIITTSS::
C1: 18.10 mm (0.713 in)
C2: 20.10 mm (0.779911 in)

Maaiinnsshhaafftt/lCcountesrshhaafftt

Checkk the spline grooves andd sliding surfaces for abnorr-- MS
maall wear or damage.
Measure the 0O..D0. of the mrnaaiinnsshhaafftt andd countershaft at Cl BUS INO
the gear andd bushhiinngg sliding areas.
12-5
SEERRVVIICCEE LIMMIITTSS::

Mainshaft (at M55 gear)):: 16.93 mm (0.0677 in)

Countershaft(at CC11 gear bushing): 14.90 mm m (0.587 in)

(at CC22 gear bushinngg)):: 19.92 mm m (0.784 in)

http://www.motorcycle.in.th

TTRRAANNSSMMIISSSSIIOONN

CCaallccuullaatteethhee ggeeaarr--ttoo-bushing, ggeeaarr--ttoo--sshhaaffttaanndd bbuusshhiinngg-
too--sshhaafftt cclleeaarraannccee..

SERVVIICCEE LLIIMMIITTSS:: 0.1100 mmmm ((00..000044 inn))
Gear-to-BBuusshhiinngg:: ClIlC2:: 0.1100 mmmm ((00..000044 in)
Geeaarr--ttoo--SShhaaftf:t MM55:: 0.1100 mmmm (00..000044 in)
Buusshhiinngg--ttoo--SShhaaftf:t ClIlC2::

Shift Drumm/lDDrruumm Journal ' 4' .';-_
Inspect the shift drum endd for scoring, scratches, or evi- .~- '(..
dence of sufficientt lubricaattiioonn.. .".#. ·(1-'>L..j' , \
Checkk the shift drum grooves for abnormal wear or dam- '.
agee.. ". ~ ~ I .".
Measuurree the shift drum O.D. at right end.
SERVICE LLIIMMIITT::25.08 mmmm (0.998877 inn)) SHIFT OR,UM

Check the shift drum journal inn the right crankcassee for ex-
cessivee wear or damage.
Measure the shift drum journal I.D.

nSERVICE LIMMIITT:: 77 mmmm m(??inin))

Shift Fork
Check the shift forks for deformation or abnormal wear.
Measure each shift fork claw thickness.
SERVICE LIMIITT::4.90 mm (0.193 in))

Measure I.D. of each fork.
SERVICE LIMIT: 10.03.,mmm (0.395 in)

12-6 http://www.motorcycle.in.th

TRANSMISSION

Shift Forkk Shaft
Check for damage andd straighhttnneessss..
Measurree the shift fork shaft 0O..0D.
SERVVICCEE LLIIMMIITT:: 9.93 mmm (0..339911 inn))

Transmissioonn Beariinngg
Turnn thhe innner raccee of eachh bearinngg with your finnggeerr..
The bearinnggss shouulldd turn smoothly and quiieettllyy..
Also chhecckk that beariinnggouter racceess fit tightly inn the crank-
casseess..

http://www.motorcycle.in.th 12-7

TRANSMISSIOONN
TRANSMISSSSIIOONN BEARINNGG REPLACE--
MENTT

Remmoovveethe bolts and mainshaafftt bearriinngg setting plateefrom
the right crankkccaassee..
Remoovvee the mainshaft bearinngg from the inside oftthe right
crankcase.

Removvee the oil seaall from the left crankcaassee..
Removvee the countershaft bearingg from the inside of the
left crankcaassee..

Removvee the bearinggss with followinngg tools.

TOOOOLS:

Rightt crankcase countershaft beraing:
-Bearriing removerr head, 15 mm 079366 - KCC1100220000
-079366 - KCC1100110000
Remover shaft

Remover weight 077774411-0000110022001

Left crankcase mainshafftt bearing:

-Beaarriinngg removerr head, 122 mm 079366 -11666600111100

Remover shaft 077993366-1660112200

Remover weight 07774411 -0000110022001

122--88 http://www.motorcycle.in.th

TRANSMISSION

Drivee new bearings into the left crankcaassee with followingg
tools:

TOOLS::

RIGHTT CRANKCCAASSEE

Mainshaft bearing: 07774499-00001100000000
Driver 07774466-00001100220000
Attachment,, 37 )xC 40 mm
Pilot, 17 mm -077466 - 0040440000

Countershaft bearing: -077499 - 001o0o0o0O0
Driver
Attachment, 32 x)C 35 mmmm 07774466-00001100110000
Pilot, 15 mm
-077466 - 0040330000

LEFT CRANKKCCAASSEE

Mainshaft bearing: 077499--00010o10o0o0O0
Driver 07774466-00001100110000

Attachment, 32 x)C 35 mm -077466 - 00400220000

Pilot, 12 mm

Countershaft bearing: 07774499-00001100000000
Driver 07774466-00001100330000
Attaacchhmmeenntt,, 42 )xC 47 mm 07774466-00004400550000
Pilloott,,200mrnm

After installing the bearings, install a new countershaft oil
seal.
Check the gearshift spindle oil seal for damage and re-
place if necessary.

Apply locking agent to the threads ofthe settinngg plate bolts, 12.-.99
and instaallll the mainshaft bearing setting plate by tighten-
ing the bolts.
Lubricate the all bearingss with engine oil.

http://www.motorcycle.in.th

TRANSMISSSSIIOONN CORREECCTT INCORRECCTT

TRANSMMIISSSSIIOONNASSEMBLY SNAP RINNGG

Cleann all partss inn solvent. M66 GEAR (266TT)) TTHHRRUUSSTTWWAASSHHEERR

Apply molybdenum oil solution to the gear andd bushing \
sliding surface and shift fork grooves to ensuree initittaalllluu-
bricatioonn.. SNAP RING

Assemble all partss into their original positionss..

NOTTEE::
* Check the gears for freedom of movement or rotatioonn

:ponn the shaft.
Insttaalll the washers andd snap rings with the chamffeerreedd
edges facing the thrust loadd side. Doo not reusee worn
snap ring which could easily spin in the groove.
Check that the snap rings are seateedd inn the grooves and
align their end gaps with the grooves of the spline.

MMAAIINNSSHHAAFFTT

M2 GEAR (17T)
SPLINE WASHER

SPLINE WASHER
M3/4 GEAR (20/22T)

WASHER AND SNAP RINNGG DIREECCTTIIOONN::

-:lID:: Gear and bushing sliding
II surfacess andd

shift fork grooves

12-100 http://www.motorcycle.in.th

TRANSMISSION

CCOOUUNNTTEERRSSHHAAFFTT

CC33 GEAARR (3300TT)) SSPPLLIINNEE WAASHER

I

CC55 GGEEAARR ((2255TT)) LOCK WASHER THRUST WAASHER

1 SSPPLLIINNEE WAASSHER I

CC11 GGEAAR BBUUSSHHIINNGG

c 1 GEAR (37T) THRUST

WASUFR

COUNTERSHAFT

C2 GEAR BUSHING

THRUST
WASHER

I SPLINE SNAP RING
WASHER

I

C4 GEAR (27TT))

WASHER AND SNAP RING DIRECTION::

--:7D: Gear and bushing sliding
II surfaces and

shift fork grooves

http://www.motorcycle.in.th 12-1111

TTRANSMISSION MA INSU AFT

If tthhee ccrraannkksshhaafftt removed,, install tthhee craannkksshhaafftt aand bbal - M YC
aancer firrsstt (page 13-51).,

AAppppllyy eengine ooil tto tthhee ccountershaft ooil sseal lips..
IInstalltthhee mmaaiinnsshhaafftt aand ccoouunntteershaft aas aan aasssseemmbbllyy iinnto
tthhe right ccrraannkcase.. Be sure tto install tthhe tthhrree end washers
(mmaaiinnsshhaafftt;; left side onnllyy//ccoouunnteterrsshhaaftf;t; both ends).

I MAR~S

Each shiifftt foorrkk has an identification markss;; "·PPRR"" (right),

"·PPC"" (center), "·PLL"" (left).

Install tthe shiftt forks into tthe shifter gear grooves with the
marks facing down (right crankcase side).

Apply molybdenum oil solution to the guide grooves in SHIFTOOUM
the shift drum and install it by aligning the shift fork gguide
pins with the guide groovess..

Apply molybdenum oil solution to the shift fork shaft inn--
sert it through the shift forks into the left crankkccaassee..

12-1122 http://www.motorcycle.in.th

TTRANSMIISSSIION

CRANKCASE ASSEMBLY

Cleeaann the leftt anndd righhtt crannkkccaassee matiinngg surfaces
throughly, beeiinngg careffuull noott too damage them anndd chheecckk
for damage.
Inssttaalll the dowel pinss onto the right crankccaassee..

Apply a light butt through coating of sealant to left crank-
cassee matingg surface except the oil passsaaggee area.

Makee sure all the partss are installedd inn the left and right RiGHT ORA KCASE
crankccaasseess..
COV R

CAUUTTIIOONN::

Do not foorrccee thhe ccrraannkkccaasseehalvves tooggeetthheerr,,H thheerree is ex-

cesssiivveeforrccee requiirreedd, something is wrroonngg.. Remove the
right crannkkccaassee and check for misalignedd Dpaarrttss..

Install the llefftt crankccaassee over the right crankcassee..

Installl the right crankccaassee bolts and washer, and tighten
the bolts in a crisscross patternn in 2 or 3 steps.

http://www.motorcycle.in.th 12·-1133

TRANSMISSION

Make sure that the crankccaassee mating surfaces are touchedd
evenly.
Instaallll the left crankccaassee bolts and clamp, then tighten the
bolts inn a crisscross pattern in 2 or 3 steps.

Install the cam chain to the cam chain drive sprocket
through the crankcase.
Installll the camm chainn tensioner, plate and bolt.
lTigighhtteenn the bolt secureellyy..

Instaallll the remainniinngg parttss..
Inssttaalll the engine inn the frame (seccttiioonn 7).

Instaallll the spring, washer andd 3 mmm screw to the beaarriinngg I (rrr WASHER ClRCLlP
pushh plug, thenn instaallll them into the left crankcase.
Insttaallll the circlip andd remove the screww..

Assemble the crankkccaassee halves (paaggee 12-122))..

I PUSSHHIINNGG PLLUUGG SPRRIINNGG

12-1144 http://www.motorcycle.in.th

CRANKSHHAAFFTTIBALANCER

1133--00 http://www.motorcycle.in.th

13. CRANKSHAFT/lBALANCCEERR

SERVVIICCEE INFORMATIOONN 13--11 CRANKSHHAAFFTT REMOVVAALL 13-2
TROUBLESHHOOOOTTIINNGG 13--11 CRANKSSHHAAFFTT INSTAALLLLAATTIIOONN 13-5

SERVIlCE INFORMATIlON

GENERAL

This section covers service of the crankshaft and balancer.
The crankcase halves must be separated to service the crankshaft and balancer. For crankcase separation and assem-
bly, refer to section 12.
Be careful not to damage the crankcase mating surfaces when servicing.

SPECIFICATIONS

Connneeccttiinngg rodd ITEMM STANDAARRDD Unit· mm (in)
Crankshaft runout
I Bigg end side clearance --- SSERVICCEE ULIMMIITT
I Bigg end raddiiaall clearance --- 0.66 (0.02)
--- 0.055 (100..00002)
0.03 (0.0011))

TOOLS 0774499 -- 00100000000

Driver 0774466 -- 00100110000
Attachmenntt,, 32 x 35 mmm 077774466-0001100220000
Attachmenntt,, 37 x 40 mmm
Attachment,, 72 x 75 mmm 0774466 -- 00100660000
Pilot,,1122 mmm
Pilot, 35 mm 077774466-0004400220000
Crankcase assembly tool 077774466-0004400880000
-asassesmemblybly collar
-asassesmebmlybly shaft 07965 -VVMM0000110000
Universal bearingg puller
07965 -- VM00200

077663311-0001100000000

TROUBLESSHHOOOOTTININGG

Exceessssiivvee noisee
Worn crankshaft maiinn journal bearinnggss

* Worn or damaaggeedd connecting rodd bearinnggss
* Worn connecctingg rroodd small end

- Worn balancer bearinggss
- Improper balancer installaattioonn

-Abnormal vibration

• Improper balancer timing

http://www.motorcycle.in.th 133--11

CRANKSHAFT/IBAALLAANNCCEERR

CRANKSHAFFTT REMOVAL

Separate the crankcase and remove the transmission
(seccttiioonn 122))..

Remove the crankshaft and balancer fromm the right
crankkccaassee..

CAUTION:
BBe careful not to ddammaggee thhe ccrraannkkccaassee mating ssuurrfface
and crankshaft asssseemmbblylr.

Remmoovveethe left crankshaft bearriinngg usinnggthe beariinngg puller
with a suitable proteeccttoorr..

CAUTTIOONN::

·.Be careful not to ddammaaggee thhee barancer ddrriivvee gearr.
·.INf thhee barancer ddrriivvee gear is sccrraattcchheedd,, fiillee off thhe
sccrratchhed parrtt..

TOOOOLL: 077663311-00001100000000
Universaall bearingg puller

NOTEE::

Always replacee the left bearinngg with a new one if it comes
out with the crankshaft.

INSSPPEECCTTIIOONN I n

Crankshaft Runout
Placcee the crankshaafftt onn a standd or V-blockkss..
Set the dial indicator onn the shafts.
Rottaatteethe crankshaft two revolutions and reaadd the runouutt..

SERVICE LLIIMMIITT:: 0.03 mm (0..000011 in)

58mm 50.0 -- 50.5 mmm 56.5 mm
(2.28 in)) (1.97 --11..9999 inn)) (2.22 in)

I

Bigg Endd Side Clearaannccee
Measure the side clearanccee of the connecting rodd bigg end.

SERVVIICCEE LLIIMMIITT:: 00.66 mmmm (0.0022 in)

13-22 http://www.motorcycle.in.th

BBiigg EEnndd RRaaddiiaall CClleeaarraannccee CRANKSHAFTI/BALAANNCCER

Measure the raddiaal clearance of the connneeccttiinngg roodd bigg I
end.

SERVVIICCEE LLIIMMIITT::0.05 mmmm (0.0022 inn))

Balancer Gear BAl.N\j CER GEA I1
Check the balancer gear for wear or damage.

CrankshaftI/BBaallaanncceerr Bearingg
Turn the inner raccee of eachh bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that bearinngg outer racess fit tightly inn the
crankkccaassee..

http://www.motorcycle.in.th 13-3

CRANKSHAFT/IBBAALLAANNCCEERR

CRANKSHHAAFfTT/IBBAALLAANNCCEER BEARIING
REPLLAACCEEMMEENNTT

REMOVVAALL

Drive the right crankshaft bearing and balancer bearings
out of the right and left crankcases.

INSTTAALLLLAATTIIOONN

Crankshaft bearings

Cleaannthe crankcassee mating surface thoroughly, be carefuull
not to damage the mating surface.

Apply engine oil to the new crankshaft bearings and place
it on the crankcassee..

CAUTION:
• Check the each bearing stamp mark before

Install the crankshaft bearing.
Right side:: TM-SC0O77AA8877CCSS2266
Left side:: TM-SC0O77AA8877CCSS4422

Drive the crankshaft bearing to the right crankcaassee using
the special tools.

TOOLS: 07749-001o0o0o0O0
077466-00001100660000
Driver 07746-0040800
Attachmeenntt,, 72 x 75 mmm
Piloott,,335 mmmm

Installll the crankshaft bearing to the left crankcaassee..
Assemble the special tools onto the crankshaft as shown.
Installll the bearing to the left crankshaft by drawing it..

TOOLS: -07965 - VMOOl1O0O0
Crankcasee assembly tool -07965 - VMMO00O22000

-- assembly collar
-- assembly shaft

Remove the crankshaft and bearing assembly from the
left crankcassee..

AS$E; MillY COL.I.A~ A.SSEM BLY SHAFT

13-4 http://www.motorcycle.in.th

Balancer bearings CRANKSHAFTIBALANCER

Drive new barancer bearings into the right and left crank- BALANCER
case with following tools: GEAR

TOOLS:

Right crankcase side: 07749 - 0010000
Driver 07746 - 0010200
Attachment, 37 x 40 mm 07746 - 0040200
Pilot,12 mm

Left crankcase side: 07749 - 0010000
Driver 07746 - 0010100
Attachment, 32 x 35 mm 07746 - 0040200
Pilot, 12 mm

CRANKSHAFT INSTALLATION

Engage the balancer and crankshaft aligning the index
lines on the balancer driven and drive gears as shown and
set the crankshaft and balancer together into the right
crankcase.

~CRANKSHAFT

CRANKSHAFT ALIGN

http://www.motorcycle.in.th 13-5

FRONT WHEEL/SUSPENSION/STEERING

88 N·m (9 kgf·m. 65 Ibf·ft)

~4

59 N·m (6.0 kgf·m. 43 Ibf·ft)

14-0 http://www.motorcycle.in.th

14. FRONT WHEEUSUSPENSION/SSTTEEEERRIINNGG

SERVICE INFORMATIOONN 144--11 FRONTT WHEELL 14-8
14-2 FORK 14-122
TROUBLLEESSHHOOOOTTIINNGG 14-3 STEERRIINNGG STEM 14-199

II
HANDLEEBBAARR

SEERVVIICE INFORMATIIO0N

GENERALL

i1fft.Jh@b'

A coonnttaammiinnaatteeddbrrake ddisc or padd reduuccess stopping poowweerr. Discard coonnttaminatedd pads and cclleann a cCoonnttaammiinnaatteeddddisc
witthh a high quality brrakke ddegrreasingg agenntt..

* This section covers maintenance of the front wheel, fork and steeringg stem. Referr to section 166 for front (hydraauulliicc))
brakee service.
Support the motorcycle securely using a hoist or work stand.

SPECIFICCAATTIIOONNSS

I ITEEMM I STANDAARRDD Unit: mmm (iinn))

Minimum tire tread depth Driver only --- I ISERVIICCEE LLIIMMIITT
Coldd tire pressuree Driver and passenger
200 kPaa (2.00 kgf/cm2',,29 psi)) To the indicator
Axle runout Raddiiaall
Wheel rimm runout Axial 200 kPaa (2.00 kgf/cm2',,29 pssii)) ---
---
' Wheel balancer weight Spring free length ---
--- 0.20 (0.0088))
Fork -__-
--- 2.00 (0.0088))
Spring direction
PiDpee runout 412..44 (16.24) 2.0 (0.088))
Recommended fork fluid
Fluuiidd leveell With the tightly wound endd facingg down 60 9g (2.1 o02z)) max.
Fluuiidd capacity
--- 404.11 (15.9911))

Honda Ultra Cushon oil Noo..1l0 ---

13311 (5..22)) 0.20 (0.00088))

206 k± 2.5 cm3' (7.00 ±L 0.08 USS 0OZ~, 77.3. 3±f ---
0.09 Impp 0o2z)) ---

-__-

TORQUE VALLUUEES

Front axle nut 59 N·.m (6.0 kgff·mm, 43 Ibbff·fWt) U-nut
Front brake disc bolt 42 N·m (4.3 kggff·m, 311 Ibf·.ft) ALOC bolt
23 NN·mm (2.3 kggff·m, 177 Ibf.·ft)
Fork bolt 20 N·.mm (2.0 kggff·m, 144 Ibf.·ft) Apply a locking agent to the threads
Fork socket bolt 88 N·mm (99 kggff·m, 65 I1bbff·.fRt))
Steerinngg stem nut See page 14-2222
Top thread 23 N·mm (2.3 kggff.m, 177 Ibf·.ft)
Top bridge pinchh bolt 26 N·mm (2.7 kggff.m, 20 Ibbff·Wft)
Bottom bridge pinchh bolt 27 N·m (2.8 kggff·m,. 20 Ibf·.ft)
Handlebar pinchh bolt 8.88 N·mm (0.9 kgff·m, 6.5 Ibf·.ft)
Grip end screw

http://www.motorcycle.in.th 144--11

FFRROONNTT WHEElL/S/SUUSSPPEENNSSIIOONN//SSTTEEEERRIlNNGG

TTOOOOLLSS

BBeeaarriinngg rreemmoovveerr hheeaadd,, 1122 mmmm 0077774466-00005500330000
BBeeaarriinngg rreemmoovveerr sshhaafftt
DDrriivveerr 0077774466-00005500110000
AAttachment, 3377 x 4400 mmmm 077774499 --0001100000000
AAttachment, 4422 x 4477 mmmm 077774466-0000110022000
PPiilloott,, 1122 mmmm 0077774466-0000110033000
Steeeerriinngg steemm socket
Baalll raaccee remoovveer 0077774466 --00004400220000
Steering stemm driver
Foorrkk seeaall driver 077991166-3377110011001
Foorrkk seeaall driver attachmmeenntt
Oiill seaall remmoovveerr 07GMMDD -- KSS4400110000

077994466-44330000110011
077774477-00001100110000
077774477-00001100330000
07774488 -- 0001100000011

TROUBLESHOOOTTIINNGG -Whheeeell turns harrdd

Haarrdd steerinngg • Faauullttyy wheeeell beeaarriinngg
Steering top threadd too tight •* Faulty speedometer gear

- Daammaaggeedd steeerriinngg heeaadd beaarriinngg Soft suspension
-• Insufficient tire presssuurree * Weak fork spring
•* Insufficient fork oill
Faulty tire
Harrdd suspennssiioonn
Steerss to one side or does not track straight Bent fork pipee
* Beennttforkk
* Bent front axle • Cloggggeedd fluid passsaaggee
* Wheel installleedd incorrectly
Frontt suspensioonn nnoiisy
Faulty steeriinngg heaadd bearing
- Insufficient fluid inn fork
- Bennttframe - Looossee front suspension fastenerss
Faulty wheel bearingg
* Worn swingarm pivot components Lackk of greassee inn speedometer gear

Front wheel wobbling
Bent rimm

-- Worn wheel bearingss
Bent or loose spoke
Faulty tire

14-2 http://www.motorcycle.in.th

FRONT WHEEL/SUSPEENNSSIIOONN//SSTTEEEERRIlNNGG

HANDLEBAR

REMMOOVVAALL

Disconnect the front brakee light switch conneeccttoorrss from
tthhee switchh..
Remove the bolts, master cylinder holder andd master
cylinder.

NOOTTEE::

Keeepp the brakkee reservoir uprighhtt to prevent air from

enterriinnga the hyvdraulic syvstem. .

Remmoovvee the throttle housinngg screws.

Remmoovvee the throttle upper housing.
Remmoovvee the throttle cablee from the throttle pipee..

Remoovvee the grip end. GRIPE D
Remmoovvee the throttle grip fromm the handlee barr..

http://www.motorcycle.in.th THFl.OTILE GRIP

14-3

FROONNTT WHEEL/SUSSPPEENNSSIIOONN//SSTTEEEERRIlNNGG

Remmoovveethhe clluuttcchh swiittcchh coonnnneeccttoorrss..

Remmoovvee thhee clluuttcchh lever hoollddeerr bboollttss..
Remoovvee thhe clluuttcchh llever hhoolldderr andd clluuttcchh llevverr brraacckkeett
assemmbbllyy..

Remmoovveethhee sccrreewwss andd lleft hhannddlleebbaarr swwiittcchh hhoouussiinngg. HO uSINCO

scm:ws

Remoovvee thhee grriipp endd andd left hhannddlleebbaarr grriipp..

14-44 http://www.motorcycle.in.th

FRONNTT WHEEL/SUSPEENNSSIIOONN//SSTTEEEERRIlNNGG

Remmoovvee the stopper ringg.. I-1ANDLEBAA
Loosseenn the handlebar pincchh bolt andd removvee the handle-
bar fromm the fork.

INSTAALLLLAATTIIOONN 14-5

Inssttaalll the handlebar onto the fork and align the bosss on
the handle bar with the cut-out onn the top bridgee..

Tighten the handlebar pincchh bolt to the specified torque.
TOORRQQUUEE: 27 NN·mm (22..88 kkggff·.mm., 20 IbfH4tt))
Insttaalll the stopper ringg into the groove onn the fork pipe.
Instaallll the right handlebar inn the same manner as for the
left handlebar.

If the left handlebar grips were removed,. apply Hondaa
Bonndd A or its equivalent to the inside surface of the grip
andd to the cleaann surface of the left handleebbaarr..

Wait 3 -- 5 minutes andd instaallll the grip.

Rottaattee the grip for evenn application of the adhesive.
NOTEE::
Allow the adhesive to dry for ann hour beforree using.

http://www.motorcycle.in.th

FRONT WHEEL/SUSPEENNSSIIOONN//SSTTEEEERRIlNNGG TH flOTTlE GRIP

Apply grease to the throttle pipeeslidingg surfaacceeand throttle
cablee contact pointt..
Inssttaalll the throttle grip to the handlebaarr..
Inssttaalll the grip end.
Tighten the grip endd screw to the speciffiieedd torque.
TOORRQQUUEE: 8.8 NN·.mm (0.9 kggff'm, 6.5 Ifbbff.4ftt))

Apply grease to the throttle cable end..
Conneecctt the throttle cablee to the throttle pipe.
Inssttaalll the throttle housing andd align its locating pinn oftthhe
throttle housing cover with the hole onn the handlebbaarr..

Insttaallllthe screws and tighten the forward screw first, then
the rear screw..

Plaaccee the front master cylinder onn the handlebar and inn--
stallll the master cylinder holder with its ·"UP"· mark facing
uUpP..

Align the endd of the holder with the punchh mark onn the
handlebbaarr..
Tighten the upper bolt first, thenn tighten the lower bolt.

14-66 http://www.motorcycle.in.th

FRONT WHEEL/SUSPENSION/STEERlING

Connect tthhe ffrroonntt brake sswitch connectoorss..

Install the left handlebaarr grip onto the handlebaarr (refer to
page 14-·551).
Instaallll the grip end.
Tightenn the grip end screw to the specified torque.
TORRQQUUEE: 8.8 NN·mm (O0.9 kggff·mm, 6.55IIbbff·4ftt))

Inssttaalll the left handlebar switch houssiinngg aligning itss locat·-
ingg pinn with the hole onn the handleebbaarr..

IInnssttaallltthhee ssccrreewwssaannddtighhtteenn tthhee foorwwaarrdd ssccrreewwffirst, thheenn SCflEWS
thhee rreeaarr sscrew.
1144--77
http://www.motorcycle.in.th

FROONNTT WHEEL/SUUSSPPEENNSSIIOONN//SSTTEEEERRIlNNGG

Plaaccee the clutchh lever bracket onn the handlebar andd instaallll
the clutchh lever holder with itss "UP" mark facingg up.

Align the endd of the holder with the punncchh mark on the
handlebaar.
TIighten the upper bolt first, thenn the lower bolltt..
Connect the clutchh switch connectors.

FRONTTWHEEL r- ""-rSf'eJEDOMElE.Fi G .Mi BOX

REMOOVVAALL ~

Raaiissee the front wheel off the ground by suitabblee support.. AXl.£ IliU
Preessss the bosss of speedometer cablee inn the speedometerr
gear boxx..
Disconnect the speedommeetteer cablee fromm the speedometerr
gear boxx..
Remmoovvee the axle nut, axlee andd front wheel.

NOOTTEE::

Doo not operate the front braakkee lever after the front wheel
iss removed. The caliper pistoonn will movee out andd make
assembly difficult.

INSSPPEECCTTIIOONN

Axle
Plaaccee the axle inn V-blocks andd meaassuurree the runout with a
dial inddiiccaattoorr..

SERRVVIICCEE LLIIMMIITT::0.2 mmmm (0.000088in)

Thee actuuaall runout iss 1/2 oftthhe total indicator reading.

Wheel Beaarriinngg
Remmoovvee the dust seaall.. (page 14-9))..
Turnn the inner raccee of eacchh bearing with your finger, the
bearingg should turn smoothly andd quietly.
Also check that the bearingg outer raccee fits tightly inn the
hubb..

Remmoovvee andd discaarrdd the bearings if the racceess do not turn
smoothly, quietly, or if they fit loosely inn the hubb..

NOTE: WHEEL BEARRIINNGG \
Reeppllaacceewheeel bearinggss inn pairss..

For bearriinngg replacement, seee paaggee 144--99.. I

14--88 http://www.motorcycle.in.th

FROONNTT WHEEL/SUSPENSION/STEERlING

Wheel rimm
Check the wheel rimm runout by placinngg the wheel inn a turn-
ingg stand.
Spin the wheell by hand and reaadd the runout usingg a
dial indicaattoorr..

SERVVIICCEELLIIMMIITT:: Actual: 2.0 mmmm /(00.08 in)
Radiiaall:: 2.00 mmmm (0.08 inn))

DISASSEMBLLYY

Remove the speedometer gearbox, dust seall andd speeedd--

ometer retainer. .

Remmoovvee the side collar and dust seall from the right hub. SIDE COLLAFI BOLT S
Remmoovvee the brake disc bolts andd brakee disc.

NOTTEF::

Checkk for disc warpage; seee pag-e-1-6---88-..------------

WHEEL BEARIINNGG REPLACEMEENNTT RJ:MOViEFI HEAO

Removvee the wheel bearings and distance collar fromm the
wheel hub..

TOOLS: -07774466 - 00005500330000
Bearriinngg remover head, 122 mmmm
Bearriinngg remover shaft 077774466-0000550011000

NOTEE::

Never reinssttaalll old bearings. Oncee the bearinnggss havee beeenn
removed, they must bee replaacceedd with a new one.

http://www.motorcycle.in.th 14-99

FRONT WHEElLISISUUSSPPEENNSSIOIONN/SISTTEEEERRIINNGG

FRONT WHE . the following tools.
Driivvee thhe new rriigghhttbbeeaarrinigngininuus~inngg the following tools.

NOTE:
INnOsstTtaaEIlI:lthe beanr.innggsswwiitthh iittss mmaarrkki.inngg siidde faciinngg ouutt..

TOOOOLLSS:: 077774499-00001100000000
ADDrtrtiivvaeecrrhmeenntt,, 3377 xx 4400 mmmm
Piloott,, 1122 mmm -07746 - 0001100220000
-077466 - 0004400220000

Installthe di.stanccee coollllaarr..

Install the dis . the same tools.

Driivvee thhe new leftt beariinngg inn uSsingg the same tools.

DISTANCE COLLAR

ASSEMBLYY BRAKKEE DISSCC

%j RIGHT WHEEL BEARING

n/

/

_......

SPEEDOMETE RGEAR

DUST SEAL w// 6/RETAAIINNEERR

,......~.. ......EiiB ~~U@ST!t./Aol. SHIM

14-10 / ..f.---.
BLBEEEFAATRRWIINNHGGEEL ,...... GSSGPPEEEEAAEERRDDBBOOOOMMXXEETTEERR

http://www.motorcycle.in.th

FRROONNTT WHEEL/SUSPENNSSIONN/STEERRIlNG

If remmoovveedd the front tire, inssppeecctt the wheeell balanccee (paaggee
155--33))..
Apply greassee to the speedometer gear retainer, and iinn--
stallll itt into the left side hub aligning its tabs with the slots
inn the hub.

Sl,OTS

Apply grease to a new left dust seall lips, then installll it into
the wheel hub.

Instaallll a new right dust seal and brake disc with the
stomped mark ""MMIINN..TTHH,, 3..55 mm" facing out side.
Apply greese to the dust seall lips.
Tighten the brakee disc mountingg bolts to the specified
torque.
TORQUE: 42 N.·m 1(44.33 kgf·.m, 311 Ibff4·t-t)l

Instaalll the right side collar.

http://www.motorcycle.in.th 14-1111

FRONT WHEEL/SUSPENSION/STEERIlNG

Install the speeddoommeetteerr gear box in the wheel hub aaliiggnn--
ing the tangs of the retainer with the slots in the speed-
ometer gear box..

INSTALLLLAATTIIOONN ,.

Posittiioonn the front wheel between the fork legs and align
the stopper of the left fork leg and groove of the speed-
ometer gear box.
Instaallll the front axle fromm the right side.

CAUTIOONN::

Whenn insttallinngg the front whheeeell,, fit thhe brake disc care-
fullyv between the brake pDaads to avoid damrnaagsiinngsthe Dpaaddss..

Inssttaalll andd tighten the axle nut to the specified torque. eAX NUr

TORRQQUUEE: 599 NN'mm (6..00 kkggff·.mm,, 43 IbHf4tt)) ..

Ilnsatlll andd connect the speedometer cable to the speed-
ometer gear boxx secureellyy..

FORK

REMMOOVVAALL

RReemmoovvee thee following:
- frofrnotnt wheeeell ((ppaaggee 1144--88))
--frofrnotnt fender ((ppaaggee 2--44))
-hahnadnldelbeabrasrs ((ppaaggee 114-3)1
--brbarkaeke ccaaliper ((ppaaggee 1166--66))

LLoooosseenntthhee ffoorrkk bboollts, bbuutt ddoo nnoott rreemmoovvee iitt..
LLoooosseenntthhee ffoorrkk toopp ppiinncchh bboollttss..

144--1122 http://www.motorcycle.in.th

FROONNTT WHEEL/SUSPEENNSSIIOONN//SSTTEEEERRIlNNGG

Loooosseenn the fork bottomm pinncchh booltss anndd remmoovvee the fork
pippee..

DISAASSSEEMMBBLLYY

Caareefuully remmoovvee the fork boolltt.

,iQ·W",,;

Thhee fork bolt is uunndder ssppring prressssuurree.. Ussee ccarre wwhheenn
rermnoovviinngo it and wwear eyve and faccee pmrotteccttiioonn..

RReemmoovvee the sprinngg collaarr,, springg seaat.

RReemmoovvee the fork spring. lSl'RING

Poouurr out the fork fluidd by pummppiinngg the fork pippee seevveerraall
timmeess..

http://www.motorcycle.in.th 14-1133

FRROONNTT WHEEL/SUSPENSION/STEERlING

Remmoovvee the dust seaall andd stopper ringg..

SfOPAER RI G

Holldd the fork slider inn a vise with pieccee of woods or shop
towel.
Remmoovvee the fork socket bolt andd sealing washerr..

NOTTEE::
If the socket bolt turnn together with the fork piston, tem-
porarily instaallll the fork spring andd fork bolt.

Remmoovvee the fork pistoonn andd reboouunndd springg.. fltllOUND SPFlING

FORK PIST ON

Remmoovvee the fork pipee andd oill lock pieccee..

A FOR PIPE

14-14 http://www.motorcycle.in.th