CGL125 Service Manual

How to use this manual
A Few Words About Safety

Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper set-up and pre-delivery are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper set-up or pre-delivery service can create

an unsafe condition that can cause your customer
to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing set-up and pre-delivery procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and precau-

tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
0-1
How To Use This Manual
This manual describes the service procedures for the CGL125 1/2/3/4/5/6 WH-A.
Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removal/installation of components that may be
required to perform service described in the following sections.
Section 4 through 18 describe parts of the motor cycle, grouped according to location.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
If you don't know the source of the trouble, go to Troubleshooting section.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messag-
es and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards as-
sociated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo-
tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER-
MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE
ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: Mar, 2009
0-2
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Honda Moly 60 (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.
0-3
CONTENTS
GENERAL INFORMATION 1
FRAME/BODY PANELS/EXHAUST SYSTEM 2
MAINTENANCE 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
ENGINE REMOVAL/INSTALLATION 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER 9
ALTERNATOR/STARTER CLUTCH 10
CRANKCASE/CRANKSHAFT/TRANSMISSION 11
FRONT WHEEL/BRAKE/SUSPENSION/STEERING 12
REAR WHEEL/BRAKE/SUSPENSION 13
HYDRAULIC DISC BRAKE 14
BATTERY/CHARGING SYSTEM 15
IGNITION SYSTEM 16
ELECTRIC STARTER 17
LIGHTS/METERS/SWITCHES 18
WIRING DIAGRAM 19
TROUBLESHOOTING 20
INDEX
MEMO
1. GENERAL INFORMATION
SERVICE RULES ··········································· 1-2 FRONT WHEEL/BRAKE/SUSPENSION/

STEERING SPECIFICATIONS ·······················1-8
MODEL IDENTIFICATION ····························· 1-2
REAR WHEEL/BRAKE/SUSPENSION
GENERAL SPECIFICATIONS ······················· 1-4 SPECIFICATIONS···········································1-8
LUBRICATION SYSTEM HYDRAULIC DISC BRAKE

SPECIFICATIONS ·········································· 1-5 SPECIFICATIONS···········································1-8
FUEL SYSTEM SPECIFICATIONS················ 1-5 BATTERY/CHARGING SYSTEM

SPECIFICATIONS···········································1-9
CYLINDER HEAD/VALVES
SPECIFICATIONS ·········································· 1-5 IGNITION SYSTEM SPECIFICATIONS ··········1-9
CYLINDER/PISTON SPECIFICATIONS ········ 1-6 ELECTRIC STARTER SPECIFICATION ········1-9
CLUTCH/GEARSHIFT LINKAGE/ LIGHTS/METERS/SWITCHES

KICKSTARTER SPECIFICATIONS ··············· 1-6 SPECIFICATIONS···········································1-9
ALTERNATOR/STARTER CLUTCH TORQUE VALUES ········································1-10

SPECIFICATION ············································ 1-7
LUBRICATION & SEAL POINTS··················1-14
CRANKCASE/CRANKSHAFT/
TRANSMISSION SPECIFICATIONS ············· 1-7 CABLE & HARNESS ROUTING···················1-16
EMISSION CONTROL SYSTEMS ················1-29
1-1
GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design
specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-16).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
ICM Ignition Control Module
PAIR Pulsed Secondary Air Injection
MODEL IDENTIFICATION
This manual covers following types of CGL125WH-A models:
Front Front
Spoke Cast
TYPE Drum Disc
Wheel Wheel
Brake Brake
1 – O O –
2 – O – O
3 O – O –
4 – O O –
5 – O – O
6 O – O –
Be sure to refer to the procedure for the appropriate version of the CGL125WH-A.
TYPE 2, 5 SHOWN:
1-2
GENERAL INFORMATION
The Vehicle Identification Number (VIN) is stamped on the right side of the
steering head.
VEHICLE IDENTIFICATION NUMBER
The engine serial number is stamped on the lower left side of the
crankcase.
ENGINE SERIAL NUMBER
The carburetor identification number is stamped on the right side of the

carburetor body.
CARBURETOR IDENTIFICATION NUMBER

The color label is attached on the left side of the frame under the seat.
When ordering color-coded parts, always specify the designated color code. COLOR LABEL
1-3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
DIMENSIONS Overall length 2,005 mm (78.9 in)
Overall width 768.5 mm (30.26 in)
Overall height 1,064 mm (41.9 in)
Wheelbase 1,297 mm (51.1 in)
Seat height 722 mm (28.4 in)
Footpeg height 316 mm (12.4 in)
Ground clearance 145 mm (5.7 in)
Curb weight (Type 1, 3, 4, 6) 125 kg (276 lbs)
(Type 2, 5) 126 kg (278 lbs)
Maximum weight capacity 153 kg (337 lbs)
FRAME Frame type Backbone type
Front suspension Telescopic fork
Front wheel travel 116 mm (4.6 in)
Rear suspension Swingarm
Rear wheel travel 80 mm (3.1 in)
Front tire size 2.75-18 42P
Rear tire size 90/90-18M/C 51P
Front tire brand C-128 (CHENGSHIN)
Rear tire brand C-907 (CHENGSHIN)
Front brake (Type 1, 3, 4, 6) Mechanical drum (leading-trailing)
(Type 2, 5) Hydraulic single disc
Rear brake Mechanical drum (leading-trailing)
Caster angle 28° 00’
Trail length 80.0 mm (3.15 in)
Fuel tank capacity 10.2 liter (2.69 US gal, 2.24 lmp gal)
Fuel tank reserve capacity 2.7 liter (0.71 US gal, 0.59 lmp gal)
ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical
Bore and stroke 52.4 x 57.8 mm (2.06 x 2.28 in)
Displacement 124.7 cm3 (7.61 cu-in)
Compression ratio 9.2 : 1
Valve train Chain driven OHC with rocker arm
Intake valve opens 10° BTDC at 1 mm (0.04 in) lift
closes 25° ABDC at 1 mm (0.04 in) lift
Exhaust valve opens 35° BBDC at 1 mm (0.04 in) lift
closes -5° ATDC at 1 mm (0.04 in) lift
Lubrication system Pressing and spray type
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Paper filter
Engine dry weight 28.6 kg (63.1 lbs)
CARBURE- Carburetor type Piston valve
TOR Throttle bore 22 mm (0.9 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 5 speeds
Primary reduction 3.350 (67/20)
Final reduction 3.214 (45/14)
Gear ratio 1st 3.076 (40/13)
2nd 1.789 (34/19)
3rd 1.304 (30/23)
4th 1.076 (28/26)
5th 0.928 (26/28)
Gearshift pattern Left foot operated return system
1-N-2-3-4-5
ELECTRICAL Ignition system DC – CDI
Starting system Kickstarter with electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted, triple phase full-wave rectification
Lighting system Battery
1-4
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil ca- After draining 0.8 liter (0.8 US qt, 0.7 lmp qt) –
pacity After disassembly 1.0 liter (1.1 US qt, 0.9 lmp qt) –
Recommended engine oil API classification: SG or higher
(except oils labeled as energy conserving
on the circular API service label) –
Viscosity: SAE 10W-30
JASO T 903 standard: MA
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.25 (0.010)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Carburetor identification number PDCBV
Main jet #98
Slow jet #38
Pilot screw opening See page 5-16
Float level 14.0 mm (0.55 in)
Idle speed 1,400 ± 100 min-1 (rpm)
Throttle grip free play 2.0 – 6.0 mm (0.08 – 0.24 in)
CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)
Cylinder compression at 800 min-1 (rpm) 1,196 kPa (12.2 kgf/cm2, 176 psi) –
Valve clearance IN 0.08 ± 0.02 (0.003 ± 0.001) –
EX 0.12 ± 0.02 (0.005 ± 0.001) –
Valve, Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.92 (0.194)
valve guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.04 (0.198)
Stem-to-guide clear- IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
ance EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)
Valve seat width IN/EX 0.9 – 1.1 (0.0035 – 0.0043) 1.5 (0.06)
Valve spring Free length INNER 38.76 (1.526) 37.89 (1.492)
OUTER 35.95 (1.415) 35.14 (1.383)
Rocker arm Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm-to-shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
Camshaft Cam lobe height IN 32.9935 – 33.2335 (1.29895 – 1.30840) 32.96 (1.298)
EX 32.8804 – 33.1204 (1.29450 – 1.30395) 32.85 (1.293)
Cylinder head warpage – 0.05 (0.002)
1-5
GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 52.400 – 52.410 (2.0630 – 2.0634) 52.50 (2.067)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Piston, Piston O.D. at 10 mm (0.4 in) from bot-
52.370 – 52.390 (2.0618 – 2.0626) 52.3 (2.059)
piston pin, pis- tom
ton ring Piston pin hole I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Second 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.85 (0.033)
Piston ring-to-ring Top 0.030 – 0.065 (0.0012 – 0.0026) 0.10 (0.004)
groove clearance Second 0.030 – 0.065 (0.0012 – 0.0026) 0.10 (0.004)
Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.10 (0.004)
Connecting rod small end I.D. 13.016 – 13.034 (0.5124 – 0.5131) 13.04 (0.513)
Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.03 (0.001)
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SPECIFICATIONS

Unit: mm (in)
Clutch lever free play 10 – 20 (0.4 – 0.8) –
Clutch Spring free length 40.5 (1.59) 39.6 (1.56)
Disc thickness 2.80 – 2.90 (0.110 – 0.114) 2.6 (0.10)
Plate warpage – 0.20 (0.008)
Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909)
Clutch outer guide O.D. 22.959 – 22.980 (0.9039 – 0.9047) 22.93 (0.903)
I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
Kickstarter idle gear I.D. 20.500 – 20.521 (0.8071 – 0.8079) 20.58 (0.810)
Kickstarter idle gear bushing O.D. 20.459 – 20.480 (0.8055 – 0.8063) 20.43 (0.804)
I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
Countershaft O.D. at kickstarter idle gear 16.966 – 16.984 (0.6680 – 0.6687) 16.94 (0.667)
Kickstarter drive gear I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.06 (0.632)
Kickstarter spindle O.D. at kickstarter drive gear 15.966 – 15.984 (0.6286 – 0.6293) 15.94 (0.628)
1-6
GENERAL INFORMATION
ALTERNATOR/STARTER CLUTCH SPECIFICATION
Unit: mm (in)
Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.60 (1.795)
CRANKCASE/CRANKSHAFT/TRANSMISSION SPECIFICATIONS
Unit: mm (in)
Crankshaft Connecting rod big end radial clear-
0 – 0.008 (0 – 0.0003) 0.05 (0.002)
ance
Connecting rod big end side clear-
0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032)
ance
Runout 0.03 (0.001) 0.08 (0.003)
Transmission Gear I.D. M4 20.000 – 20.018 (0.7874 – 0.7881) 20.05 (0.789)
M5 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)
C2, C3 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
Bushing O.D. C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)
C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)
Gear-to-bushing C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance C2 0.015 – 0.057 (0.0006 – 0.0022) 0.10 (0.004)
C3 0.015 – 0.057 (0.0006 – 0.0022) 0.10 (0.004)
Bushing I.D. C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
Mainshaft O.D. at M4 19.968 – 19.980 (0.7861 – 0.7866) 19.93 (0.785)
at M5 16.968 – 16.980 (0.6680 – 0.6685) 16.93 (0.667)
Countershaft O.D. at C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667)
at C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785)
at C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785)
Bushing-to-shaft C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Shift fork, shift Shift fork shaft O.D. 9.986 – 9.995 (0.3931 – 0.3935) 9.93 (0.391)
fork shaft Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)
1-7
GENERAL INFORMATION
FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
Minimum tire tread depth – To indicator
Cold tire Driver only 200 kPa (2.00 kgf/cm2, 29 psi) –
pressure Driver and passenger 200 kPa (2.00 kgf/cm2, 29 psi) –
Axle runout – 0.2 (0.01)
Wheel rim Radial – 1.0 (0.04)
runout Axial – 1.0 (0.04)
Wheel hub-to-rim distance (Type 3, 6) 6.5 ± 1 (0.3 ± 0.04) –
Front brake Lever freeplay 10 – 20 (0.4 – 0.8) –
(Type 1, 3, 4, 6) Drum I.D. 130.0 – 130.3 (5.12 – 5.13) 131 (5.2)
Fork Spring free length 485 (19.1) 453 (17.8)
Tube runout – 0.20 (0.008)
Recommended fork fluid Fork fluid –
Fluid level 147 (5.8) –
Fluid capacity 159 ± 2.5 cm3 (5.4 ± 0.08 US oz, 5.6 ±
–
0.09 lmp oz)
REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Unit: mm (in)
Cold tire pres- Driver only 225 kPa (2.25 kgf/cm2, 33 psi) –
sure Driver and passenger 225 kPa (2.25 kgf/cm2, 33 psi) –
Wheel hub-to-rim distance (Type 3, 6) 2.0 ± 1 (0.08 ± 0.04)
Drive chain Size/link 428H/112 –
Slack 15 – 25 (0.6 – 1.0) –
Rear brake Pedal freeplay 20 – 30 (0.8 – 1.2) –
Drum I.D. 130.0 – 130.3 (5.12 – 5.13) 131 (5.2)
HYDRAULIC DISC BRAKE SPECIFICATIONS

Unit: mm (in)
Specified brake fluid DOT 3 or DOT 4 –
Brake pad wear indicator – To the groove
Brake disc thickness 3.8 – 4.2 (0.15 – 0.17) 3.5 (0.14)
Brake disc runout – 0.10 (0.004)
1-8
GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 7 Ah
Current leakage 1 mA max.
Specific gravi- Fully charged 1.270 – 1.290
ty (20°C/68°F) Needs charging Below 1.230
Voltage Fully charged 13.0 – 13.2 V
(20°C/68°F) Needs charging Below 12.3 V
Charging current Normal 0.6 A/5 – 10 h
Quick 3 A/1 h
Alternator Capacity 0.16 kW/5,000 min-1 (rpm)
Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATION
Spark plug Standard CPR7EA-9 (NGK)
For extended high speed riding CPR8EA-9 (NGK)
Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)
Ignition coil primary peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing ("F" mark) 8° BTDC at idle
ELECTRIC STARTER SPECIFICATION

Unit: mm (in)
Starter motor brush length 10.00 – 10.05 (0.394 –0.396) 3.5 (0.14)
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATION
Bulbs Headlight (Hi/low beam) 12 V - 35/35 W
Position light 12 V - 3 W
Brake/tail light 12 V - 21/5 W
Turn signal light 12 V - 10 W x 4
Instrument light 12 V - 1.7 W x 3
Turn signal indicator 12 V - 1.7 W x 2
High beam indicator 12 V - 1.7 W
Gear position indicator LED x 5
Neutral indicator 12 V - 1.7 W
Fuse Main 20 A
Sub 15 A
Fuel level sensor resistance Full 4 – 10 Ω
(20°C/68°F) Empty 90 – 108 Ω
1-9
GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm bolt and nut 5 (0.5, 3.7) 5 mm screw 4 (0.4, 3.0)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.6)
(Include SH flange bolt) 6 mm flange bolt 12 (1.2, 9)
8 mm bolt and nut 22 (2.2, 16) (Include NSHF) and nut
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Side cover screw 1 6 5 (0.5, 3.7)
Sidestand pivot bolt 1 10 10 (1.0, 7)
Sidestand pivot nut 1 10 45 (4.6, 33)
Exhaust pipe stud bolt 2 8 11 (1.1, 8) See page 2-10
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
Fuel strainer cup 1 – 16 (1.6, 12)
Choke cable lock nut 2 6 10 (1.0, 7)
Air cleaner element mounting screw 1 5 4.2 (0.43, 3.1)
Spark plug 1 10 16 (1.6, 12)
Valve adjusting lock nut 2 6 14 (1.4, 10) Apply engine oil to
the threads and seat-
ing surface
Crankshaft hole cap 1 32 15 (1.5, 11) Apply grease to the
threads
Timing hole cap 1 14 10 (1.0, 7)
Engine oil drain bolt 1 12 30 (3.1, 22)
Oil filter rotor cover screw 3 5 4 (0.4, 3.0)
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Oil pump cover screw 1 4 3 (0.3, 2.2)
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Tool box cover bolt 2 5 1.8 (0.18, 1.3)
Choke cable stay screw 1 5 3.4 (0.35, 2.5)
Carburetor drain screw 1 6 1.5 (0.15, 1.1)
Slow jet 1 6 1.8 (0.18, 1.3)
Needle jet holder 1 7 2.5 (0.25, 1.8)
Main jet 1 5 2.1 (0.21, 1.5)
Float chamber screw 3 4 2.1 (0.21, 1.5)
Insulator socket bolt 2 6 12 (1.2, 9)
Fuel valve lock nut 1 16 22 (2.2, 16)
PAIR check valve cover screw 2 4 2.1 (0.21, 1.5)
1-10
GENERAL INFORMATION
ENGINE REMOVAL/INSTALLATION
THREAD TORQUE
ITEM Q'TY REMARKS
Front/upper engine hanger nut 4 8 27 (2.8, 20)
Rear engine hanger nut 2 10 54 (5.5, 40)
Drive sprocket bolt 2 6 12 (1.2, 9)
THREAD TORQUE
ITEM Q'TY REMARKS
Cylinder head cover bolt 2 6 10 (1.0, 7)
Rocker arm shaft bolt 2 5 5 (0.5, 3.7)
Cam sprocket bolt 2 5 9 (0.9, 6.6)
Camshaft holder nut 4 8 32 (3.3, 24) Apply engine oil to
ing surface
Cam chain tensioner lifter plug 1 6 4 (0.4, 3.0)
CYLINDER/PISTON
THREAD TORQUE
ITEM Q'TY REMARKS
Cylinder stud bolt 4 8 11 (1.1, 8) See page 8-7
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER
THREAD TORQUE
ITEM Q'TY REMARKS
Clutch center lock nut 1 14 74 (7.5, 55) Apply engine oil to
ing surface
Clutch lifter plate bolt 4 6 12 (1.2, 9)
Oil filter rotor lock nut 1 14 64 (6.5, 47) Apply engine oil to
ing surface
Gearshift cam bolt 1 6 12 (1.2, 9) Apply locking agent
to the threads
Shift drum stopper arm bolt 1 6 12 (1.2, 9) Apply locking agent
to the threads
ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
ITEM Q'TY REMARKS
Flywheel nut 1 14 74 (7.5, 55) Apply engine oil to
ing surface
Starter clutch bolt 6 6 16 (1.6, 12) Apply locking agent
to the threads
Alternator stator socket bolt 3 6 12 (1.2, 9)
Ignition pulse generator socket bolt 2 6 12 (1.2, 9) Apply locking agent
to the threads
Wire guide socket bolt 1 6 12 (1.2, 9) Apply locking agent
to the threads
CRANKCASE/CRANKSHAFT/TRANSMISSION
THREAD TORQUE
ITEM Q'TY REMARKS
Mainshaft bearing setting plate bolt 2 6 12 (1.2, 9) Apply locking agent
to the threads
Push plug bolt 1 6 10 (1.0, 7) Apply locking agent
to the threads
Gearshift spindle return spring pin 1 8 22 (2.2,16) Apply locking agent
to the threads
1-11
GENERAL INFORMATION
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
Front axle nut 1 12 52 (5.3, 38) U-nut
Front brake disc bolt (Type 2, 5) 6 8 42 (4.3, 31) ALOC bolt: replace
with a new one
Spoke (Type 3, 6) 36 BC3.2 3.7 (0.38, 2.7)
Front brake arm nut (Type 1, 3, 4, 6) 1 6 10 (1.0, 7)
Handlebar holder bolt 4 6 12 (1.2, 9)
Clutch lever pivot bolt 1 6 1 (0.1, 0.7)
Clutch lever pivot nut 1 6 5.9 (0.6, 4.4)
Rearview mirror lock nut 2 10 34 (3.5, 25)
Fork socket bolt 2 8 20 (2.0, 15) Apply locking agent
to the threads
Fork cap 2 26 22 (2.2, 16)
Bottom bridge pinch bolt 2 8 34 (3.5, 25)
Top bridge pinch bolt 2 8 23 (2.3, 17)
Steering bearing adjustment nut 1 22 – For tightening se-
quence; See page
12-37
Steering stem nut 1 22 – For tightening se-
quence; See page
12-37
THREAD TORQUE
ITEM Q'TY REMARKS
Rear brake arm nut 1 6 10 (1.0, 7) U-nut
Driven sprocket bolt 4 8 34 (3.5, 25)
Rear axle nut 1 14 59 (6.0, 44) U-nut
Shock absorber upper mounting bolt 2 8 29 (3.0, 21)
Shock absorber lower mounting bolt 2 10 34 (3.5, 25)
Rear brake stopper arm nut 2 8 22 (2.2, 16)
Spoke (Type 3, 6) 36 BC3.2 3.7 (0.38, 2.7)
Swingarm pivot nut 1 12 59 (6.0, 44) U-nut
HYDRAULIC DISC BRAKE
THREAD TORQUE
ITEM Q'TY REMARKS
Caliper bleed valve 1 8 8 (0.8, 5.9)
Master cylinder reservoir cap screw 2 4 1.5 (0.15, 1.1)
Brake caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt: replace
with a new one
Front brake light switch screw 1 4 1.0 (0.10, 0.7)
Brake lever pivot bolt 1 6 1.0 (0.10, 0.7)
Brake lever pivot nut 1 6 6.0 (0.6, 4.4)
Brake hose oil bolt 2 10 34 (3.5, 25)
Brake caliper slide pin 2 8 18 (1.8, 13) Apply locking agent
to the threads
Pad pin 2 10 18 (1.8, 13)
Pad pin plug 2 10 2.5 (0.25, 1.8)
1-12
GENERAL INFORMATION
BATTERY/CHARGING SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Battery holder bolt 4 6 1.8 (0.18, 1.3)
ELECTRIC STARTER SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Starter motor case bolt 2 4 4.9 (0.50, 3.6)
LIGHTS/METERS/SWITCHES
THREAD TORQUE
ITEM Q'TY REMARKS
Fuel level sensor mounting nut 4 6 10 (1.0, 7)
Ignition switch mounting bolt 2 8 24 (2.4, 18) ALOC bolt: replace
with a new one
1-13
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Sealant (Three bond 1215 Crankcase mating area See page 11-18
or 1207G or equivalent) Alternator wire grommet seating surface
Engine oil Oil pump rotors
Oil filter rotor lock nut threads and seating surface
Oil through sliding area
Rocker arm shaft whole surface
Rocker arm inner surface and roller surface
Rocker arm tappet adjusting nut threads
Cam chain whole surface
Camshaft holder nut threads and seating surface
Cylinder inner surface
Piston sliding surface, piston pin hole and ring grooves
Piston rings whole surface
Clutch discs whole surface
Clutch center lock nut threads and seating surface
Clutch lifter arm sliding surface
Flywheel nut threads and seating surface
Gearshift spindle journal
Starter reduction gear shaft whole surface
Starter clutch rolling surface
Shift fork shaft whole surface
Shift drum journals and guide grooves
Gear teeth (primary, transmission kickstarter)
Each bearing rotating area
Each O-ring
Multi-purpose grease Each oil seal lip
Crankshaft hole cap threads
Molybdenum oil solution (a Valve stem sliding surface and stem end
mixture of engine oil and Camshaft cam whole surface
molybdenum disulfide Piston pin outer surface
grease in a ratio of 1:1) Clutch outer guide outer surface
Crankshaft connecting rod big end needle bearing Drip 1 - 2 cc
Crankshaft connecting rod small end inner surface
Crankshaft bearing push plug whole surface
Right crankshaft bearing rotating surface
Starter driven gear inner surface
M4, M5, C1, C2, C3 gear rotating surface
C1, C2, C3 gear bushing whole surface
M3, C4, C5 gear shift fork grooves
Kickstarter pinion inner surface
Kickstarter idle gear inner bush whole surface
Locking agent Shift drum stopper arm bolt threads Coating width:
6.5 ± 1.0 mm from tip
Starter clutch bolt threads Coating width:
Ignition pulse generator mounting bolt threads Coating width:
Mainshaft bearing setting plate bolt threads Coating width:
Alternator stator wire guide bolt threads Coating width:
Crankshaft bearing push plug bolt threads Coating width:
Degreasing Flywheel and crankshaft contact areas
1-14
GENERAL INFORMATION
FRAME
MATERIAL LOCATION REMARKS
Multi-purpose grease with Steering head bearings 3 g per each bearing
extreme pressure agent Steering head bearing dust seal lips
(Example: Excelite EP2
manufactured by Kyodo
Yushi, Japan/Shell Alvania
EP2 or equivalent)
Multi-purpose grease Front wheel dust seal lips
Driven flange dust seal lips
Rear wheel hub O-ring
Front brake panel dust seal lips (Type 1, 3, 4, 6)
Front brake lever pivot (Type 1,3, 4, 6)
Front brake panel anchor pin sliding surface (Type 1, 3, 4, Apply 0.2 – 0.3 g
6)
Rear brake panel anchor pin sliding surface Apply 0.2 – 0.3 g
Front brake cam and shoe sliding surface (Type 1, 3, 4, 6) Apply 0.2 – 0.3 g
Rear brake cam and shoe sliding surface Apply 0.2 – 0.3 g
Speedometer gear teeth Apply 3 g
Speedometer gear inner surface Apply 0.2 – 0.3 g
Speedometer pinion shaft Apply 0.2 – 0.3 g
Speedometer pinion seal lip surface
Speedometer cable seal lips
Sidestand pivot
Centerstand/rear brake pivot
Clutch lever pivot
Gear oil Front brake cam felt seal (Type 1, 3, 4, 6)
Rear brake cam felt seal
Silicone grease Front brake lever pivot (Type 2, 5)
Front brake lever-to-master piston contacting area (Type 2,
5)
Front brake caliper slide pin boot inside (Type 2, 5)
Front brake cable inside (Type 1, 3, 4, 6) Apply 0.2 g/m
Throttle cable end boot inside
Throttle cable inside
Clutch cable inside
Choke cable inside
DOT3 or DOT4 brake fluid Master cylinder piston and piston cups (Type 2, 5)
Brake caliper piston (Type 2, 5)
Brake caliper piston seal (Type 2, 5) Apply 0.02 g
Brake caliper dust seal (Type 2, 5) Apply 0.02 g
Locking agent Fork socket bolt threads
Fork fluid Fork seal lips
Fork cap O-ring
Honda Bond A or equivalent Handlebar grip rubber inside
Air cleaner case-to-connecting hose mating area
1-15
GENERAL INFORMATION
CABLE & HARNESS ROUTING
DRUM BRAKE TYPE
FRONT BRAKE CABLE CLUTCH CABLE
RIGHT HANDLEBAR CLUTCH SWITCH

SWITCH WIRE WIRES
THROTTLE CABLE
CHOKE CABLE
FRONT BRAKE LIGHT

SWITCH WIRES LEFT HANDLEBAR
SWITCH WIRE
RIGHT TURN
LEFT TURN
SIGNAL WIRE
SIGNAL WIRE
SPEEDOMETER SUB
HARNESS
SPEEDOMETER CABLE
HEADLIGHT SUB HARNESS

MAIN WIRE HARNESS
DISC BRAKE TYPE

FRONT BRAKE HOSE CLUTCH SWITCH
WIRES
CLUTCH CABLE
FRONT BRAKE LIGHT

SWITCH WIRES
THROTTLE CABLE CHOKE CABLE
RIGHT HANDLEBAR
SWITCH WIRE LEFT HANDLEBAR
SWITCH WIRE
RIGHT TURN
LEFT TURN
SIGNAL WIRE
SIGNAL WIRE
SPEEDOMETER
SUB HARNESS
SPEEDOMETER CABLE
MAIN WIRE HARNESS HEADLIGHT SUB HARNESS
1-16
GENERAL INFORMATION
DRUM BRAKE TYPE
FRONT BRAKE LIGHT

SWITCH WIRES
CLUTCH CABLE FRONT BRAKE CABLE
CLUTCH SWITCH
WIRES
RIGHT HANDLEBAR
SWITCH WIRE
CHOKE CABLE THROTTLE CABLE
LEFT HANDLEBAR
SWITCH WIRE
DISC BRAKE TYPE
CLUTCH CABLE FRONT BRAKE HOSE RIGHT HANDLEBAR

CLUTCH SWITCH SWITCH WIRE
WIRES
FRONT BRAKE LIGHT

SWITCH WIRES
LEFT HANDLEBAR
SWITCH WIRE
CHOKE CABLE THROTTLE CABLE
1-17
GENERAL INFORMATION
DRUM BRAKE TYPE
LEFT HANDLEBAR
SWITCH WIRE
CHOKE CABLE
FRONT BRAKE CABLE
CLUTCH CABLE
SPEEDOMETER CABLE
1-18
GENERAL INFORMATION
DISC BRAKE TYPE
LEFT HANDLEBAR
SWITCH WIRE
CHOKE CABLE
SPEEDOMETER CABLE
CLUTCH CABLE
1-19
GENERAL INFORMATION
DRUM BRAKE TYPE
THROTTLE
CABLE
FRONT BRAKE LIGHT

SWITCH WIRE
RIGHT HANDLEBAR
SWITCH WIRE
CHOKE CABLE
1-20
GENERAL INFORMATION
DISC BRAKE TYPE
RIGHT HANDLEBAR
SWITCH WIRE
THROTTLE
CABLE
BRAKE HOSE
CHOKE CABLE
BRAKE HOSE
1-21
GENERAL INFORMATION
IGNITION COIL WIRE
NEUTRAL DIODE
REGULATOR/RECTIFIER
6P CONNECTOR
HORN WIRES
MAIN WIRE HARNESS
CLUTCH CABLE
VACUUM HOSE
1-22
GENERAL INFORMATION
BATTERY BREATHER
MAIN WIRE
HOSE BATTERY POSITIVE
BATTERY NEGATIVE HARNESS
(–) CABLE (+) CABLE
SUB FUSE WIRES
STARTER RELAY
SWITCH WIRE
ALTERNATOR
WIRE
SUB FUSE REAR BRAKE LIGHT MAIN FUSE WIRE

GEAR POSITION SWITCH WIRE
SWITCH WIRE
BATTERY BREATHER MAIN FUSE STARTER MOTOR WIRE
HOSE
ALTERNATOR
WIRE
GEAR POSITION
SWITCH WIRE
1-23
GENERAL INFORMATION
THROTTLE CABLE
CHOKE CABLE
SPARK PLUG WIRE
VACUUM HOSE CHOKE CABLE
IGNITION COIL
WIRE
GROUND WIRE
ONE WAY VALVE-TO

CARBURETOR HOSE
AIR SUPPLY HOSES
SPARK PLUG WIRE
CLUTCH CABLE
1-24
GENERAL INFORMATION
CRANKCASE BREATHER HOSE CARBURETOR AIR

VENT HOSE
EVAP AIR JOINT HOSE
CARBURETOR
DRAIN HOSE
EVAP DRAIN HOSE
EVAP BREATHER HOSE
BATTERY BREATHER HOSE
BRAKE LIGHT
SWITCH SPRING
BRAKE LIGHT
SWITCH ROD
BRAKE PEDAL
RETURN SPRING
1-25
GENERAL INFORMATION
CRANKCASE
BREATHER HOSE
FUEL TANK-TO- CARBURETOR AIR
CANISTER HOSE VENT HOSE
EVAP AIR JOINT
REAR BRAKE LIGHT HOSE
ONE WAY VALVE-
SWITCH WIRE
CANISTER-TO-ONE TO-CARBURETOR
WAY VALVE HOSE HOSE
FUEL HOSE
CARBURETOR
DRAIN HOSE
STARTER MOTOR
CABLE
EVAP BREATHER
HOSE
BATTERY NEGATIVE
EVAP DRAIN (–) CABLE
HOSE
REAR BRAKE LIGHT STARTER MOTOR 45º

SWITCH WIRE CABLE
STARTER MOTOR
CABLE
BATTERY NEGATIVE
(–) CABLE
1-26
GENERAL INFORMATION
HORN WIRES
REGULATOR/RECTIFIER
6P CONNECTOR
THROTTLE CABLE
MAIN WIRE SPARK PLUG WIRE

HARNESS
CHOKE CABLE
FUEL TANK-TO-
VACUUM HOSE CANISTER HOSE
AIR SUPPLY HOSE
FUEL LEVEL SENSOR

2P CONNEECTOR
1-27
GENERAL INFORMATION
BRAKE/TAIL LIGHT BRAKE/TAIL LIGHT

RIGHT REAR TURN GROUND WIRE WIRES
SIGNAL LIGHT WIRE
LEFT REAR TURN

SIGNAL LIGHT WIRE
TAIL LIGHT SUB

WIRE HARNESS
FUEL TANK-TO-
CANISTER HOSE MAIN WIRE
HARNESS
CANISTER-TO-ONE AIR SUPPLY
WAY VALVE HOSE ICM WIRE HOSE
1-28
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of carbon
monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they react to form
photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes appropriate carburetor settings as well as other systems, to reduce carbon monoxide, oxides of
nitrogen and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by
gas is returned to the combustion chamber through the air cleaner housing and carburetor.
AIR CLEANER HOUSING
CARBURETOR
Fresh Air
Blow-by Gas
CRANKCASE
BREATHER HOSE
1-29
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a pulsed secondary air supply system and lean carburetor settings, and no
adjustment should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is
separate from the crankcase emission control system.
SECONDARY AIR SUPPLY SYSTEM
The pulsed secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the
exhaust port by the function of the Pulsed Secondary Air Injection (PAIR) control valve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and
carbon monoxide into relatively harmless carbon dioxide and water vapor.
The PAIR check valve prevents reverse air flow through the system. The PAIR control valve reacts to high intake manifold vacuum
and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended.
PAIR CONTROL VALVE AIR CLEANER HOUSING
PAIR CHECK VALVE
Fresh Air
Exhaust Gas
Vacuum Pressure
EXHAUST PORT
1-30
GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM
Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the
engine is stopped. When the engine is running and the evaporative emission (EVAP) one way valve is open, fuel vapor in the EVAP
canister is drawn into the engine through the carburetor.
FUEL TANK
EVAP CANISTER
FRESH AIR
FUEL VAPOR
CARBURETOR EVAP ONE WAY VALVE
1-31
MEMO
2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION ······························ 2-2 REAR CARRIER ·············································2-6
TROUBLESHOOTING···································· 2-2 REAR COWL···················································2-6
HEADLIGHT CASE ········································ 2-3 REAR FENDER ···············································2-7
HEADLIGHT BACK PLATE ··························· 2-3 DRIVE SPROCKET COVER ···························2-8
SEAT······························································· 2-4 SIDESTAND ····················································2-8
SIDE COVER ·················································· 2-4 FOOTPEG BAR···············································2-9
FUEL TANK···················································· 2-5 EXHAUST PIPE/MUFFLER ····························2-9
FRONT FENDER ············································ 2-5
2-1
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels, fuel tank and exhaust system.
• Always replace the gasket when removing the exhaust system.
• Always inspect the exhaust system for leaks after installation.
• For centerstand service, see Rear Wheel/Brake/Suspension section (page 13-16).
TORQUE VALUE
Side cover screw 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
Sidestand pivot bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Sidestand pivot nut 45 N·m (4.6 kgf·m, 33 lbf·ft)
Exhaust pipe stud bolt 11 N·m (1.1 kgf·m, 8 lbf·ft) See page 2-10
Shock absorber upper 29 N·m (3.0 kgf·m, 21 lbf·ft)
mounting bolt
Swingarm pivot nut 59 N·m (6.0 kgf·m, 44 lbf·ft) U-NUT
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
2-2
HEADLIGHT CASE
REMOVAL/INSTALLATION
The procedure is Remove the two screws and setting plates.
LEFT SIDE SHOWN: PLATES
same for both Release the turn signal light from the rubber and
sides. disconnect the turn signal light 2P connector.
TURN SIGNAL LIGHT
2P CONNECTOR SCREWS
The procedure is Remove the two bolts and rubber mount. RIGHT SIDE SHOWN: HEADLIGHT CASE
same for both
sides.
Be careful not to Release the bosses of the headlight case from the hole
BOSSES
damage the bosses and hook of headlight back plate.
and hooks. Pull the headlight case forward while releasing the turn
signal light wire connectors from the headlight case
hole.
Remove the headlight case by releasing the slot from
the mount rubber.
HOLE
HOOK
MOUNT RUBBER
RUBBER SLOT
MOUNT
BOLTS TURN SIGNAL LIGHT WIRE
HEADLIGHT BACK PLATE

Remove the ignition switch (page 18-9).
HEADLIGHT BACK PLATE
Tape the back plate Remove the headlight back plate by pulling the
surface to prevent speedometer forward.
scratches.
Installation is in the reverse order of removal.
SPEEDOMETER
2-3
SEAT
Remove the two bolts.
Move the seat rearward and remove it. SEAT BOLTS
Install the seat by aligning the two hooks with the frame
grooves.
Align the bolt holes in the seat base and frame.
Install the two bolts and tighten them. HOOKS
GROOVES
SIDE COVER
LEFT SIDE
Unlock the side cover with the ignition key.
GROMMETS
Release the two bosses from the grommets and
remove the side cover.
Be careful not to Installation is in the reverse order of removal.
damage the
bosses.
BOSSES
KEY LEFT SIDE COVER
RIGHT SIDE
Remove the screw.
GROMMETS
Release the two bosses from the grommets and
remove the side cover.
damage the
bosses.
TORQUE:
Side cover screw: 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
BOSSES
SCREW RIGHT SIDE COVER
2-4
FUEL TANK
REMOVAL INSTALLATION
Remove the following:
FUEL TANK BOLT/COLLAR/
– seat (page 2-4) RUBBER WASHER
– side covers (page 2-4)
MOUNTS
Turn the fuel valve to OFF and clamp the fuel hose.
Wipe the spilled fuel Disconnect the fuel hose from the fuel valve.
immediately.
Remove the mounting bolt, collar and rubber washer.
While raising the fuel tank, disconnect the fuel level
sensor 2P connector and fuel tank-to-EVAP canister
hose.
Slide the fuel tank rearward to remove it from the rubber
mounts.
pinch the fuel tank-
to-EVAP canister
hose.
After installation,
turn the fuel valve
ON and make sure
that there are no
FUEL VALVE
fuel leaks.
FUEL HOSE
FUEL TANK-TO-
2P CONNECTOR CANISTER HOSE
FRONT FENDER
Be careful not to Remove the nut, bolt and cable guide. DISC BRAKE TYPE SHOWN:
scratch the fender. Remove the front fender mount bolts and front fender.
Installation is in the reverse order of removal. FRONT FENDER BOLT GUIDE
MOUNT
BOLTS
NUT
2-5
REAR CARRIER
Remove the seat (page 2-4).
SEAT BOTTOM GUIDE BOLTS
Loosen the rear shock absorber upper mounting bolts.
Remove the two bolts and seat bottom guide.
REAR CARRIER
Be careful not to Remove the carrier by pulling for rearward.
scratch the rear
cowl.
Be careful not to Install the rear carrier by inserting it between the
scratch the rear washer and collar as shown.
cowl.
Install the two bolts and seat bottom guide.
Tighten the shock absorber upper mounting bolts to the
specified torque.
TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft)
UPPER
MOUNTING REAR
BOLT CARRIER
WASHER COLLAR
REAR COWL
Remove the side covers (page 2-4).
Remove the rear carrier (page 2-6). REAR COWL
Disconnect the brake light/rear turn signal light
connectors. CONNECTORS
Remove the two bolts and rear cowl by pulling it
rearward.
Install the rear cowl by inserting it between the collar
and frame as shown.
Install the two bolts and tighten them.
Route the wire Connect the brake light/rear turn signal light
harness properly connectors.
(page 1-16).
Install the following:
– rear carrier (page 2-6)
– side covers (page 2-4)
REAR
COWL
BOLTS
COLLAR FRAME
2-6
DISASSEMBLY/ASSEMBLY
The procedure is Remove the two screws and setting plates.
RIGHT SIDE SHOWN:
same for both sides Remove the turn signal light from the rubber by PLATES
disconnecting the turn signal light 2P connector.
TURN SIGNAL LIGHT
2P CONNECTOR SCREWS

BOLTS RAIL RUBBERS
– rail rubbers
– screws and bolts/washers WASHERS SCREWS
– rubber mounts, rear cowl rail, rear cowl bracket and
brake/tail light assembly REAR COWL
BRACKET
Assembly is in the reverse order of disassembly.
BRAKE/TAIL
LIGHT UNIT
REAR COWL
RAIL
BOLTS RUBBER MOUNTS
REAR FENDER
REAR FENDER A REMOVAL/
INSTALLATION
Remove the rear cowl (page 2-6).
REAR FENDER A
Remove the two bolts and nuts.
Remove the rear fender A by pulling it backward.
NUTS
BOLTS
2-7
REAR FENDER B REMOVAL/
INSTALLATION
Remove the rear fender A (page 2-5).
NUT REAR FENDER B
Remove the nut and bolt stay.
Remove the rear fender B by sliding it rearward.
Install the rear fender B by sliding it forward.
Install the bolt stay and nut, then tighten it.
Install the rear fender A (page 2-7).
BOLT STAY
DRIVE SPROCKET COVER

DRIVE SPROCKET
– two bolts COVER
– drive sprocket cover
– chain guide
Align the locating Installation is in the reverse order of removal.
pins on the cover
with the holes in the
guide.
CHAIN GUIDE Align BOLTS
SIDESTAND
Place the motorcycle on its centerstand and retract the
sidestand. NUT RETURN SPRING

– return spring
– nut
– bolt
– sidestand
Apply grease to the pivot sliding surface.
Install the sidestand and pivot bolt, then tighten it to the
specified torque. BOLT
Install the pivot nut and tighten it to the specified torque
SIDESTAND
while holding the pivot bolt.
Install the return spring in the shown direction.
2-8
FOOTPEG BAR
Place the motorcycle on its centerstand and retract the
sidestand. FOOTPEG BAR
Remove the muffler (page 2-9).

Remove the four bolts and footpeg bar while pushing
down the rear brake pedal.
BOLTS
EXHAUST PIPE/MUFFLER
REMOVAL
Place the motorcycle on its centerstand.
Release the hoses from the clamps of the muffler.
– joint nuts
– swingarm pivot nut
– muffler
– spacer and collar
– gasket
COLLAR
SPACER
GASKET
PIVOT NUT
JOINT NUTS
MUFFLER
HOSES
CLAMPS
2-9
INSTALLATION
EXHAUST PIPE STUD BOLT
Thread two nuts to the stud bolt and tighten them
together, then use a wrench on them to turn the stud
bolt out.
Install and tighten new stud bolts into the cylinder head
to the specified torque.
After tightening the stud bolts, check that the length
from the bolt head to the cylinder head surface is within
specification. 20.5 – 22.5 mm
(0.81 – 0.89 in)
Always replace the Install a new gasket into the exhaust port of the cylinder
gasket with a new head.
one.
GASKET

COLLAR
– spacer and collar
– muffler SPACER
Temporarily install the swingarm pivot nut, but do not
tighten it yet.
MUFFLER NUT
Install the joint nuts and tighten them. NUTS
2-10
Retract the centerstand carefully and support the
motorcycle securely, then tighten the swingarm pivot NUT
nut to the specified torque.
Route the hoses Insert the hoses into the clamps.

properly (page 1-
16).
After installation, inspect the exhaust system for leaks.
CLAMPS HOSES
2-11
MEMO
3. MAINTENANCE
SERVICE INFORMATION ······························ 3-2 DRIVE CHAIN················································3-14
MAINTENANCE SCHEDULE························· 3-4 BATTERY ······················································3-16
FUEL LINE······················································ 3-5 BRAKE FLUID (DISC BRAKE)·····················3-17
FUEL STRAINER SCREEN ··························· 3-5 BRAKE SHOES WEAR (DRUM BRAKE)·····3-17
THROTTLE OPERATION······························· 3-6 BRAKE PADS WEAR (DISC BRAKE) ·········3-18
CHOKE OPERATION····································· 3-6 BRAKE SYSTEM ··········································3-19
AIR CLEANER················································ 3-7 BRAKE LIGHT SWITCH ·······························3-21
SPARK PLUG················································· 3-8 HEADLIGHT AIM ··········································3-21
VALVE CLEARANCE····································· 3-9 CLUTCH SYSTEM ········································3-21
ENGINE OIL ················································· 3-10 SIDESTAND ··················································3-22
ENGINE OIL STRAINER SCREEN ·············· 3-11 SUSPENSION ···············································3-23
ENGINE OIL CENTRIFUGAL FILTER ········· 3-12 NUTS, BOLTS, FASTENERS ·······················3-24
ENGINE IDLE SPEED ·································· 3-13 WHEELS/TIRES ············································3-24
SECONDARY AIR SUPPLY SYSTEM········· 3-13 STEERING HEAD BEARINGS ·····················3-25
EVAPORATIVE EMISSION CONTROL

SYSTEM ······················································· 3-14
3-1
MAINTENANCE
SERVICE INFORMATION
MAINTENANCE
GENERAL
• Place the motorcycle on a level ground before starting any work.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the
engine in an open area or with an exhaust evacuation system in an enclosed area.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle grip freeplay 2.0 – 6.0 mm (0.08 – 0.24 in)
Valve clearance Intake 0.08 ± 0.02 mm (0.003 ± 0.001 in)
Exhaust 0.12 ± 0.02 mm (0.005 ± 0.001 in)
Engine oil capacity after draining 0.8 liter (0.8 US qt, 0.7 lmp qt)
after disassembly 1.0 liter (1.1 US qt, 0.9 lmp qt)
(except oils labeled as energy conserving on the circular
API service label)
Engine idle speed 1,400 ± 100 min-1 (rpm)
Drive chain slack 15 – 25 mm (0.6 – 1.0 in)
Drive chain size/link 428H/112
Recommended brake fluid DOT 3 or DOT 4
Brake lever freeplay (Type 1, 3, 4, 6) 10 – 20 mm (0.4 – 0.8 in)
Brake pedal freeplay 20 – 30 mm (0.8 – 1.2 in)
Clutch lever freeplay 10 – 20 mm (0.4 – 0.8 in)
Cold tire pressure Driver only Front 200 kPa (2.00 kgf/cm2, 29 psi)
Rear 225 kPa (2.25 kgf/cm2, 33 psi)
Driver and passenger Front 200 kPa (2.00 kgf/cm2, 29 psi)
Rear 225 kPa (2.25 kgf/cm2, 33 psi)
Tire size Front 2.75-18 42P
Rear 90/90-18M/C 51P
Tire brand Front HFC-301E (DURO)
Rear HFC-329 (DURO)
TORQUE VALUES
Fuel strainer cup 16 N·m (1.6 kgf·m, 12 lbf·ft)
Choke cable lock nut 10 N·m (1.0 kgf·m, 7 lbf·ft)
Air cleaner element mounting screw 4.2 N·m (0.43 kgf·m, 3.1 lbf·ft)
Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft)
Valve adjusting lock nut 14 N·m (1.4 kgf·m, 10 lbf·ft) Apply engine oil to the threads and seating sur-
face
Crankshaft hole cap 15 N·m (1.5 kgf·m, 11 lbf·ft) Apply grease to the threads
Timing hole cap 10 N·m (1.0 kgf·m, 7 lbf·ft)
Engine oil drain bolt 30 N·m (3.1 kgf·m, 22 lbf·ft)
Oil filter rotor cover screw 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
Rear axle nut 59 N·m (6.0 kgf·m, 44 lbf·ft) U-NUT
Spoke 3.7 N·m (0.38 kgf·m, 2.7 lbf·ft)
3-2
MAINTENANCE
TOOLS
Spoke wrench, 5.8×6.1 Tappet adjusting wrench, ( □3 )
07701-0020300 07708-0030400
3-3
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult an authorized Honda dealer.
FREQUENCY WHICHEVER
ODOMETER READING (NOTE 1)
COMES
FIRST REFER TO
x 1,000 km 1 4 8 12
PAGE
x 1,000 mi 0.6 2.5 5 7.5
ITEMS MONTHS 6 12 18
* FUEL LINE I I I 3-5
* FUEL STRAINER SCREEN C C C 3-5
* THROTTLE OPERATION I I I 3-6
* CHOKE OPERATION I I I 3-6
AIR CLEANER NOTE 2 Every 16,000 km (10,000 mi) R 3-7
SPARK PLUG I R I 3-8
* VALVE CLEARANCE I I I I 3-9
ENGINE OIL R R R R 3-10
** ENGINE OIL STRAINER SCREEN C 3-11
** ENGINE OIL CENTRIFUGAL FILTER C 3-12
* ENGINE IDLE SPEED I I I I 3-13
* SECONDARY AIR SUPPLY SYSTEM NOTE 4 I 3-13
* EVAPORATIVE EMISSION CONTROL SYS- I 3-14
TEM
DRIVE CHAIN Every 1,000 km (600 mi) I, L 3-14
BATTERY I I I 3-16
BRAKE FLUID (DISC BRAKE) NOTE 3 I I I 3-17
BRAKE SHOES WEAR (DRUM BRAKE) I I I 3-17
BRAKE PADS WEAR (DISC BRAKE) I I I 3-17
BRAKE SYSTEM I I I I 3-19
* BRAKE LIGHT SWITCH I I I 3-21
* HEADLIGHT AIM I I I 3-21
CLUTCH SYSTEM I I I I 3-21
SIDESTAND I I I 3-22
* SUSPENSION I I I 3-23
* NUTS, BOLTS, FASTENERS I I 3-24
** WHEELS/TIRES (CAST WHEEL) I I I 3-24
** WHEELS/TIRES (SPOKE WHEEL) I I I I 3-24
** STEERING HEAD BEARINGS I I 3-25
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
Honda recommends that an authorized Honda dealer should road test the motorcycle after each periodic maintenance is carried
out.
NOTES:
1. At higher odometer reading, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years. Replacement requires mechanical skill.
4. Replace the PAIR air filter every 3 years or 24,000km (16,000 mile). Replacement requires mechanical skill.
3-4
MAINTENANCE
FUEL LINE
Check the fuel hose between the fuel tank and
carburetor for deterioration, damage or leakage. FUEL HOSE
Replace the fuel hose if necessary.
FUEL STRAINER SCREEN

Turn the fuel valve to OFF.
FUEL VALVE
– fuel strainer cup (and drain the gasoline in the cup)
– O-ring
– strainer screen
Clean the strainer screen thoroughly with non-
flammable or high flash point solvent.
Replace the O-ring Install the removed parts in the reverse order of
with new one. removal.
After filling the fuel tank, turn the fuel valve ON and
check that there are no leaks. STRAINER CUP
STRAINER
O-RING SCREEN
3-5
MAINTENANCE
THROTTLE OPERATION
Check for any deterioration or damage of the throttle
cable. Check the throttle grip for smooth operation.
Check that the throttle opens and automatically closes 2.0 – 6.0 mm (0.08 – 0.24 in)
in all steering positions.
If the throttle grip does not return properly, lubricate the
throttle cable and clean the throttle housing.
If the throttle grip still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does not
change. If idle speed increases, check the throttle grip
freeplay and throttle cable connection.
Measure the freeplay at the throttle grip flange.
FREEPLAY: 2.0 – 6.0 mm (0.08 – 0.24 in)
Throttle grip freeplay can be adjusted at throttle cable
adjuster.
Slide the dust cover from the adjuster.
Loosen the lock nut, turn the adjuster as required and
tighten the lock nut.
Recheck the throttle operation.
Replace the any damaged parts if necessary.
LOCK NUT
ADJUSTER
DUST COVER
CHOKE OPERATION
Check for smooth choke lever operation.
Lubricate the choke cable if the operation is not smooth. CHOKE LEVER
Inspect the cable for cracks which could allow moisture

to enter.
Replace the choke cable if necessary.
CHOKE CABLE
3-6
MAINTENANCE
Remove the right side cover (page 2-4).
CHOKE LEVER
Loosen the lock nuts and adjuster of the carburetor
side, and make it free.
Align the handlebar side choke lever with the detent
line.
Align the carburetor side choke lever end face with
detent line of choke cable stay as shown by adjusting
the adjuster.
Tighten the lock nut to the specified torque by holding
the adjuster.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) DETENT LINE
Operate the handlebar side choke lever several times
and align it with the detent line again.
Make sure that the carburetor side choke lever is in Align
detent position as shown.
Install the right side cover (page 2-4).
ADJUSTER
LOCK NUTS
AIR CLEANER
• If the motorcycle is used in wet or dusty conditions,
more frequent service is required.
• The viscous paper element type air cleaner cannot
be cleaned because the element contains a dust
adhesive.
STORAGE AIR CLEANER CLAMPS
Disconnect the following: TANK HOUSING COVER
– carburetor air vent hose from the clamps
– crankcase breather hose from the storage tank
BAND
Loosen the air cleaner connecting hose band screw. SCREW
Remove the four screws and air cleaner housing cover.
AIR VENT
SCREWS BREATHER HOSE HOSE
Remove the screw/washer and air cleaner element
from the air cleaner housing cover. AIR CLEANER SCREW/
HOUSING COVER WASHER
Replace the air cleaner element in accordance with the
maintenance schedule or any time it is excessively dirty
or damaged.
Clean the inside of the air cleaner housing and cover.
Install a new air cleaner element in the reverse order of
removal.
TORQUE:
AIR CLEANER ELEMENT MOUNTING SCREW:
4.2 N·m (0.43 kgf·m, 3.1 lbf·ft)
AIR CLEANER
ELEMENT
3-7
MAINTENANCE
SPARK PLUG
Clean around the Disconnect the spark plug cap.
spark plug base Remove the spark plug. PLUG CAP
with compressed air
before removing the
plug, and be sure
that no debris is
allowed to enter
into the combustion
chamber.
SPARK PLUG
Check the insulator for cracks or damage, and the

electrodes for wear, fouling or discoloration. Replace
the plug if necessary. CENTER ELECTRODE
RECOMMENDED SPARK PLUG:
Standard: CPR7EA-9 (NGK)
For extended high speed riding: CPR8EA-9 (NGK)
INSULATOR
SIDE ELECTRODE
Clean the spark plug electrodes with a wire brush or

special plug cleaner.
Check the gap between the center and side electrodes
with a wire-type feeler gauge. 0.80 – 0.90 mm
(0.031 – 0.035 in)
SPARK PLUG GAP: 0.80 – 0.90 mm (0.031 – 0.035 in)
If necessary, adjust the gap by bending the side
electrode carefully.
Thread the spark plug into the cylinder head in by hand
to prevent cross-threading and tighten it with a spark
plug wrench.
Connect the spark plug cap.
3-8
MAINTENANCE
VALVE CLEARANCE
• Inspect and adjust the valve clearance while the
engine is cold (below 35°C/95°F).
Remove the cylinder head cover (page 7-6).
TIMING HOLE CAP
Remove the timing and crankshaft hole caps.
CRANKSHAFT
HOLE CAP
Rotate the crankshaft counterclockwise and align the
"T" mark on the flywheel with the index notch in the
crankcase cover.
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
This position can be obtained by confirming that there is INDEX NOTCH
slack in each rocker arm. If there is no slack, it is
because the piston is moving through the exhaust
stroke to TDC. Rotate the crankshaft one full turn and
match up the "T" mark again.
"T" MARK
When checking the Check the clearances of the intake and exhaust valves
clearance, slide the by inserting the feeler gauge between the adjusting
feeler gauge from screw and valve stem.
the center toward
the outside. VALVE CLEARANCE:
IN: 0.08 ± 0.02 mm (0.003 ± 0.001 in)
EX: 0.12 ± 0.02 mm (0.005 ± 0.001 in)
FEELER GAUGE
Adjust by loosening the lock nut and turning the

adjusting screw until there is a slight drag on the feeler ADJUSTING WRENCH
gauge.
TOOL:
Valve adjusting wrench 07708-0030400
Apply engine oil to the lock nut.
Hold the adjusting screw and tighten the lock nut. ADJUSTING
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) SCREW
After tightening the lock nut, recheck the valve

clearance.
LOCK NUT
3-9
MAINTENANCE
Coat new O-rings with engine oil and install them onto
TIMING
the crankshaft hole cap and timing hole cap.
Apply grease to crankshaft hole cap threads. HOLE
O–RINGS CAP
Install the caps and tighten them to the specified torque.
TORQUE:
Crankshaft hole cap: 15 N·m (1.5 kgf·m, 11 lbf·ft)
Timing hole cap: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Install the cylinder head cover (page 7-6).
CRANKSHAFT
HOLE CAP
ENGINE OIL
LEVEL CHECK
Place the motorcycle on its centerstand on a level
FILLER CAP/DIPSTICK
surface.
Start the engine and let it idle for 3 – 5 minutes.
Stop the engine and wait for 2 – 3 minutes.
Remove the oil filler cap/dipstick and wipe the oil from
the dipstick with a clean cloth. UPPER
Insert the filler cap/dipstick without screwing it in,
remove it and check the oil level. LOWER
The level should be between the upper and lower level
lines on the dipstick.
If the oil level is below or near the lower level line, add
the recommended oil to the upper level line.
OIL VISCOSITIES
RECOMMENDED ENGINE OIL:
API classification: SG or higher
(except oils labeled as energy conserving on the
circular API service label)
• Other viscosities shown in the chart may be used

when the average temperature in your riding area is
within the indicated range.
Make sure the O-ring is in good condition and install the
oil filler cap/dipstick.
3-10
MAINTENANCE
OIL CHANGE
Change the oil with Start the engine, warm it up and stop it.
the engine warm
Remove the oil drain bolt and filler cap/dipstick, and
and the motorcycle
drain the engine oil.
on its sidestand to
assure complete After draining the oil completely, install the drain bolt
and rapid draining. with a new sealing washer and tighten it to the specified SEALING
torque. WASHER
Pour the recommended oil into the crankcase to the
upper level line on the dipstick.
OIL CAPACITY:
0.8 liter (0.8 US qt, 0.7 lmp qt) at draining
1.0 liter (1.1 US qt, 0.9 lmp qt) at disassembly DRAIN BOLT
Install the filler cap/dipstick.

FILLER CAP/DIPSTICK
Check the oil level (page 3-10).
Make sure there are no oil leaks.
ENGINE OIL STRAINER SCREEN

Remove the right crankcase cover (page 9-5).
STRAINER
Remove the oil strainer screen out of the crankcase. SCREEN
Wash the strainer screen thoroughly in non-flammable
or high flash point solvent until all accumulated dirt has
been removed.
Blow dry it with compressed air to clean completely.
Before installing the strainer, the screen mesh should
be examined closely for damage.
Install the strainer screen in the direction as shown.
Install the right crankcase cover (page 9-18).
Up
Crankcase
Side
3-11
MAINTENANCE
ENGINE OIL CENTRIFUGAL FILTER
SCREWS GASKET
– three screws
– filter rotor cover
– gasket
COVER
Do not allow dust Clean the inside of the centrifugal filter rotor with a lint-
FILTER ROTOR
and dirt to enter the free cloth.
oil passage in the
crankshaft. Never
use compressed air
for cleaning.
Remove the clip while holding the oil through. ROTOR COVER
Remove the oil through and spring.
Blow compressed air through the oil through hole and CLIP
the rotor cover to clean them.
Apply engine oil to the oil through sliding area.
Install the spring and oil through, and secure it with the
clip.
Check that the oil through operates freely, without
binding.
SPRING
OIL THROUGH
Install the rotor cover with a new gasket and tighten the
ROTOR COVER
three screws.
TORQUE: 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
GASKET
3-12
MAINTENANCE
ENGINE IDLE SPEED
• Inspect and adjust the idle speed after all other
engine maintenance items have been performed
and are within specifications.
• The engine must be warm for accurate idle speed
inspection and adjustment. Ten minutes of stop-and-
go riding is sufficient.
Warm up the engine, shift the transmission into neutral
and support the motorcycle upright on a level surface.
Check the engine idle speed.
IDLE SPEED: 1,400 ± 100 min-1 (rpm)
If the adjustment is necessary, turn the throttle stop
screw as required.
THROTTLE STOP SCREW

• The pulsed secondary air injection (PAIR) control
valve and the PAIR check valve are combined in one
assembly.
Remove the fuel tank (page 2-5).
AIR SUPPLY HOSE
Check the air supply hoses for cracks, deterioration,
damage or loose connections. AIR SUPPLY PIPE
Check the vacuum hose between the air suction valve
and carburetor insulator for cracks, deterioration or
loose connections.
If the air supply hose show any signs of heat damage,
replace the air suction valve (page 5-21).
Check the air supply pipe between the air suction valve
and cylinder head cover for damage or loose fasteners.
VACUUM HOSE
AIR SUCTION
VALVE
3-13
MAINTENANCE
EVAPORATIVE EMISSION CONTROL
SYSTEM
CANISTER
– canister cover (page 5-21)
– right side cover (page 2-4)
Check the hoses between the fuel tank, EVAP canister,
EVAP one way valve and carburetor for deterioration,
damage or loose connection. HOSES
Check the EVAP canister for cracks or other damage.
Refer to the Cable & Harness Routing for hose
connections (page 1-16). HOSES
ONE WAY VALVE
HOSES
DRIVE CHAIN
CHAIN SLACK INSPECTION
Never inspect and Turn the ignition switch to OFF, place the motorcycle on
adjust the drive its centerstand and shift the transmission into neutral.
chain while the
Check the slack in the drive chain lower run midway
engine is running.
between the sprockets.
CHAIN SLACK: 15 – 25 mm (0.6 – 1.0 in)
Excessive chain slack, 50 mm (2.0 in) or more, may

damage the frame.
15 – 25 mm (0.6 – 1.0 in)
3-14
MAINTENANCE
ADJUSTMENT
ADJUST PLATE
Loosen the rear axle nut and both adjuster lock nuts.
Turn both adjust bolts an equal number of turn until the
correct drive chain slack is obtained. AXLE NUT
Make sure that the both chain adjust plates are in same
position on each scale of the chain adjuster stay.
Tighten the rear axle nut.
SCALE
Tighten each adjuster lock nut while holding the adjust ADJUSTER
bolt securely. STAY
Recheck the drive chain slack and free wheel rotation.
ADJUST BOLT LOCK NUT
Check the rear brake pedal freeplay (page 3-20).
CLEANING, INSPECTION AND

LUBRICATION
If the drive chain becomes extremely dirty, it should be
removed and cleaned prior to lubrication.
Remove the drive sprocket cover (page 2-8). RETAINING CLIP
Carefully remove the retaining clip with pliers.

Remove the link plate, master link and drive chain.
Clean the chain with non-flammable or high-flash point

solvent and wipe it dry. NON-FLAMMABLE OR HIGH-FLASH
Be sure the chain has dried completely before POINT SOLVENT
lubricating.
Lubricate the drive chain with #80 – 90 gear oil or chain
lubricant. Clean
Wipe off excess oil.
Wipe and Dry GEAR OIL
Lubricate
Inspect the drive chain for possible damage or wear.

Replace any chain that has damaged rollers, loose
fitting links, or otherwise appears unserviceable.
Measure the drive chain length between a span of 41
pins from pin center to pin center with the chain held 41 PINS (40 LINKS)
straight.
SERVICE LIMIT: 518 mm (20.4 in)
3-15
MAINTENANCE
Inspect the drive and driven sprocket teeth for wear or
damage. Replace if necessary.
Wear
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condition, or
the new replacement parts will wear rapidly.
Check the attaching bolts and nuts on the drive and
driven sprockets. If any are loose, torque them.
Damage Normal
Install the drive chain onto the sprockets.

Install the master link and link plate, and the retaining MASTER
clip so that its open end is opposite the normal rotation LINK
of the chain. RETAINING CLIP
Install the drive sprocket cover (page 2-8).
LINK PLATE
BATTERY
Remove the battery (page 15-5).
FILLER CAPS
Inspect the electrolyte level.
When the electrolyte level nears the lower level,
remove the filler caps and add distilled water to the
upper level line.
After filling, install each filler cap firmly.
Make sure that the battery breather hose is correctly

positioned, not kinked, trapped or bent in such a way as
to obstruct the passage of the air.
• If the hose is blocked, the battery’s internal pressure
will not be relieved, the breather may come off, or
the battery crack as a result.
Install the battery (page 15-5).
3-16
MAINTENANCE
BRAKE FLUID (DISC BRAKE)
Spilling fluid can damage painted, plastic or rubber

parts. Place a rag over these parts whenever the
system is serviced.
• Do not mix different types of fluid, as they are not

compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• When the fluid level is low, check the brake pads for
wear (page 3-17). A low fluid level may be due to
worn brake pads. If the brake pads are worn, the
caliper pistons are pushed out, and this causes a
low reservoir level. If the brake pads are not worn
and the fluid level is low, check entire system for
leaks (page 3-19).
Turn the handlebar to the left side so the reservoir is
level and check the fluid level through the sight glass.
If the level is near the lower level mark, check the brake
pads for wear (page 3-18).
SIGHT "LOWER"
GLASS LEVEL MARK
BRAKE SHOES WEAR (DRUM BRAKE)

FRONT DRUM BRAKE SHOES (TYPE
1, 3, 4, 6)
Check the wear indicator position when the brake is
Front:
applied.
If the arrow on the brake arm aligns with the reference " " MARK
mark " " on the brake panel, inspect the brake drum
(page 3-2). ARROW
3-17
MAINTENANCE
REAR BRAKE SHOES
Check the wear indicator position when the brake is
Rear:
applied.
If the arrow on the brake arm aligns with the reference " " MARK
mark " " on the brake panel, inspect the brake drum ARROW
(page 13-14).
Replace the brake shoes if the drum I.D. is within the
service limit (page 13-14).
BRAKE PADS WEAR (DISC BRAKE)

FRONT DISC BRAKE PADS (TYPE 2, 5)
Check the brake pads for wear.
Replace the brake pads if either pad is worn to the wear
limit groove.
See hydraulic disc brake section for brake pads
replacement (page 14-7).
LIMIT GROOVE
3-18
MAINTENANCE
BRAKE SYSTEM
HYDRAULIC SYSTEM (TYPE 2, 5)
Firmly apply the brake lever and check that no air has
entered the system. If the lever feels soft or spongy BRAKE HOSE
when operated, bleed air from the system (page 14-5).
See Hydraulic Disc Brake section for air bleeding
procedure.
Inspect the brake hose and fittings for deterioration,
cracks, damage and signs of leakage. Tighten any
loose fittings.
Replace hose and fittings as required.
BRAKE HOSE
FRONT DRUM BRAKE (TYPE 1, 3, 4, 6)

Inspect the brake cable for kinks or damage, and
lubricate the cable if necessary. 10 - 20 mm
Measure the brake lever freeplay at the end of the (0.4 - 0.8 in)
lever.
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)
Minor adjustments are made with the upper adjuster at

the brake lever. LOCK NUT
The adjuster may Slide the dust cover off the lever bracket, loosen the
ADJUSTER
be damaged if it is lock nut and turn the adjuster to obtain the freeplay.
positioned too far Tighten the lock nut and install the dust cover.
out, leaving minimal
If the adjuster is threaded out near its limit and the
thread
correct freeplay cannot be obtained, turn the adjuster all
engagement.
the way in and back out one turn.
Tighten the lock nut and make a major adjustments as
described below.
DUST COVER
3-19
MAINTENANCE
Major adjustments are made with the lower adjusting Correct
nut at the brake panel.
Turn the adjusting nut to obtain correct freeplay.
Make sure the cutout of the adjusting nut is seated on
the brake arm joint pin. Incorrect
ADJUSTING NUT
REAR DRUM BRAKE

PEDAL FREEPLAY
Check the brake pedal and brake rod for deformation or
damage.
Measure the brake pedal freeplay.
FREEPLAY: 20 – 30 mm (0.8 – 1.2 in) 20 - 30 mm
(0.8 - 1.2 in)
Adjust the freeplay by turning the adjusting nut. Correct

Make sure the cutout of the adjusting nut is seated on
the brake arm joint pin.
Check for brake light switch operation after adjustment
(page 3-21). Incorrect
ADJUSTING NUT
3-20
MAINTENANCE
BRAKE LIGHT SWITCH
• The front brake light switch cannot be adjusted. If
the front brake light switch actuation and brake
engagement are not synchronized, either replace
the switch unit or the malfunctioning parts of the
system.
Check that the brake light comes on just prior to the
BRAKE LIGHT
brake actually being engaged.
If the light fails to come on, adjust the switch so that the SWITCH
light comes on at the proper time.
Hold the switch body and turn the adjusting nut. Do not
turn the switch body.
ADJUSTING
NUT
HEADLIGHT AIM
Adjust the headlight Support the motorcycle upright on a level surface.
beam as specified
Adjust the headlight beam vertically by turning the
by local laws and
adjusting screw.
regulations.
ADJUSTING SCREW
CLUTCH SYSTEM
Inspect the clutch cable for kinks or damage, and
lubricate the cable if necessary. 10 - 20 mm
(0.4 - 0.8)
Measure the clutch lever freeplay at the end of the
lever.
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)
3-21
MAINTENANCE
Minor adjustment are made with the upper adjuster at
the clutch lever. ADJUSTER LOCK NUT
The adjuster may Slide the dust cover off the lever bracket, loosen the
be damaged if it is lock nut and turn the adjuster to obtain the freeplay.
positioned too far Tighten the lock nut and install the dust cover.
out, leaving minimal
If the adjuster is threaded out near its limit and the
thread
correct freeplay cannot be obtained, turn the adjuster all
engagement.
the way in and back out one turn.
Tighten the lock nut and make a major adjustments as
described below.
DUST COVER
Major adjustments are made with the lower adjusting

nut at the engine.
Loosen the lock nut and turn the adjusting nut.
After adjustment is complete, tighten the lock nut while ADJUSTING NUT
holding the adjusting nut.
Check the clutch operation.
If the correct freeplay cannot be obtained, or the clutch
slips during the test ride, disassemble and inspect the
clutch (page 9-4).
LOCK NUT
SIDESTAND
Check the sidestand spring for damage or loss of
tension.
Check the sidestand operation for freedom of
movement and lubricate the sidestand pivot if
necessary.
Check that the sidestand pivot bolt and lock nut are
tightened.
SIDESTAND
3-22
MAINTENANCE
SUSPENSION
FRONT
Check the action of the forks by applying the front brake
and compressing them several times.
Check the entire fork assembly for leaks, damage or
loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer to Front Wheel/Brake/Suspension/Steering
section for front suspension service (page 12-26).
REAR
Check the action of the shock absorber by compressing
it several times.
Check the entire shock absorber assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer to Rear Wheel/Brake/Suspension section for rear
suspension service (page 13-19).

Check for worn swingarm bearings by grabbing the
swingarm and attempting to move the wheel side to
side.
Check the pivot bushings if any looseness is noted
(page 13-20).
3-23
MAINTENANCE
NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-10).
Check that all cotter pins, safety clips, hose clamps and
cable stays are in place and properly secured.
WHEELS/TIRES
Support the motorcycle securely and raise the front
wheel off the ground.
Hold the fork leg and move the front wheel sideways
with force to see if the wheel bearing are worn.
Check for worn wheel bearings by holding the

swingarm and move the rear wheel sideways.
Replace the wheel bearings if any looseness is noted
(page 13-9).
Tire pressure Check the cold tire pressure.

should be checked
when the tires are RECOMMENDED TIRE PRESSURE:
cold. Driver only:
Front: 200 kPa (2.00 kgf/cm2, 29 psi)
Rear: 225 kPa (2.25 kgf/cm2, 33 psi)
Driver and passenger:
Front: 200 kPa (2.00 kgf/cm2, 29 psi)
Rear: 225 kPa (2.25 kgf/cm2, 33 psi)
Check the tires for cuts, embedded nails, or other
damage.
Check the front and rear wheels for trueness.
Check the wear indicator to check for insufficient tread
depth.
If the wear indicator is visible, the tire should be
replaced.
3-24
MAINTENANCE
Type 3, 6. Inspect the wheel rims and spokes for damage.
Tighten any loose spokes.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300
TORQUE: 3.7 N·m (0.38 kgf·m, 2.7 lbf·ft)
SPOKE WRENCH
STEERING HEAD BEARINGS

Place the motorcycle on its centerstand and raise the
front wheel off the ground.
Check that the handlebar moves freely from side to
side. Make sure the control cables do not interfere with
the handlebar rotation.
Check for steering stem bearings by grabbing the fork
legs and attempting to move the front fork side to side.
If the handlebar moves unevenly, binds, or has vertical
movement, inspect the steering head bearings (page
12-33).
3-25
MEMO
4. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM ············· 4-2 TROUBLESHOOTING ····································4-3
SERVICE INFORMATION ······························ 4-3 OIL PUMP························································4-4
4-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM
ROCKER ARM
CAMSHAFT
OIL FILTER ROTOR
CRANKSHAFT
OIL PUMP
OIL STRAINER SCREEN
MAINSHAFT
COUNTERSHAFT
4-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
• The oil pump can be serviced with the engine installed in the frame.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limit, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
• Engine oil level inspection (page 3-10)
• Engine oil change (page 3-11)
• Engine oil centrifugal filter cleaning (page 3-12)
• Engine oil strainer screen cleaning (page 3-11)
SPECIFICATIONS
Unit: mm (in)
Engine oil ca- After draining 0.8 liter (0.8 US qt, 0.7 lmp qt) –
pacity After disassembly 1.0 liter (1.1 US qt, 0.9 lmp qt) –
(except oils labeled as energy conserving
on the circular API service label) –
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.25 (0.010)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
TORQUE VALUE
Oil pump cover screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
TROUBLESHOOTING
Engine oil level too low, high oil consumption
• External oil leaks
• Worn valve guide or stem seal
• Worn piston rings or incorrect piston ring installation
• Worn cylinder
Engine oil contamination
• Oil not changed often enough
• Clogged oil strainer
• Oil centrifugal filter not cleaned often enough
• Worn piston rings
4-3
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
Remove the oil pump driven gear.
DRIVEN GEAR
Remove the two mounting bolts and oil pump.

OIL PUMP
BOLTS
DISASSEMBLY/INSPECTION
Remove the screw, dowel pins and oil pump cover.
DOWEL PINS
PUMP COVER SCREW
Measure at several Measure the rotor tip clearance.

places and use the TIP CLEARANCE:
largest reading to SERVICE LIMIT: 0.20 mm (0.008 in)
compare to the
service limit.
4-4
LUBRICATION SYSTEM
Measure the pump body clearance.
BODY CLEARANCE:
SERVICE LIMIT: 0.25 mm (0.010 in)
Remove the rotor shaft.

SIDE CLEARANCE:
Measure the side clearance.
ASSEMBLY
PUMP BODY
ROTOR SHAFT
PUMP COVER
OUTER ROTOR
INNER ROTOR
SCREW
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
4-5
LUBRICATION SYSTEM
Apply engine oil to the outer and inner rotors and install
them into the oil pump body. OUTER ROTOR INNER ROTOR
Inert the oil pump shaft into the inner rotor by aligning
the flats and into the oil pump body.
ROTOR SHAFT
Install the dowel pins into the oil pump body.

Install the oil pump cover and screw, and tighten the DOWEL PINS
screw.
PUMP COVER SCREW
INSTALLATION
Install the oil pump onto the right crankcase by aligning
the dowel pins with the holes. OIL PUMP
Install the two mounting bolts and tighten them.
MOUNTING BOLTS
Install the oil pump driven gear.

DRIVEN GEAR
4-6
5. FUEL SYSTEM
SYSTEM COMPONENTS······························· 5-2 CARBURETOR ASSEMBLY ························5-11
SERVICE INFORMATION ······························ 5-3 INSULATOR INSTALLATION·······················5-13
TROUBLESHOOTING···································· 5-4 CARBURETOR INSTALLATION ··················5-14
AIR CLEANER HOUSING······························ 5-5 PILOT SCREW ADJUSTMENT ····················5-16
STORAGE TANK ··········································· 5-6 FUEL STRAINER ··········································5-17
CARBURETOR REMOVAL···························· 5-6 SECONDARY AIR SUPPLY SYSTEM··········5-17
INSULATOR REMOVAL ································ 5-8 EVAP ONE WAY VALVE ······························5-20
CARBURETOR DISASSEMBLY/ EVAP CANISTER··········································5-21

INSPECTION ·················································· 5-8
5-1
FUEL SYSTEM
SYSTEM COMPONENTS
FUEL SYSTEM
1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)
1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)
4.2 N·m (0.43 kgf·m, 3.1 lbf·ft)
5-2
FUEL SYSTEM
SERVICE INFORMATION
GENERAL
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss
of vehicle control.
• 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.
• If the vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause clogged
jets, resulting in hard starting or poor driveability.
• Before removing the carburetor, place an approved gasoline container under the carburetor drain hose, loosen the drain screw
and drain the carburetor.
• When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with a piece of tape to prevent any
foreign material from dropping into the engine. Be sure to remove the cover when reinstalling the carburetor.
SPECIFICATIONS
ITEM SPECIFICATIONS
Carburetor identification number PDCBV
Main jet #98
Slow jet #38
Pilot screw opening See page 5-16
Float level 14.0 mm (0.55 in)
Idle speed 1,400 ± 100 min-1 (rpm)
Throttle grip free play 2 – 6 mm (0.08 – 0.24 in)
TORQUE VALUES
Battery holder bolt 1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)
Tool box cover bolt 1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)
Choke cable stay screw 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
Carburetor drain screw 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
Slow jet 1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)
Needle jet holder 2.5 N·m (0.25 kgf·m, 1.8 lbf·ft)
Main jet 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
Float chamber screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
Insulator socket bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Fuel valve lock nut 22 N·m (2.2 kgf·m, 16 lbf·ft)
PAIR check valve cover screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
TOOLS
Float level gauge
07401-0010000
5-3
FUEL SYSTEM
TROUBLESHOOTING
Engine won’t start
• No fuel in tank
• No fuel to carburetor
– Clogged fuel strainer
– Clogged fuel line
– Clogged fuel tank breather
• Too much fuel getting to the engine
– Clogged air cleaner
– Flooded carburetor
• Intake air leak
• Contaminated/deteriorated fuel
• Clogged jets
• Improper choke operation
• Improper throttle operation
• No spark at plug (faulty ignition system)
Lean mixture
• Clogged fuel jets
• Faulty float valve
• Float level too low
• Restricted fuel line
• Clogged carburetor air vent hose
• Restricted fuel tank breather
• Intake air leak
• Faulty throttle valve
Rich mixture
• Faulty float valve
• Float level too high
• Clogged air jets
• Clogged air cleaner
• Worn jet needle or needle jet
• Faulty vacuum piston
Engine stall, hard to start, rough idling
• Restricted fuel line
• Fuel mixture too lean/rich
• Contaminated/deteriorated fuel
• Intake air leak
• Misadjusted idle speed
• Misadjusted pilot screw
• Clogged slow circuit
• Faulty ignition system
Afterburn when engine braking is used
• Lean mixture in slow circuit
• Faulty secondary air supply system
– Faulty PAIR control valve
– Clogged hose of the secondary air supply system
Backfiring or misfiring during acceleration
• Fuel mixture too lean
Poor performance (driveability) and poor fuel economy
• Clogged fuel system
5-4
FUEL SYSTEM
AIR CLEANER HOUSING
BREATHER HOSE
– seat (page 2-4)
– battery (page 15-5)
– air cleaner cover (page 3-7)
Release the breather hose from the hole.
HOLE
Remove the four battery holder bolts and battery stays.

BOLTS
BATTRY STAYS
Remove the two tool box cover bolts/washers and tool

box cover. BOLTS/WASHERS
TOOL BOX COVER
Remove the tool box by releasing the boss from the

TOOL BOX
grommet of the frame and sliding it to left side.
BOSS GROMMET
5-5
FUEL SYSTEM
Remove the air cleaner housing by releasing the MOUNT RUBBER
WIND GUARD HOLES
bosses from the fuel tank mount rubber holes.
Remove the rubber cover from the air cleaner housing. RUBBER
Route the hoses Installation is in the reverse order of removal.

and wire harness
properly (page 1-
TORQUE:
16) TOOL BOX COVER BOLT:
1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)
BATTERY HOLDER BOLT:
1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)
BOSSES
AIR CLEANER HOUSING
STORAGE TANK
STORAGE TANK CLIP
Remove the crankcase breather hose, clip and storage
tank.
Check breather hose for deterioration, damage or loose
connection.
Make sure that the hose is not cracked.
Check the storage tank for clogging, damage or fatigue.
BREATHER HOSE
CARBURETOR REMOVAL
FUEL HOSE EVAP HOSE
Place a suitable container under the carburetor drain
hose and drain fuel from the carburetor by loosening
the drain screw.
Tighten the carburetor drain screw to the specified
torque.
Disconnect the following:
DRAIN
– fuel hose SCREW
– drain hose
– EVAP one way valve-to-carburetor hose
– air vent hose AIR VENT HOSE DRAIN HOSE
5-6
FUEL SYSTEM
Loosen the lock nuts and release the choke cable from
the cable holder stay. LOCK NUTS
Remove the choke cable from the carburetor side
choke lever.
CHOKE CABLE
STAY
CHOKE LEVER
Remove the carburetor top and throttle valve from the

carburetor. CARBURETOR TOP
THROTTLE VALVE
Release the spark plug wire from the cable holder.

NUTS HOLDER
Loosen the air cleaner connecting hose band screw.
Remove the carburetor mounting nuts, cable holder,
and carburetor from the insulator.
SCREW
CARBURETOR PLUG WIRE
Remove the O-ring from the carburetor groove.
O-RING
5-7
FUEL SYSTEM
INSULATOR REMOVAL
Disconnect the vacuum hose.
Remove the insulator socket bolts and insulator from VACUUM HOSE
the cylinder head.
BOLTS
Remove the O-ring and gasket.

O-RING
GASKET
CARBURETOR DISASSEMBLY/
INSPECTION
THROTTLE VALVE
Remove the throttle cable from the throttle valve while
SPRING THROTTLE CABLE
compressing the throttle valve spring.
THROTTLE VALVE
Remove the retainer, spring, and jet needle while

pushing the retainer with a screwdriver slightly and THROTTLE VALVE
turning it counterclockwise.
Check the throttle valve and jet needle for scratches,
wear or damage.
Replace them if necessary.
SPRING
JET NEEDLE RETAINER
5-8
FUEL SYSTEM
FLOAT AND JETS
Remove the three screws and float chamber. FLOAT CHAMBER SCREWS
Remove the O-ring from the float chamber groove.

FLOAT CHAMBER
O-RING
Remove the float pin, float and float valve.

FLOAT VALVE FLOAT PIN
Inspect the float for deformation or damage.
Replace the float if there is fuel in the float.
FLOAT
Check the float valve and valve seat for scoring,

scratches, clogging or damage. VALVE SEAT PIN
Check the tip of the float valve, where it contacts the
valve seat, for stepped wear or contamination.
Check the operation of the float valve.
Push the pin on the float valve and make sure that it
returns smoothly.
FLOAT VALVE
5-9
FUEL SYSTEM
Handle the jets with Remove the following:
care. They can SLOW JET MAIN JET
– main jet for clogging
easily be scored or
– needle jet holder NEEDLE JET
scratched.
HOLDER
Damage to the pilot Turn the pilot screw in and carefully count the number
screw seat will of turn until it seats lightly. Make a note of this to use as
occur if the pilot a reference when reinstalling the pilot screw.
screw is tightened
Remove the pilot screw, spring, washer and O-ring.
against the seat.
PILOT SCREW NEEDLE JET
Check the following: O-RING

SLOW WASHER
– each jet for clogging JET
– each passage for clogging SPRING
– pilot screw needle for wear or damage
PILOT
– pilot screw spring for deterioration
SPRING SCREW
Replace the damaged parts, if necessary.
Clean the jets with cleaning solvent and blow them
open with compressed air.
O-RING
NEEDLE JET MAIN JET
STOP SCREW NEEDLE JET HOLDER
CARBURETOR BODY CLEANING

Remove the all jets and pilot screw (page 5-9).
Blow open each air and fuel passage in the carburetor
body with compressed air.
5-10
FUEL SYSTEM
CARBURETOR ASSEMBLY
THROTTLE CABLE
THROTTLE STOP SCREW

SPRING
O-RING
CARBURETOR BODY
CARBURETOR TOP
O-RING
SPRING
DRAIN SCREW
1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
NEEDLE JET
NEEDLE JET
SLOW JET HOLDER
O-RING
1.8 N·m (0.18 kgf·m, 1.3 lbf·ft) 2.5 N·m
(0.25 kgf·m,
1.8 lbf·ft)
RETAINER
JET NEEDLE FLOAT VAVLE
O-RING
WASHER
SPRING
PILOT SCREW
O-RING
FLOAT
FLOAT PIN CHAMBER
FLOAT
SCREWS
THROTTLE VALVE 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
MAIN JET
2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
5-11
FUEL SYSTEM
FLOAT AND JETS
Damage to the pilot Install the pilot screw with the spring, washer and a new O-RING
SLOW WASHER
screw seat will O-ring, and return it to its original position as noted
occur if the pilot during removal. JET SPRING
screw is tightened Perform the pilot screw adjustment if a new pilot screw
against the seat. is installed. PILOT
SPRING SCREW
Install the throttle stop screw with the spring and a new
O-ring, and return it to its original position as noted
during removal.
Handle the jets with Install the following: O-RING
care. They can – needle jet
easily be scored or – needle jet holder
scratched. – main jet NEEDLE JET MAIN JET
– slow jet
STOP SCREW NEEDLE JET HOLDER
Tighten to the specified torque.
TORQUE:
Slow jet 1.8 Nm (0.18 kgf·m, 1.3 lbf·ft)
Needle jet holder 2.5 N·m (0.25 kgf·m, 1.8 lbf·ft)
Main jet 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
Hang the float valve onto the float arm lip.
Install the float valve and float, and insert the float pin. FLOAT VALVE FLOAT PIN
FLOAT
Check the float level after checking the float valve,

valve seat and float. FLOAT LEVEL
GAUGE
Set the float level With the float valve seated and the float arm just
gauge so that it is touching the valve, measure the float level with the float
perpendicular to the level gauge.
float chamber face
at the highest point
TOOL:
of the float. Carburetor float level gauge 07401-0010000
FLOAT LEVEL: 14.0 mm (0.55 in)

The float level cannot be adjusted.
Replace the float assembly if the float level is out of
specification.
Install a new O-ring into the float chamber groove.

FLOAT CHAMBER
O-RING
5-12
FUEL SYSTEM
Install the float chamber with the three screws and SCREWS
tighten them to the specified torque.
THROTTLE VALVE
Install the jet needle into the throttle valve.
Secure the jet needle with retainer and spring while THROTTLE VALVE
pushing the retainer with a screwdriver slightly and
turning it clockwise.
SPRING
JET NEEDLE RETAINER
Install the throttle valve spring onto the throttle cable.

SPRING THROTTLE CABLE
Connect the throttle cable to the throttle valve while
compressing the throttle valve spring.
THROTTLE VALVE
INSULATOR INSTALLATION
Install the new O-ring and gasket.
O-RING
GASKET
5-13
FUEL SYSTEM
Install the insulator to the cylinder head by tightening
the insulator socket bolt. VACUUM HOSE

Connect the vacuum hose.
BOLTS
CARBURETOR INSTALLATION
Install a new O-ring into the carburetor groove.
O-RING
Install the carburetor to the insulator.

Install the cable holder and tighten the carburetor NUTS HOLDER
mounting nuts.
Install the spark plug wire to the cable holder.
Tighten the air cleaner connecting hose band screw.
SCREW PLUG WIRE
Install the throttle valve into the carburetor body by

aligning its cut-out with the throttle stop screw. THROTTLE VALVE
Align
5-14
FUEL SYSTEM
Tighten the carburetor top.
CARBURETOR TOP
Connect the choke cable to the carburetor side choke

CHOKE CABLE
lever.
Install the choke cable to the cable holder stay.
STAY
CHOKE LEVER
Connect the following:

FUEL HOSE EVAP HOSE
– air vent hose
– EVAP one way valve-to-carburetor hose
– drain hose
– fuel hose
Install the right side cover (page 2-4).
After installing the carburetor, check for the following:
– throttle grip free play (page 3-6)
– choke operation (page 3-6)
– engine idle speed (page 3-13)
AIR VENT HOSE DRAIN HOSE
5-15
FUEL SYSTEM
PILOT SCREW ADJUSTMENT
IDLE DROP PROCEDURE
• 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. Remove the left side cover (page 2-5).
Damage to the pilot Turn the pilot screw clockwise until it seats lightly,
screw seat will then back it out to specification given.
occur if the pilot This is an initial setting prior to the final pilot screw
screw is tightened adjustment.
against the seat.
INITIAL OPENING: 1 - 1/2 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
according to its manufacturer’s instructions.
PILOT SCREW
4. Disconnect the PAIR control valve vacuum hose

VACUUM HOSE VACUUM PUMP
from the intake manifold and plug the hose joint.
Connect the vacuum pump to the vacuum hose.
5. Apply the vacuum more than 57 kPa (430 mmHg) to PLUG
the PAIR control valve.
PAIR CONTROL VALVE
6. Start the engine and adjust the idle speed with the
throttle stop screw.
IDLE SPEED: 1,400 ± 100 min–1 (rpm)
7. Turn the pilot screw in or out slowly to obtain the
highest 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 100 min–1 (rpm).
10.Turn the pilot screw out to the final opening from the
position obtained step 9.
THROTTLE STOP SCREW
FINAL OPENING: 1/2 turn out
11.Disconnect the plug from the vacuum joint, then
remove the vacuum pump from the PAIR control
valve vacuum hose and connect the vacuum hose to
the vacuum joint.
12.Readjust the idle speed with the throttle stop screw.
IDLE SPEED: 1,400 ± 100 min–1 (rpm)
Install the left side cover (page 2-5).
5-16
FUEL SYSTEM
FUEL STRAINER
CLEANING
LOCK NUT
Drain the fuel from the fuel tank into the approved
gasoline container.
Loosen the lock nut and remove the fuel valve from the
fuel tank.
Remove the O-ring and fuel strainer from the fuel valve.
Clean the fuel strainer with compressed air.
Install the fuel strainer and a new O-ring to the fuel
valve.
Install the fuel valve into the fuel tank and tighten the
lock nut.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) FUEL VALVE
Install the fuel tank (page 2-5).
FUEL STRAINER
O-RING

PAIR CHECK VALVE INSPECTION
Remove the screws and check valve cover from the
PAIR control valve body.
CHECK VALVE
COVER SCREWS
Remove the check valve from the PAIR control valve

PAIR CONTROL VALVE
body.
CHECK VALVE
5-17
FUEL SYSTEM
Check the reed for damage or fatigue, replace if
necessary. RUBBER SEAT
Replace the PAIR check valve if the rubber seat is

cracked, deteriorated or damaged, or if there is
clearance between the reed and seat.
TORQUE:
PAIR check valve cover screw:
2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
REED
PAIR CONTROL VALVE REMOVAL/

INSTALLATION
Disconnect the vacuum hose and air supply hoses from
the PAIR control valve. AIR SUPPLY HOSES
VACUUM HOSE
PAIR CONTROL VALVE
Remove the bolts and PAIR control valve.

BOLTS
PAIR CONTROL VALVE
5-18
FUEL SYSTEM
SYSTEM INSPECTION
Start the engine and warm it up to normal operating
temperature and stop the engine. AIR SUPPLY HOSE
Disconnect the air supply hose from the separate air VACUUM PUMP
filter (page 5-19). VACUUM HOSE
Remove the PAIR check valve (page 5-17) and check
the inside of PAIR control valve is clean and free of
carbon deposits.
Check the PAIR check valve if the inside of PAIR PLUG
control valve is carbon fouled.
Disconnect the PAIR control valve vacuum hose from
the inlet pipe and plug the hose joint.
Connect the vacuum pump to the PAIR control valve
vacuum hose.
Start the engine and open the throttle slightly to be
certain 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 valve vacuum hose.
Check that the air supply hose stops drawing air, and PAIR
that the vacuum does not bleed. CONTROL
VALVE
SPECIFIED VACUUM: 57 kPa (430 mmHg)
If the air is drawn in or if the specified vacuum is not
maintained, install a new PAIR control valve.
If afterburn occurs on deceleration, even when the
secondary air supply system is normal.
Install the removed parts in the reverse order of
removal.
SEPARATE AIR FILTER
SEPARATE AIR FILTER
Release the front side hose clip and disconnect the
front side air supply hose from the separate air filter.
HOSES
Release the separate air filter from the clamp of the
frame and remove the rear side hose clip, rear side air
supply hose and separate air filter.
CLAMP HOSE CLIPS
AIR INJECTION PIPE REMOVAL

Disconnect the air supply hose.
Remove the two bolts and air injection pipe from the INJECTION PIPE
cylinder head cover.
Remove the O-ring from the air injection pipe. O-RING
HOSE BOLTS
5-19
FUEL SYSTEM
AIR INJECTION PIPE INSPECTION
Check the air supply pipe for crack or damage.
AIR INJECTION
PIPE
AIR INJECTION PIPE INSTALLATION

Coat a new O-ring with engine oil and install it onto the
air injection pipe. INJECTION PIPE
O-RING
Install the air injection pipe onto the cylinder head cover
and tighten the two bolts. INJECTION PIPE
Connect the air supply hose.
HOSE BOLTS
EVAP ONE WAY VALVE

CANISTER-TO-ONE ONE WAY VALVE
Disconnect the EVAP canister-to-one way valve hose WAY VALVE HOSE
and one way valve-to-carburetor hose.
Remove the EVAP one way valve by releasing it from
the holder tab.
properly (page 1-
16).
ONE WAY VALVE-TO

HOLDER TAB CARBURETOR HOSE
5-20
FUEL SYSTEM
EVAP CANISTER
Remove the two special screws.
Remove the canister cover by releasing the tab from GROMMET CANISTER
the grommet of the canister cover stay. COVER
SPECIAL SCREWS TAB

Disconnect the following hoses from the EVAP canister.
CANISTER-TO-ONE WAY
– Fuel tank-to-EVAP canister hose CHECK VALVE HOSE
– EVAP canister-to-one way valve hose
– EVAP canister breather hose
HOLDER TABS
– EVAP canister drain hose
Release the EVAP canister from the holder tabs of the BREATHER
frame and remove it. HOSE

properly (page 1-
16).
CANISTER
FUEL TANK-TO-
CANISTER HOSE DRAIN HOSE
DISASSEMBLY
Loosen the screw and remove the canister cover stay.
SCREW
Remove the canister rubber from the canister.
CANISTER
RUBBER
CANISTER COVER
CANISTER STAY
ASSEMBLY
Install the canister rubber onto the canister.
SCREW
Install the canister cover stay by aligning the slot with
the boss of the canister rubber, then tighten the screw CANISTER
until the band ends are fully seated. RUBBER
Align
CANISTER COVER
CANISTER STAY
5-21
MEMO
6. ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS······························· 6-2 ENGINE REMOVAL ········································6-4
SERVICE INFORMATION ······························ 6-3 ENGINE INSTALLATION································6-6
6-1
SYSTEM COMPONENTS
54 N·m (5.5 kgf·m, 40 lbf·ft)
27 N·m (2.8 kgf·m, 20 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
6-2
SERVICE INFORMATION
GENERAL
• A floor jack or other adjustable support is required to support and maneuver the engine.
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components require engine removal for service:
– cylinder head (page 7-17)
– transmission (page 11-8)
– crankshaft (page 11-14)
Other components can be serviced with the engine installed in the frame.
SPECIFICATIONS
ITEM SPECIFICATIONS
Engine oil capacity After draining 0.8 liter (0.8 US qt, 0.7 lmp qt)
After disassembly 1.0 liter (1.1 US qt, 0.9 lmp qt)
Engine dry weight 28.6 kg (63.1 lbs)
TORQUE VALUES
Front/upper engine hanger nut 27 N·m (2.8 kgf·m, 20 lbf·ft)
Rear engine hanger nut 54 N·m (5.5 kgf·m, 40 lbf·ft)
Drive sprocket bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
6-3
ENGINE REMOVAL
Drain the engine oil (page 3-11).
3P CONNECTOR
– drive sprocket cover (page 2-8)
– fuel tank (page 2-5)
– carburetor (page 5-6)
– exhaust pipe/muffler (page 2-9)
– alternator 3P connector 6P CONNECTOR
– ignition pulse generator 2P connector
– gear position switch 6P connector 2P CONNECTOR
Release the wires from the wire clamp.

CLAMP
– spark plug cap

– air supply hose THROTTLE CABLE AIR SUPPLY
HOSE
Release the spark plug wire, throttle cable and choke
cable from the wire clamp.
CLAMP
CHOKE
CABLE
PLUG WIRE PLUG CAP
Remove the wind guard rubber by releasing the slots

from the tabs as shown.
WIND GUARD RUBBER

– crankcase breather hose
BREATHER HOSE MOTOR CABLE
– battery (–) cable (by removing the motor mounting
bolt)
– starter motor cable (by removing the rubber cap and RUBBER CAP
terminal nut)
– clutch cable (by removing the two bolts)
NUT
BOLT
(–) CABLE CLUTCH CABLE BOLTS
6-4
Loosen the rear axle nut, and the adjuster lock nuts and
adjusting bolts fully to loosen the drive chain
LOCK NUT
AXLE NUT
ADJUSTING BOLT
CHAIN
– two bolts
– fixing plate (by aligning the splines of the plate and
countershaft) BOLTS
– drive sprocket (pull it off the countershaft and
remove from the chain)
SPROCKET
FIXING PLATE
Remove the rear brake switch rod and brake pedal

return spring.
BRAKE SWITCH ROD RETURN SPRING
Place a jack or other adjustable support under the CAP NUTS

engine. PLATES
• The jack height must be continually adjusted to

relieve stress for ease of bolt removal.
– upper engine hanger nut and bolt
– cap nuts, bolts and upper engine hanger plates
NUT
BOLTS
6-5
– front engine hanger nuts and bolts NUTS AND BOLTS
– hanger plate
HANGER PLATE
– rear engine hanger nuts and bolts

During engine Carefully maneuver the engine and remove it out of the
removal, hold the frame to the left.
engine securely and
be careful not to
damage the frame
and engine. NUTS AND
BOLTS
ENGINE INSTALLATION
• Note the installation direction of the engine hanger
bolts. All the hanger bolts are installed from the left
side.
• Route the wires, hoses and cables properly (page 1-
16).
During engine Using a jack or other adjustable support, carefully place

installation, hold the the engine into the frame and maneuver it into place.
engine securely
Carefully align the bolt holes in the frame and engine.
and be careful not
to damage the Align the mounting bolt holes and install the following
frame and engine. fasteners:
– rear engine hanger bolts and nuts NUTS AND
BOLTS
6-6
– hanger plate NUTS AND BOLTS
– front engine hanger bolts and nuts
HANGER PLATE
– cap nuts, bolts and upper engine hanger plates CAP NUTS
– upper engine hanger nut and bolt PLATES
After installing all the engine mounting fasteners,
tighten them to the specified torque.
TORQUE:
Rear (10 mm): 54 N·m (5.5 kgf·m, 40 lbf·ft)
Front/upper (8 mm): 27 N·m (2.8 kgf·m, 20 lbf·ft)
NUT
BOLTS
Install the brake pedal return spring and rear brake

switch rod.
BRAKE SWITCH ROD RETURN SPRING
Place the drive sprocket onto the drive chain with the
stamp (“14T”) facing out and install it onto the CHAIN FIXING PLATE
countershaft.
Install the fixing plate with the chamfered edge facing
in, and set it into the countershaft groove to align the
bolt holes in the plate and sprocket, then install the
bolts.
Tighten the sprocket bolts.
SPROCKET BOLTS
6-7
Connect the clutch cable and install the clutch cable
BREATHER HOSE MOTOR CABLE
stay bolts and tighten it.
Connect the starter motor cable with the terminal nut
and tighten it as specified. RUBBER CAP
Install the rubber cap over the motor terminal properly.
Connect the battery (–) cable with the starter motor NUT
mounting bolt and tighten it. BOLT
Connect the crankcase breather hose.
(–) CABLE CLUTCH CABLE BOLTS
STARTER
MOTOR
CABLE
45º
BATTERY
NEGATIVE
(–) CABLE
Install the wind guard rubber by aligning the slots with
the tabs as shown.
WIND GUARD RUBBER
Set the following items to the clamp:

THROTTLE CABLE AIR SUPPLY
– plug wire HOSE
– choke cable
– throttle cable
– spark plug cap
– air supply hose CLAMP
CHOKE
CABLE
PLUG WIRE PLUG CAP
6-8
3P CONNECTOR
– alternator 3P connector
– ignition pulse generator 2P connector
– gear position switch 6P connector
Route the wires Secure the wires with the clamp.
properly (page 1-
Adjust the drive chain slack (page 3-15).
16).
– carburetor (page 5-14)
– fuel tank (page 2-5) 6P CONNECTOR
– exhaust pipe/muffler (page 2-10) 2P CONNECTOR
Fill the crankcase with engine oil (page 3-11). CLAMP
Check the exhaust system for leaks.
6-9
MEMO
7. CYLINDER HEAD/VALVES
SYSTEM COMPONENTS······························· 7-2 CAMSHAFT·····················································7-8 7
SERVICE INFORMATION ······························ 7-3 CAMSHAFT HOLDER···································7-13
TROUBLESHOOTING···································· 7-5 CYLINDER HEAD ·········································7-17
CYLINDER COMPRESSION·························· 7-6 CAM CHAIN TENSIONER LIFTER···············7-26
CYLINDER HEAD COVER····························· 7-6
7-1
SYSTEM COMPONENTS
10 N·m (1.0 kgf·m, 7 lbf·ft)
32 N·m (3.3 kgf·m, 24 lbf·ft)
16 N·m (1.6 kgf·m, 12 lbf·ft)
9 N·m (0.9 kgf·m, 6.6 lbf·ft)
4 N·m (0.4 kgf·m, 3.0 lbf·ft)
7-2
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves, rocker arms and camshaft.
• The camshaft can be serviced with the engine installed in the frame.
• The cylinder head service requires engine removal.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike the
cylinder head cover and cylinder head too hard during removal.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshaft and rocker arm lubricating oil is fed through oil passages in the cylinder head and camshaft holder. Clean the oil
passages before assembling cylinder head.
SPECIFICATIONS
Unit: mm (in)
Cylinder compression at 800 min-1 (rpm) 1,196 kPa (12.2 kgf/cm2, 176 psi) –
Valve clearance IN 0.08 ± 0.02 (0.003 ± 0.001) –
EX 0.12 ± 0.02 (0.005 ± 0.001) –
Valve, Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.92 (0.194)
valve guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.04 (0.198)
Stem-to-guide clear- IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
ance EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)
Valve seat width IN/EX 0.9 – 1.1 (0.0035 – 0.0043) 1.5 (0.06)
Valve spring Free length INNER 38.76 (1.526) 37.89 (1.492)
OUTER 35.95 (1.415) 35.14 (1.383)
Rocker arm Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm-to-shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
Camshaft Cam lobe height IN 32.9935 – 33.2335 (1.29895 – 1.30840) 32.96 (1.298)
EX 32.8804 – 33.1204 (1.29450 – 1.30395) 32.85 (1.293)
Cylinder head warpage – 0.05 (0.002)
TORQUE VALUES
Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Rocker arm shaft bolt 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
Camshaft holder nut 32 N·m (3.3 kgf·m, 24 lbf·ft) Apply engine oil to the threads and
seating surface.
Cam sprocket bolt 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
Cam chain tensioner lifter plug 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft)
Crankshaft hole cap 15 N·m (1.5 kgf·m, 11 lbf·ft) Apply grease to the threads.
7-3
TOOLS
Tensioner stopper Valve spring compressor set Seat cutter, 24.5
070MG-0010100 07757-0010000 07780-0010100
Seat cutter, 27.5 Flat cutter, 25 Flat cutter, 28

07780-0010200 07780-0012000 07780-0012100
Interior cutter, 30 Interior cutter, 22 Cutter holder, 5.0

07780-0014000 07780-0014202 07781-0010400
Valve guide driver Valve guide reamer, 5.010

07942-8920000 07984-MA60001
7-4
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by
tracing top-end noise with a sounding rod or stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for
a seized piston ring.
Compression too low, hard starting or poor performance at low speed
• Valves
– Incorrect valve clearance
– Burned or bent valve
– Incorrect valve timing
– Weak valve spring
– Uneven valve seating
– Valve stuck open
• Cylinder head
– Leaking or damaged cylinder head gasket
– Warped or cracked cylinder head
– Loose spark plug
• Cylinder/piston problem.
Compression too high
• Excessive carbon build-up on piston head or combustion chamber
Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Cylinder/piston problem (page 8-3)
Excessive noise
• Incorrect valve clearance
• Sticking valve or broken valve spring
• Excessive worn valve seat
• Worn or damaged camshaft
• Worn rocker arm and/or shaft
• Worn rocker arm and valve stem end
• Worn cam sprocket teeth
• Worn cam chain
• Worn or damaged cam chain tensioner
• Cylinder/piston problem (page 8-3)
Rough idle
• Low cylinder compression
7-5
CYLINDER COMPRESSION
Warm up the engine to normal operating temperature.
Stop the engine and remove the spark plug (page 3-8). COMPRESSION GAUGE
Install the compression gauge into the spark plug hole.

Shift the transmission into neutral.
Open the throttle all the way and crank the engine with
the starter motor until the gauge reading stops rising.
The maximum reading is usually reached within 4 – 7
seconds.
COMPRESSION PRESSURE:
1,196 kPa (12.2 kgf/cm2, 176 psi) at 800 min–1 (rpm)
If compression is high, it indicates that carbon deposits
have accumulated on the combustion chamber and/or
the piston crown.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of
engine oil into the cylinder through the spark plug hole
and recheck the compression.
If the compression increases from the previous value,
check the cylinder, piston and piston rings.
• Leaking cylinder head gasket
• Worn piston ring
• Worn cylinder and piston
If compression is the same as the previous value, check
the valves for leakage.
CYLINDER HEAD COVER

REMOVAL
Release the vacuum hose from the hose clamp and
remove the bolt and hose clamp. BOLT
VACUUM HOSE
HOSE CLAMP
Disconnect the air supply hose from the air injection

BOLTS/MOUNTING RUBBERS
pipe.
Remove the cylinder head cover special bolts/mounting
rubbers and cylinder head cover.
AIR SUPPLY
HOSE
CYLINDER HEAD COVER
7-6
Remove the gasket and O-ring from the cylinder head
GASKET CYLINDER HEAD COVER
cover.
O-RING
Remove the dowel pin and O-ring from the camshaft

holder. DOWEL PIN
O-RING
INSTALLATION
Install the dowel pin into the camshaft holder.
Coat a new O-ring with engine oil and install it onto the DOWEL PIN
dowel pin.
O-RING
dowel pin. GASKET CYLINDER HEAD COVER
Install a new gasket into the cylinder head cover
groove.
Install the cylinder head cover onto the cylinder head.
O-RING
7-7
Install the mounting rubbers onto the cylinder head
cover with their “UP” marks facing up. "UP" MARKS
Install the head cover bolts/mounting rubbers and BOLTS/MOUNTINGRUBBERS

tighten them.

Connect the air supply hose to the air injection pipe.
AIR SUPPLY
HOSE
Install the hose clamp and tighten the bolt.

Set the vacuum hose to the hose clamp. BOLT
VACUUM HOSE
HOSE CLAMP
CAMSHAFT
CAM SPROCKET REMOVAL
Remove the cylinder head cover (page 7-6).
TIMING HOLE CAP
Remove the timing and crankshaft hole caps.
Remove the O-rings from the hole caps.
O-RINGS
CRANKSHAFT
HOLE CAP
7-8
Rotate the crankshaft counterclockwise and align the
“T” mark on the flywheel with the index notch on the left
crankcase cover. INDEX NOTCH
Make sure the piston is at TDC (Top Dead Center) on

the compression stroke.
This position can be confirmed by checking for slack in
the rocker arms.
If there is no slack, rotate the crankshaft
counterclockwise one full turn and align the "T" mark
with the index notch again.
"T" MARK
Remove the plug and O-ring from the cam chain

tensioner lifter. PLUG
O-RING
Turn the cam chain tensioner lifter shaft clockwise fully

TENSIONER STOPPER
and secure it using the special tool.
TOOL:
Tensioner stopper 070MG-0010100
TENSIONER LIFTER SHAFT
Be careful not to let Remove the cam sprocket bolts.

the sprocket bolts Remove the cam sprocket off the camshaft flange and BOLTS CAM CHAIN
fall into the cam chain.
crankcase. Attach a piece of wire to the cam chain to prevent it
from falling into the crankcase.
SPROCKET
7-9
CAMSHAFT REMOVAL
Be careful not to let Remove the bolt and camshaft retainer plate.
BOLT CAMSHAFT
the bolt and plate Remove the camshaft from the camshaft holder.
fall into the
crankcase.
RETAINER PLATE
INSPECTION
Turn the outer race of each bearing with your finger.
The bearings should turn smoothly and quietly. Also
check that the bearing inner race fits tightly on the
camshaft.
Measure the height of each cam lobe.
SERVICE LIMITS: IN: 32.96 mm (1.298 in)

EX: 32.85 mm (1.293 in)
Inspect the cam lobes for damage or excessive wear.
CAMSHAFT INSTALLATION
Lubricate the camshaft bearings with engine oil.
Apply molybdenum oil solution to the cam lobes. BEARINGS
CAM LOBES
7-10
Make sure the tab of camshaft is facing the upward.
TAB
CAMSHAFT
Install the camshaft, retainer plate and tighten the bolt.

BOLT CAMSHAFT
RETAINER PLATE
CAM SPROCKET INSTALLATION

Be careful not to Rotate the crankshaft counterclockwise and align the
jam the cam chain. “T” mark on the flywheel with the index notch on the left
crankcase cover. INDEX NOTCH
Make sure the piston is at TDC (Top Dead Center).
"T" MARK
Apply engine oil to the cam chain.

CAM CHAIN SPROCKET
Install the cam sprocket onto the cam chain so that the
index line aligns with the upper surface of the cylinder
head.
Install the cam sprocket onto the camshaft flange.
INDEX LINE
7-11
Tighten the "o" Install the cam sprocket bolts and tighten them.
mark side bolt first.
TORQUE: 9 N·m (0.9 kgf·m, 6.6 lbf·ft) "o" MARK
BOLTS
Remove the tensioner stopper from the cam chain

TENSIONER STOPPER
tensioner lifter.
Turn the crankshaft counterclockwise one full turn

(360°). INDEX LINE
Be sure that the index line on the cam sprocket aligns
with the upper surface of the cylinder head when the "T"
mark on the flywheel is aligned with the index notch on
the crankcase cover.
Coat a new O-ring with engine oil and install it into the
PLUG
tensioner lifter groove.
Install the plug and tighten it.
O-RING
7-12
Coat new O-rings with engine oil and install them onto
the timing and crankshaft hole caps. TIMING HOLE CAP
Apply grease to the crankshaft hole cap threads.
Install the crankshaft hole cap and tighten it.
CRANKSHAFT
Install the timing hole cap and tighten it. HOLE CAP
Install the cylinder head cover (page 7-7)
O-RINGS
CAMSHAFT HOLDER
REMOVAL
Remove the cam sprocket (page 7-8). NUTS, WASHERS
Loosen the cylinder head bolts.
Remove the camshaft holder nuts, washers and the
camshaft holder.
BOLTS
CAMSHAFT HOLDER
DISASSEMBLY
Remove the bolt and camshaft retainer plate.
Remove the camshaft from the camshaft holder.
BOLT PLATE
CAMSHAFT
Remove the rocker arm shaft bolts.

BOLTS
7-13
Remove the rocker arm shafts and rocker arms from
the holder. ROCKER ARM
SHAFT
INSPECTION
Turn the rocker arm roller with your finger.
The roller should turn smoothly and quietly.
Measure the rocker arm I.D.
ROLLER
Measure the rocker arm shaft O.D.

Calculate the rocker arm-to-shaft clearance.
7-14
ASSEMBLY
ROCKER ARMS * : molybdenum oil solution to cam lobes
ROCKER ARM SHAFT

BOLTS
5 N·m (0.5 kgf·m, 3.7 lbf·ft)
* CAMSHAFT
ROCKER ARM SHAFT
CAMSHAFT HOLDER ROCKER ARM SHAFT

RETAINER PLATE
Apply engine oil to the rocker arm inner surfaces, rollers

and rocker arm shaft entire surfaces. ROCKER ARM
SHAFT
Note the directions Set the rocker arms in the camshaft holder, then install
ROCKER ARMS
of the bolt holes in the rocker arm shafts into the camshaft holder through
the rocker arm the rocker arms.
shafts.
SHAFTS
7-15
Align the bolt holes in the camshaft holder and rocker
BOLT
arm shafts using a screwdriver, and install the rocker
arm shaft bolts.
Tighten the rocker arm shaft bolts.

BOLTS
Lubricate the camshaft bearings with engine oil.

Apply molybdenum oil solution to the cam lobes. BEARINGS
CAM LOBES
Make sure the tab of camshaft is facing the upward.

Install the camshaft into the camshaft holder.
TAB
CAMSHAFT
7-16
Install the camshaft retainer plate and tighten the bolt
securely.
BOLT PLATE
CAMSHAFT
INSTALLATION
Install the camshaft holder onto the cylinder head by
CAMSHAFT HOLDER
aligning the pins with the holes.
Align
Align
Apply engine oil to the threads and seating surfaces of NUTS, WASHERS
the camshaft holder nuts.
Install the washers onto the camshaft holder nuts.
Install the camshaft holder nuts and tighten them.
Tighten the cylinder head bolts.
Install the cam sprocket (page 7-11). BOLTS
CYLINDER HEAD
REMOVAL
BOLTS CYLINDER HEAD
– engine (page 6-4)
– camshaft holder (page 7-13)
– spark plug
– two cylinder head bolts and cylinder head.
SPARK PLUG
7-17
Remove the cylinder head gasket and two dowel pins.
DOWEL PINS
Be careful not to Clean off any gasket materials from the cylinder head
damage the mating mating surface.
surfaces.
GASKET
DISASSEMBLY
To prevent loss of While compressing the valve spring with a valve spring
tension, do not compressor, remove the valve cotters.
compress the valve
spring more than TOOL:
necessary to Valve spring compressor 07757 – 0010000 COTTERS
remove the cotters.
VALVE SPRING
COMPRESSOR
Mark all Remove the following:

disassembled parts
– spring retainers
to ensure correct
– inner and outer valve springs
reassembly.
– intake and exhaust valves VALVE SPRINGS
– stem seals
– spring seats
Remove the carbon deposits from the combustion
chamber.
VALVE
SPRING SEAT
STEM SEAL RETAINER
INSPECTION
CYLINDER HEAD
Remove the carbon deposits from the combustion
chamber COMBUSTION CHAMBER
Check the spark plug hole and valve areas for cracks.
7-18
Check the cylinder head for warpage with a straight
edge and a feeler gauge.
VALVE SPRING
Measure the valve spring free length.
SERVICE LIMITS:
INNER: 37.89 mm (1.492 in)
OUTER: 35.14 mm (1.383 in)
VALVE/VALVE GUIDE
Inspect the valve for trueness, burning, scratches or
abnormal stem wear.
Measure each valve stem O.D. and record it.
EX: 4.90 mm (0.193 in)
Insert each valve into the valve guide and check the
valve movement in the guide.
Take care not to tilt Ream the valve guide to remove the carbon build-up
VALVE GUIDE
or lean the reamer before checking the valve guide.
in the guide while Insert the reamer from the combustion chamber side of REAMER
reaming. the cylinder head and always rotate the reamer
clockwise.
TOOL:
Valve guide reamer 07984-MA60001
7-19
Measure each valve guide I.D. and record it.
SERVICE LIMIT: IN/EX: 5.04 mm (0.198 in)
Calculate the stem-to-guide clearance.
EX: 0.09 mm (0.004 in)
If the stem-to-guide clearance exceeds the service limit,
determine if a new guide with standard dimensions
would bring the clearance within tolerance. If so replace
the guides as necessary and ream to fit.
If the stem-to-guide clearance still exceeds the service
limit with a new guide, replace the valve and guide.
Inspect and reface the valve seat whenever new valve
guides are installed.
VALVE GUIDE REPLACEMENT
Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Wear insulated Heat the cylinder head to 130°C – 140°C (275°F –
gloves to avoid 290°F) with a hot plate or oven. Do not heat the cylinder
burns when head beyond 150°C (300°F). Use temperature indicator
handling the heated sticks, available from welding supply stores, to be sure
cylinder head. the cylinder head is heated to the proper temperature.
Using a torch to
heat the cylinder
head may cause
warping.
Be careful not to Support the cylinder head and drive the valve guides
damage the mating and clips out of the cylinder head from the combustion VALVE GUIDE DRIVER
surface. chamber side.
TOOL:
Valve guide driver 07942-8920000
While the cylinder head is still heated, take off the new
valve guides from the freezer and install the new clips VALVE GUIDE DRIVER
to the new guides.
Drive new guides in the cylinder head from the
camshaft side.
TOOL:
Valve guide driver 07942-8920000
Let the cylinder head cool to room temperature.
Take care not to tilt
or lean the reamer
in the guide while
reaming.
Use cutting oil on VALVE GUIDE CLIP
the reamer during
this operation.
7-20
Ream the new valve guides.
VALVE GUIDE
Insert the reamer from the combustion chamber side of
the cylinder head and always rotate the reamer REAMER
clockwise.
TOOL:
Valve guide reamer 07984-MA60001
Clean the cylinder head thoroughly to remove any
metal particles after reaming, and inspect and reface
the valve seats (page 7-22).
VALVE SEAT INSPECTION

Clean the intake and exhaust valves thoroughly to
HAND LAPPING TOOL
remove the carbon deposits.
Apply light coating of Prussian Blue to the valve seats.
Tap the valve against the valve seat several times
without rotating the valve, using a rubber hose or other
hand lapping tool.
The valve cannot Remove the valve and inspect the width of each valve
be grounded. If the seat.
valve face is burned
The valve seat contact should be within the specified
or badly worn or if it
width and even all around the circumference.
contacts the seat
unevenly, replace STANDARD: 0.9 – 1.1 mm (0.035 – 0.043 in)
the valve. SERVICE LIMIT: 1.5 mm (0.06 in)
If the valve seat width is not within specification, reface
the valve seat.
SEAT WIDTH
Inspect the valve seat face for:

• Damaged face:
– Replace the valve and reface the valve seat.
• Uneven seat width:
– Bent or collapsed valve stem;
Replace the valve and reface the valve seat.
DAMAGED FACE UNEVEN SEAT WIDTH
7-21
• Contact area (too high or too low area)
– Reface the valve seat.
TOO LOW TOO HIGH
VALVE SEAT REFACING

Follow the refacing Valve Seat Cutters, a grinder or equivalent valve seat
manufacturer’s refacing equipment are recommended to correct a worn
operating valve seat.
instructions.
45°
60°
32°
If the contact area is too high on the valve, the seat

must be lowered using a 32 degree flat cutter. CONTACT TOO HIGH
OLD SEAT
If the contact area is too low on the valve, the seat must WIDTH
be raised using a 60 degree inner cutter.
32°
CONTACT TOO LOW

OLD SEAT
WIDTH
60°
Reface the valve Use a 45 degree cutter to remove the roughness or

VALVE SEAT CUTTER ROUGHNESS
seat with a 45 irregularities from the seat.
degree cutter when
a valve guide is TOOLS:
replaced. Seat cutter, 27.5 (IN) 07780-0010200
Seat cutter, 24.5 (EX) 07780-0010100
Cutter holder 07781-0010400
7-22
Using 32 degree cutter, remove top 1/4 of the existing
valve seat material.
TOOLS:
Flat cutter, 28 (IN) 07780-0012100 OLD SEAT WIDTH
Flat cutter, 25 (EX) 07780-0012000
32°
Using 60 degree cutter, remove the bottom 1/4 of the

old seat.
TOOLS: OLD SEAT WIDTH

Interior cutter, 30 (IN) 07780-0014000
Interior cutter, 22 (EX) 07780-0014202
Remove the cutter and inspect the area you have just
removed.
60°
Install a 45 degree finish cutter and cut the seat to

proper width.
STANDARD SEAT WIDTH: SEAT WIDTH

0.9 – 1.1 mm (0.035 – 0.043 in)
Make sure that all pitting and irregularities are removed.
45°
Excessive lapping After cutting the seat, apply lapping compound to the HAND LAPPING TOOL
pressure may valve face and lap the valve using light pressure.
deform or damage Change the angle of lapping tool frequently to prevent
the seat. uneven seat wear.
Lapping compound
After lapping, wash any residual compound off the
can cause damage
cylinder head and valve.
if it enters between
Recheck the seat contact after lapping.
the valve stem and
guide.
7-23
ASSEMBLY
RETAINER
VALVE COTTERS
STEM SEAL
VALVE SPRINGS
CLIP
SPRING SEAT
VALVE GUIDE
INTAKE VALVE
EXHAUST VALVE
Clean the cylinder head assembly with solvent and

blow through all oil passage with compressed air.
Install the spring seats and new valve stem seals.
VALVE
Lubricate each valve stem with molybdenum oil VALVE SPRINGS
solution.
To avoid damage to Insert the intake and exhaust valves into the valve
the seal, turn the guides.
valve slowly when
inserting.
SPRING SEAT
STEM SEAL RETAINER
Install the inner and outer valve springs with the tightly
wound coils facing the combustion chamber.
Install the spring retainers.
Combustion chamber side
7-24
Grease the cotters Compress the valve spring and install the valve cotters.
to ease installation.
To prevent loss of TOOL:
tension, do not Valve spring compressor 07757-0010000
compress the valve COTTERS
spring more than
necessary.
VALVE SPRING
COMPRESSOR
Support the cylinder Tap the stems gently with a bar and hammer to firmly
head above the seat the cotters. VALVE STEMS
work bench surface
to prevent valve
damage.
INSTALLATION
Be careful not to Clean any gasket material from the cylinder mating
damage the mating surface. DOWEL PINS
surfaces.
Install the dowel pins and a new gasket.
Do not allow gasket
material to enter the
engine.
GASKET
Route the cam chain through the cylinder head and

BOLTS CYLINDER HEAD
install the cylinder head onto the cylinder.
Loosely install the cylinder head bolts.
Install the spark plug and tighten it.
– camshaft holder (page 7-17).
SPARK PLUG
7-25
CAM CHAIN TENSIONER LIFTER
REMOVAL/INSPECTION
Remove the plug and O-ring from the cam chain
tensioner lifter. PLUG
O-RING

TENSIONER STOPPER
TOOL:
Remove the two mounting bolts.
TENSIONER LIFTER SHAFT BOLTS
Remove the cam chain tensioner lifter and gasket from

the cylinder. TENSIONER LIFTER
Remove the tensioner stopper from the tensioner lifter.
GASKET
Check the cam chain tensioner lifter operation:

TENSIONER LIFTER
– The tensioner lifter shaft should not go into the body
when it is pushed.
– When it is turned clockwise with a screwdriver, the
tensioner lifter shaft should be pulled into the body.
The shaft should spring out of the body as soon as
the screwdriver is released.
TENSIONER STOPPER
7-26
INSTALLATION
TOOL:
TENSIONER STOPPER
Install a new gasket and cam chain tensioner lifter onto

the cylinder. TENSIONER LIFTER
GASKET
Install the two mounting bolts and tighten them.

Remove the tensioner stopper from the tensioner lifter. TENSIONER STOPPER
BOLTS
PLUG
tensioner lifter groove.
Install the plug and tighten it.
O-RING
7-27
MEMO
8. CYLINDER/PISTON
SYSTEM COMPONENTS······························· 8-2 CYLINDER/PISTON REMOVAL ·····················8-4

8
SERVICE INFORMATION ······························ 8-3 PISTON/CYLINDER INSTALLATION·············8-8
TROUBLESHOOTING···································· 8-3
8-1
CYLINDER/PISTON
SYSTEM COMPONENTS
CYLINDER/PISTON
8-2
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• The cylinder and piston services require engine removal.
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal.
• Camshaft and rocker arm lubricating oil is fed through an oil passage in the cylinder. Clean the oil passage before installing
cylinder.
SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 52.400 – 52.410 (2.0630 – 2.0634) 52.50 (2.067)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Piston, Piston O.D. at 10 mm (0.4 in) from bot-
52.370 – 52.390 (2.0618 – 2.0626) 52.3 (2.059)
piston pin, pis- tom
ton ring Piston pin hole I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Second 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.85 (0.033)
Piston ring-to-ring Top 0.030 – 0.065 (0.0012 – 0.0026) 0.10 (0.004)
groove clearance Second 0.030 – 0.065 (0.0012 – 0.0026) 0.10 (0.004)
Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.10 (0.004)
Connecting rod small end I.D. 13.016 – 13.034 (0.5124 – 0.5131) 13.04 (0.513)
Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.03 (0.001)
TORQUE VALUE
Cylinder stud bolt 11 N·m (1.1 kgf·m, 8 lbf·ft) See page 8-7
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
Compression too high, overheating or knocking
• Excessive carbon built-up on piston or combustion chamber.
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnormal noise (piston)
• Worn piston pin or piston pin hole
• Worn cylinder, piston or piston ring
• Worn connecting rod small end
8-3
CYLINDER/PISTON
CYLINDER/PISTON REMOVAL
CYLINDER REMOVAL
CYLINDER
– cam chain tensioner lifter if necessary (page 7-26)
– cam chain guide
Do not strike the Lift the cylinder and remove it, being careful not to
cylinder too hard damage the piston.
and do not damage
Clean the top of the cylinder thoroughly.
the mating surface
with a screwdriver.
CAM CHAIN GUIDE
Remove the dowel pins and gasket.

DOWEL PINS
GASKET
PISTON REMOVAL
Place a clean shop towel over the crankcase to prevent
PISTON PIN
the possibility of the clip falling into the crankcase.
Remove the piston pin clip using the pair of pliers.
Push the piston pin out of the piston and connecting
rod, and remove the piston.
PISTON PIN CLIP

Do not damage the Spread each piston ring and remove it by lifting it up at
piston ring by a point just opposite the gap.
spreading the ends
too far.
8-4
CYLINDER/PISTON
Never use a wire Clean carbon deposits from the piston ring grooves with
brush; it will scratch a ring that will be discarded.
the grooves.
INSPECTION
CYLINDER
Inspect the cylinder wall for scratches and wear.
Measure and record the cylinder I.D. at three levels in
both the X and Y axes. Take the maximum reading to
determine the cylinder wear.
Calculate the cylinder-to-piston clearance (Piston O.D.
measurement: page 8-6).
Calculate the cylinder for taper and out of round at three

levels in an X and Y axis. Take the maximum reading to
determine the out of round. Y
SERVICE LIMITS: Taper: 0.10 mm (0.004 in) TOP X

Out of round: 0.10 mm (0.004 in)
The cylinder must be rebored, and an oversize piston
MIDDLE
and rings be fitted if the service limit is exceeded.
The 0.25 mm, 0.50 mm, 0.75 mm and 1.00 mm
oversize pistons and rings are available.
BOTTOM
The cylinder must be rebored so that the clearance for
an oversize piston is 0.010 – 0.040 mm (0.0004 –
0.0016 in).
Check the cylinder for warpage by placing a straight

edge and a feeler gauge across the stud bolt holes as
shown.
8-5
CYLINDER/PISTON
PISTON/PISTON PIN/CONNECTING ROD
Inspect the piston for cracks or other damage.
Measure the piston O.D. at 10 mm (0.4 in) from the
bottom, and 90° to the piston pin hole. 90°

Compare this measurement against the maximum 10 mm (0.4 in)
cylinder I.D. measurement and calculate the cylinder-
to-piston clearance (page 8-5).
Measure the piston pin hole I.D. Take the maximum

reading to determine I.D.
Measure the piston pin O.D. at three points.

Calculate the piston-to-piston pin clearance.
Measure the connecting rod small end I.D.

Calculate the connecting rod small end-to-piston pin
clearance.
8-6
CYLINDER/PISTON
PISTON RING
Insert each piston ring into the bottom of the cylinder
squarely using the piston.
Measure the ring end gap using a feeler gauge.
SERVICE LIMITS: Top: 0.40 mm (0.016 in)
Second: 0.40 mm (0.016 in)
Oil: 0.85 mm (0.033 in)
Reinstall the piston rings (page 8-8) into the piston ring
grooves.
Inspect the piston rings for smooth movement by
rotating them. The rings should be able to move in their
grooves without catching.
Push in the ring until the outer surface of the piston ring
is nearly flush with the piston and measure the ring-to-
ring groove clearance using a feeler gauge.
SERVICE LIMITS: Top: 0.10 mm (0.004 in)
Second: 0.10 mm (0.004 in)
STUD BOLT REPLACEMENT

Thread two 8 mm nuts onto the stud bolt and tighten
113.4 – 115.4 mm
them together, and use a wrench on them to turn the
(4.46 – 4.54 in) STUD BOLT
stud bolt out.
Install new stud bolts into the crankcase and tighten
them
After installing the stud bolts, measure the stud height
from the crankcase surface.
STANDARD: 113.4 – 115.4 mm (4.46 – 4.54 in)
Adjust the height if necessary.
8-7
CYLINDER/PISTON
PISTON/CYLINDER INSTALLATION
PISTON INSTALLATION
Carefully install the piston rings into the piston ring
grooves with the markings facing up.
• Do not damage the piston ring by spreading the
ends too far.
• Be careful not to scratch the piston surface.
• Do not confuse the top and second rings.
Stagger the ring end gaps 120 degrees apart from each
other.
Stagger the side rail end gaps as shown.
TOP RING
MARK)
SECOND RING 120°

(MARK)
120° 120°
TOP RING
SECOND RING
A
SPACER
SIDE RAILS
A
TOP RING A: 20 mm (0.8 in) or more
SECOND RING
OIL RING
Apply molybdenum oil solution to the piston pin outer

"IN" MARK PISTON
surface and connecting rod small end inner surface.
Apply engine oil to the piston pin holes.
Install the piston with its “IN” mark toward the intake
side and insert the piston pin through the piston and
connecting rod.
PIN HOLE PISTON PIN
8-8
CYLINDER/PISTON
Place a shop towel over the crankcase opening to
prevent piston pin clips from falling into the crankcase.
Install new piston pin clips into the grooves in the piston
pin holes.
• Make sure that the piston pin clips are seated
securely.
• Do not align the piston pin clip end gap with the
piston cutout.
PISTON PIN CLIP
CYLINDER INSTALLATION
Be careful not to Clean any gasket material from the cylinder mating
damage the mating surface of the crankcase. DOWEL PINS
surfaces.
Install the two dowel pins and a new gasket.
Do not allow gasket
material to enter the
crankcase.
GASKET
Apply engine oil to the cylinder wall, piston outer

CYLINDER CAM CHAIN
surface and piston rings.
Be careful not to Route the cam chain through the cylinder and install the
damage the piston cylinder over the piston while compressing the piston
rings and cylinder rings with your fingers.
wall.
PISTON/
PISTON RINGS
Insert the cam chain guide into the cylinder and

CAM CHAIN GUIDE
crankcase grooves.
Install the cylinder head (page 7-25).
GROOVES
8-9
MEMO
9. CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER
SYSTEM COMPONENTS······························· 9-2 GEARSHIFT LINKAGE ·································9-15
SERVICE INFORMATION ······························ 9-3 PRIMARY DRIVE GEAR ·······························9-18

9
TROUBLESHOOTING···································· 9-4 RIGHT CRANKCASE COVER
INSTALLATION·············································9-18
RIGHT CRANKCASE COVER REMOVAL ···· 9-5
KICKSTARTER IDLE GEAR·························9-19
CLUTCH LIFTER ARM··································· 9-6
KICKSTARTER ·············································9-21
CLUTCH ························································· 9-8
9-1
SYSTEM COMPONENTS
12 N·m (1.2 kgf·m, 9 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
64 N·m (6.5 kgf·m, 47 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft) 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
74 N·m (7.5 kgf·m, 55 lbf·ft)
9-2
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch, gearshift linkage and kickstarter. These services can be performed with the engine
installed in the frame.
• Engine oil viscosity, oil level and the use of oil additives have an effect on clutch operation. Oil additives of any kind are
specifically not recommended. When the clutch does not disengage or the vehicle creeps with the clutch disengaged, inspect
the engine oil viscosity and oil level before servicing the clutch system.
• Engine lubricating oil is fed through the oil passages in the right crankcase cover. Clean the oil passages before installing the
right crankcase cover.
• The crankcase must be separated when the transmission, shift drum and shift forks require service (page 11-6).
SPECIFICATIONS
Unit: mm (in)
Clutch lever free play 10 – 20 (0.4 – 0.8) –
Clutch Spring free length 40.5 (1.59) 39.6 (1.56)
Disc thickness 2.80 – 2.90 (0.110 – 0.114) 2.6 (0.10)
Plate warpage – 0.20 (0.008)
Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909)
Clutch outer guide O.D. 22.959 – 22.980 (0.9039 – 0.9047) 22.93 (0.903)
I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
Kickstarter idle gear I.D. 20.500 – 20.521 (0.8071 – 0.8079) 20.58 (0.810)
Kickstarter idle gear bushing O.D. 20.459 – 20.480 (0.8055 – 0.8063) 20.43 (0.804)
I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
Countershaft O.D. at kickstarter idle gear 16.966 – 16.984 (0.6680 – 0.6687) 16.94 (0.667)
Kickstarter drive gear I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.06 (0.632)
Kickstarter spindle O.D. at kickstarter drive gear 15.966 – 15.984 (0.6286 – 0.6293) 15.94 (0.628)
TORQUE VALUES
Clutch center lock nut 74 N·m (7.5 kgf·m, 55 lbf·ft) Apply engine oil to the threads and seating surface.
Clutch lifter plate bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Oil filter rotor lock nut 64 N·m (6.5 kgf·m, 47 lbf·ft) Apply engine oil to the threads and seating surface.
Gearshift cam bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent to the threads.
Shift drum stopper arm bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent to the threads.
Oil filter rotor cover screw 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
9-3
TOOLS
Lock nut wrench, 5.5×2.5/30 Gear holder, M1.5 Pin driver, 3.0
07716-0020100 07724-0010200 07744-0010200
Clutch center holder, P.D. 54

07GMB-KT70101
TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the freeplay.
Clutch lever difficult to pull in
• Damaged, kinked or dirty clutch cable
• Improperly routed clutch cable
• Damaged clutch lifter mechanism
• Faulty clutch lifter plate bearing
Clutch will not disengage or motorcycle creeps with clutch disengaged
• Excessive clutch lever free play
• Clutch plate warped
• Oil level too high, improper oil viscosity, or additive used
Clutch slips
• Clutch lifter sticking
• Worn clutch discs
• Weak clutch springs
• No clutch lever free play
Hard to shift
• Misadjusted clutch cable
• Damaged or bent shift fork
• Bent shift fork shaft
• Damaged gearshift spindle assembly
• Damaged shift drum guide grooves
Transmission jumps out of gear
• Worn shift drum stopper arm
• Worn or broken gearshift spindle return spring
• Damaged shift drum guide grooves
• Worn gear dogs or dog holes
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Bent gearshift spindle
9-4
RIGHT CRANKCASE COVER
REMOVAL
BOLT
Remove the footpeg bar (page 2-8).
When removing the Remove the bolt and kickstarter pedal
kickstarter pedal,
mark the pedal
position to ensure
the original position.
KICKSTARTER PEDAL
Remove the two bolts and clutch cable stay.

LIFTER ARM CABLE STAY
Disconnect the clutch cable from the clutch lifter arm.
BOLTS CLUTCH CABLE
Loosen the ten right crankcase cover bolts in a

COVER
crisscross pattern in 2 or 3 steps.
Remove the bolts and right crankcase cover.
BOLTS
Remove the two dowel pins and gasket.

GASKET
DOWEL PINS
9-5
CLUTCH LIFTER ARM
REMOVAL
LIFTER PIECE
Remove the clutch lifter piece by turning the lifter arm
clockwise slightly.
Drive the spring pin into the clutch lifter arm until the pin
end is flush with the lifter arm surface, using the pin CLUTCH
driver. LIFTER ARM
TOOL:
Pin driver 07744-0010200
PIN DRIVER
Pull the clutch lifter arm out and remove the return
spring.
RETURN SPRING SPRING PIN
Remove the kickstarter spindle dust seal.

Remove the clutch lifter arm and dust seal.
DUST SEALS
Check the lifter piece and arm for wear or damage.
Check the return spring for fatigue or damage.
Replace them if necessary.
CLUTCH LIFTER ARM
9-6
INSTALLATION
Apply grease to a new kickstarter spindle dust seal lip
and install it into the right crankcase cover as specified. DUST SEALS
Apply grease to a new clutch lifter arm dust seal lip and
install it into the right crankcase cover as specified.
Apply engine oil to the clutch lifter arm sliding surface
and install it into the right crankcase cover.
CLUTCH LIFTER ARM
CLUTCH LIFTER ARM KICKSTARTER

DUST SEAL: SPINDLE DUST SEAL:
0.5 - 1.0 mm
0.5 mm (0.02 in) (0.02 - 0.04 in)
Install the return spring onto the lifter arm end.

Hook the return From the opposite side, drive the spring pin until it
spring ends to the projects as specified, using the pin driver.
right crankcase SPRING PIN
cover and spring
TOOL:
pin. Pin driver 07744-0010200
PIN DRIVER
2.5 - 3.5 mm
(0.10 - 0.14 in)
RETURN SPRING
Install the lifter piece into the lifter arm groove while
turning the lifter arm clockwise slightly. LIFTER PIECE
CLUTCH
LIFTER ARM
9-7
CLUTCH
REMOVAL
SCREWS GASKET
– right crankcase cover (page 9-5)
– oil pump driven gear
– three screws
– oil filter rotor cover and gasket
ROTOR COVER
OIL PUMP DRIVEN GEAR
Install the gear holder between the primary drive and

driven gears, and loosen the oil filter rotor lock nut. LOCK NUT WRENCH GEAR HOLDER
TOOLS:
Gear holder 07724-0010200
Lock nut wrench 07716-0020100
LOCK NUT
Remove the washer and oil filter rotor.

OIL FILTER ROTOR
WASHER
Loosen the clutch lifter plate bolts in a crisscross

pattern in several steps. LIFTER PLATE
Remove the bolts, lifter plate and clutch springs.
BOLTS, SPRINGS
9-8
Attach the clutch center holder to the pressure plate
using four clutch lifter plate bolts to hold the clutch CLUTCH CENTER HOLDER
center, and then loosen the lock nut.
TOOL:
Clutch center holder 07GMB-KT70101
Remove the clutch center holder.
LOCK NUT
Remove the washer.

WASHER
– clutch center
– clutch disc A DISC A
DISCS B
– three clutch plates and two discs B
– clutch disc A
– pressure plate CLUTCH
CENTER
PRESSURE
PLATE
PLATES
DISC A
– washer
– clutch outer WASHER CLUTCH OUTER
9-9
– clutch outer guide
CLUTCH OUTER GUIDE
INSPECTION
CLUTCH LIFTER BEARING
Turn the inner race of the lifter bearing with your finger.
LIFTER PLATE LIFTER PLATE BEARING
The bearing should turn smoothly and quietly. Also
check that the outer race fits tightly in the lifter plate.
Replace the bearing if the inner race does not turn
smoothly, quietly, or if the outer race fits loosely in the
lifter plate.
CLUTCH SPRING
Replace the clutch Check the clutch spring for fatigue or damage.
springs as a set.
Measure the clutch spring free length.
CLUTCH CENTER
Check the grooves of the clutch center for damage or
wear caused by the clutch plates. CLUTCH CENTER
GROOVE
9-10
CLUTCH DISC
Replace the clutch Check the clutch discs for signs of scoring or
discs and plates as discoloration.
a set.
Measure the thickness of each disc.
CLUTCH PLATE
Replace the clutch Check the plate for discoloration.
discs and plates as Check the clutch plate for warpage on a surface plate
a set. using a feeler gauge.
CLUTCH OUTER/OUTER GUIDE

Check the slots in the clutch outer for nicks, cuts or
indentations made by the clutch discs.
Check the primary driven gear teeth for wear or
damage.
Measure the clutch outer I.D.
Measure the clutch outer guide I.D. and O.D.
SERVICE LIMITS: O.D.: 22.93 mm (0.903 in)

I.D.: 17.04 mm (0.671 in)
9-11
MAINSHAFT
Measure the mainshaft O.D. at the clutch outer guide.
INSTALLATION
Apply molybdenum oil solution to the outer surface of
CLUTCH OUTER GUIDE
the clutch outer guide and install it onto the mainshaft.
Apply engine oil to the primary driven gear teeth.

Install the clutch outer and washer. WASHER
CLUTCH OUTER
Coat the clutch discs with engine oil.

DISC A DISC B
9-12
Install the clutch disc A, three clutch plates and two
PRESSURE PLATE
discs B alternately, and clutch disc A onto the clutch
center. PLATES, DISCS B
Install the pressure plate onto clutch center by aligning DISC A
the "o" marks as shown.
DISC A
CLUTCH CENTER Align
Install the tabs of Install the clutch center assembly into the clutch outer.
CLUTCH OUTER SHALLOW SLOT
clutch disc A (out
side) into the
shallow slots in the
clutch outer.
DISC A
CLUTCH CENTER ASSEMBLY (OUT SIDE)
Install the washer onto the mainshaft.

WASHER
Apply engine oil to the threads and seating surface of

CLUTCH CENTER HOLDER
the clutch center lock nut.
Install the lock nut onto the mainshaft.
Attach the clutch center holder to the pressure plate
using four clutch lifter plate bolts to hold the clutch
center, and then tighten the lock nut.
TOOL:
Clutch center holder 07GMB-KT70101
LOCK NUT
9-13
Install the clutch springs, lifter plate and bolts.
Tighten the bolts in a crisscross pattern in several LIFTER PLATE
steps.
BOLTS, SPRINGS
Install the oil filter rotor and washer onto the crankshaft.
OIL FILTER ROTOR
WASHER
Apply engine oil to the threads and seating surface of

the oil filter rotor lock nut, and install it. LOCK NUT WRENCH
Install the gear holder between the primary drive and
driven gears, and tighten the oil filter rotor lock nut.
TOOLS:
Gear holder 07724-0010200
Lock nut wrench 07716-0020100
GEAR HOLDER LOCK NUT
Install a new gasket onto the oil filter rotor cover.

ROTOR COVER
GASKET
9-14
Install the oil filter rotor cover with the three screws and
SCREWS
tighten screws.
Install the oil pump driven gear.
ROTOR COVER
OIL PUMP DRIVEN GEAR
GEARSHIFT LINKAGE
REMOVAL/INSPECTION
Remove the following: GEARSHIFT PEDAL
When removing the – pinch bolt and gearshift pedal
gearshift pedal, – clutch (page 9-8)
mark the pedal
Clean the left end of the gearshift spindle.
position to ensure
the original position.
PINCH BOLT
Pull the gearshift spindle out of the crankcase being

careful not to damage the oil seal lip and remove the WASHER
thrust washer from the spindle.
GEARSHIFT SPINDLE

GEARSHIFT CAM
– gearshift cam bolt
– gearshift cam
BOLT
9-15
– dowel pins
– stopper arm bolt RETURN SPRING
– stopper arm DOWEL PINS
– washer WASHER
– return spring
STOPPER ARM BOLT
Inspect the gearshift spindle oil seal for deterioration or

damage, replace if necessary. 0.5 - 1.0 mm
If replacing the oil seal, install it as specified. (0.02 - 0.04 in)
OIL SEAL
Check the gearshift spindle for wear or bend.
Check the spindle plate for wear, damage or PLATE
GEARSHIFT SPINDLE
deformation.
Check the return spring for fatigue or damage.
RETURN SPRING
INSTALLATION
Apply locking agent to the stopper arm bolt threads.
RETURN SPRING
Install the return spring, washer, stopper arm and bolt,
while holding the spring end to the groove on the
stopper arm.
BOLT
Tighten the stopper arm bolt to the specified torque.
WASHER
Hook
STOPPER
ARM
9-16
Install the dowel pins into the shift drum holes.
STOPPER ARM
Hold the stopper arm using a screwdriver and install the Align
gearshift cam by aligning the holes with the dowel pins.
GEARSHIFT CAM
Apply locking agent to the gearshift cam bolt threads.

Install the gearshift cam bolt and tighten it. GEARSHIFT CAM
BOLT
Apply engine oil to the gearshift spindle journals.

Install the thrust washer onto the gearshift spindle and WASHER
insert the spindle into the crankcase.
GEARSHIFT SPINDLE
Be careful not to Install the spindle over the spring pin by aligning the
damage the oil seal return spring ends with the spring pin.
lip in the left Align
crankcase.
GEARSHIFT SPINDLE
9-17
Install the clutch (page 9-12) GEARSHIFT PEDAL
Install the gearshift pedal in the original position noted
during removal.
Install the pinch bolt and tighten it.
PINCH BOLT
PRIMARY DRIVE GEAR

PRIMARY DRIVE GEAR
– clutch (page 9-8)
– primary drive gear
Be careful not to – spacer

damage the – woodruff key WOODRUFF KEY SPACER
crankshaft.
Install the woodruff key into the crankshaft key groove.
Apply engine oil to the primary drive gear teeth.
Install the spacer and primary drive gear onto the
crankshaft by aligning the key grooves with the
woodruff key.
Install the clutch (page 9-12).
PRIMARY DRIVE GEAR
RIGHT CRANKCASE COVER

INSTALLATION
Be careful not to Clean off any gasket material from the right crankcase
GASKET
damage the mating and cover mating surfaces.
surfaces.
DOWEL PINS
9-18
Install the right crankcase cover and bolts.
COVER
Tighten the bolts in a crisscross pattern in 2 or 3 steps.
BOLTS
Connect the clutch cable to the clutch lifter arm.

LIFTER ARM CABLE STAY
Install the clutch cable stay onto the right crankcase
cover and tighten the two bolts.
BOLTS CLUTCH CABLE
Install the kickstarter pedal in the original position noted

during removal and tighten the bolt. BOLT
Install the footpeg bar (page 2-8).

Fill the crankcase with the recommended engine oil
(page 3-11).
KICKSTARTER PEDAL
KICKSTARTER IDLE GEAR

REMOVAL
Remove the clutch assembly (page 9-8).
IDLE GEAR WASHER
Remove the snap ring, washer and kickstarter idle gear.
SNAP RING
9-19
Remove the bushing and washer.
WASHER BUSHING
INSPECTION
Measure the kickstarter idle gear I.D.
Measure the bushing I.D. and O.D.
SERVICE LIMIT:
I.D.: 17.04 mm (0.671 in)
O.D.: 20.43 mm (0.804 in)
IDLE GEAR BUSHING
Measure the countershaft O.D. at the kickstarter idle

COUNTER SHAFT
gear.
INSTALLATION
Apply molybdenum oil solution to the bushing.
WASHER
Install the washer and bushing. BUSHING
9-20
Apply engine oil to the kickstarter idle gear teeth.
WASHER
Install the idle gear, washer and snap ring. IDLE GEAR
Install the clutch assembly (page 9-12).
SNAP RING
KICKSTARTER
REMOVAL
Unhook the return spring from the crankcase.
RETURN SPRING
Remove the following: WASHER KICKSTARTER ASSEMBLY

– kickstarter assembly
– ratchet spring
– washer
RATCHET SPRING
DISASSEMBLY
RATCHET GEAR
– collar
– return spring
– starter ratchet gear
RETURN SPRING COLLAR
9-21
WASHER B DRIVE GEAR
– snap ring
– washer A WASHER A
– kickstarter drive gear
– washer B
WASHER A
WASHER B
SNAP RING
INSPECTION
Check the following:
DRIVE GEAR
– Ratchet gear and drive gear for excessive wear or
damage.
– Spindle for bend or damage.
Measure the drive gear I.D. and spindle O.D. at the
drive gear.
SERVICE LIMIT:
DRIVE GEAR I.D.: 16.06 mm (0.632 in)
SPINDLE O.D.: 15.94 mm (0.628 in)
SPINDLE
ASSEMBLY
WASHER B
DRIVE GEAR
– washer B
– kickstarter drive gear WASHER A
– washer A
– snap ring
WASHER A
WASHER B
SNAP RING
Install the ratchet gear.
RATCHET GEAR
9-22
Hook the return spring to the hole of the spindle.
RETURN SPRING
Hook
Install the collar to the return spring, aligning the cut-out

of the collar with the spring. Align
COLLAR
INSTALLATION
Apply engine oil to the kickstarter drive gear teeth. WASHER KICKSTARTER
Install the ratchet spring and washer to the spindle. ASSEMBLY
Install the kickstarter assembly.
RATCHET SPRING
Hook the return spring to the crankcase.

RETURN SPRING
Hook
9-23
MEMO
10. ALTERNATOR/STARTER CLUTCH
SYSTEM COMPONENTS····························· 10-2 STATOR/IGNITION PULSE

GENERATOR ················································10-5
SERVICE INFORMATION ···························· 10-3
FLYWHEEL/STARTER CLUTCH ·················10-6
TROUBLESHOOTING·································· 10-3
LEFT CRANKCASE COVER 10
LEFT CRANKCASE COVER REMOVAL ···· 10-4 INSTALLATION···········································10-11
10-1
SYSTEM COMPONENTS
74 N·m (7.5 kgf·m, 55 lbf·ft)
10-2
SERVICE INFORMATION
GENERAL
• This section covers the removal and installation of the alternator stator, flywheel and starter clutch. These services can be done
with the engine installed in the frame.
• Alternator inspection (page 15-8).
• Starter motor servicing (page 17-6).
SPECIFICATION
Unit: mm (in)
Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.60 (1.795)
TORQUE VALUES
Starter clutch bolt 16 N·m (1.6 kgf·m, 12 lbf·ft) Apply locking agent to the threads.
Flywheel nut 74 N·m (7.5 kgf·m, 55 lbf·ft) Apply engine oil to the threads and seating
surface.
Alternator stator socket bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Ignition pulse generator socket bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent to the threads.
Wire guide socket bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent to the threads.
TOOLS
Flywheel holder Flywheel puller
07725-0040001 07933-KM10000
TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter motor pinion gear, starter reduction gear or shaft
10-3
LEFT CRANKCASE COVER REMOVAL
Remove the drive sprocket cover (page 2-8).
Remove the left side cover (page 2-4). IGNITION PULSE ALTERNATOR
GENERATOR 2P 3P CONNECTOR
Disconnect the alternator 3P connector and ignition CONNECTOR
pulse generator 2P connector, then release them from
the wire clamp.
CLAMP
Remove the gear position switch wire from the left

crankcase cover.
The left crankcase Loosen the left crankcase cover bolts in a crisscross
cover (stator) is pattern in several steps. LEFT CRANKCASE COVER
magnetically Remove the bolts and left crankcase cover.
attracted to the
flywheel, be careful
during removal.
BOLTS
Remove the dowel pins and gasket.

GASKET
DOWEL PINS
10-4
STATOR/IGNITION PULSE
GENERATOR
REMOVAL
Remove the left crankcase cover (page 10-4).
WIRE GUIDE GROMMET
Remove the following from the left crankcase cover:
– socket bolt and wire guide ALTERNATOR
– grommet STATOR
– two socket bolts and ignition pulse generator
– three socket bolts and alternator stator assembly
IGNITION PULSE
GENERATOR
SOCKET BOLTS
INSTALLATION
ALTERNATOR STATOR WIRE GUIDE SOCKET BOLT
GROMMET
SOCKET BOLT 12 N·m (1.2 kgf·m, 9 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
WIRE GUIDE
ALTERNATOR STATOR
IGNITION PULSE GENERATOR

SOCKET BOLTS
12 N·m (1.2 kgf·m, 9 lbf·ft)
IGNITION PULSE
GENERATOR
Install the alternator stator assembly onto the left

crankcase cover. SOCKET BOLTS
Install the three socket bolts and tighten them to the
specified torque.
ALTERNATOR STATOR
10-5
Apply liquid sealant to the wire grommet seating
surface and install it into the cover groove. IGNITION PULSE
GENERATOR
Apply locking agent to the bolt threads. GROMMET
Install the wire guide and ignition pulse generator onto
the cover.
Install the bolts and tighten them to the specified torque.
SOCKET
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) BOLTS
Install the left crankcase cover (page 10-11).
WIRE GUIDE
FLYWHEEL/STARTER CLUTCH
REMOVAL
Remove the left crankcase cover (page 10-4).
STARTER REDUCTION GEAR
Remove the collar, starter reduction gear shaft and
reduction gear. COLLAR
SHAFT
Hold the flywheel with the special tool and loosen the
FLYWHEEL HOLDER
flywheel nut.
TOOL:
Flywheel holder 07725-0040001
FLYWHEEL NUT
Remove the flywheel nut and washer.

WASHER
FLYWHEEL NUT
10-6
Remove the flywheel using the special tool.
FLYWHEEL
TOOL:
Flywheel puller 07933-KM10000
FLYWHEEL PULLER
Be careful not to Remove the woodruff key and needle bearing.

NEEDLE BEARING
damage the
crankshaft.
WOODRUFF KEY
STARTER CLUTCH DISASSEMBLY

Check that the starter driven gear turns
STARTER DRIVEN GEAR
counterclockwise smoothly and does not turn
clockwise.
Remove the starter driven gear from the flywheel while
Hold the flywheel using the special tool and remove the
starter clutch bolts. BOLTS
TOOL:
Remove the starter clutch assembly from the flywheel.
FLYWHEEL
HOLDER
10-7
INSPECTION
Check the starter reduction gear, shaft and collar for
REDUCTION GEAR
wear or damage.
COLLAR
SHAFT
Remove the starter sprag clutch from the clutch outer.

Check the starter sprag clutch for abnormal wear or SPRAG CLUTCH
damage.
Check the sprag clutch sliding surface of the clutch
outer for abnormal wear or damage.
CLUTCH OUTER
Check the starter driven gear for abnormal wear or

damage.
Measure the starter driven gear boss O.D.
10-8
ASSEMBLY
BOLTS
16 N·m (1.6 kgf·m, 12 lbf·ft)
DRIVEN GEAR
CLUTCH OUTER
SPRAG CLUTCH
FLYWHEEL
Apply engine oil to the starer sprag clutch.

SPRAG CLUTCH
Install the sprag clutch into the clutch outer with its
flange side facing the flywheel.
CLUTCH OUTER
Install the starter clutch assembly onto the flywheel.

FLYWHEEL
STARTER CLUTCH
ASSEMBLY
10-9
Apply locking agent to the starter clutch bolt threads.
Align the bolt holes in the flywheel and starter clutch, BOLTS
and install the bolts.
Hold the flywheel with the special tool and tighten the
bolts.
TOOL:
FLYWHEEL
HOLDER
Apply molybdenum oil solution to the starter driven gear

STARTER DRIVEN GEAR
inner surface.
Apply engine oil to the starter driven gear sliding
surface.
Install the starter driven gear into the flywheel while
Make sure that the starter driven gear turns
counterclockwise smoothly and does not turn
clockwise.
INSTALLATION
Apply engine oil to the needle bearing and install it onto
the crankshaft.
NEEDLE BEARING
Install the woodruff key into the crankshaft key groove.
Clean any oil from the tapered portions of the
crankshaft and flywheel.
WOODRUFF KEY
Install the flywheel by aligning the key way with the key Align
on the crankshaft.
FLYWHEEL
10-10
Apply engine oil to the flywheel nut threads and seating
surface.
Install the washer and flywheel nut. WASHER
FLYWHEEL NUT
Hold the flywheel with the special tool and tighten the
flywheel nut. FLYWHEEL HOLDER
TOOL:
FLYWHEEL NUT
Apply engine oil to the starter reduction gear shaft.

STARTER REDUCTION GEAR
Install the starter reduction gear, shaft and collar.
Install the left crankcase cover (page 10-11).
COLLAR
SHAFT
LEFT CRANKCASE COVER

INSTALLATION
Be careful not to Clean any gasket material from the mating surfaces of
damage the mating the left crankcase and cover. GASKET
surfaces.
DOWEL PINS
10-11
Install the left crankcase cover and bolts, and tighten
LEFT CRANKCASE COVER
the bolts in a crisscross pattern in several steps.
BOLTS
Route the wire Route the gear position switch wire onto the left
properly (page 1- crankcase cover.
16).
Route the wire Route the wires into the clamp and connect the
properly (page 1- alternator 3P connector and ignition pulse generator 2P IGNITION PULSE ALTERNATOR
16). connector. GENERATOR 2P 3P CONNECTOR
CONNECTOR
Install the drive sprocket cover (page 2-8).
(page 3-11).
CLAMP
10-12
11. CRANKCASE/CRANKSHAFT/TRANSMISSION
SYSTEM COMPONENTS····························· 11-2 TRANSMISSION ···········································11-8
SERVICE INFORMATION ···························· 11-3 CRANKSHAFT ············································11-14
TROUBLESHOOTING·································· 11-5 CRANKCASE BEARING ····························11-15
CRANKCASE SEPARATION······················· 11-6 CRANKCASE ASSEMBLY ·························11-17 11
11-1
SYSTEM COMPONENTS
10 N·m (1.0 kgf·m, 7 lbf·ft)
11-2
SERVICE INFORMATION
GENERAL
• The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine must be
removed from the frame (page 6-4).
• Be careful not to damage the crankcase mating surfaces when servicing.
• Engine lubricating oil is fed through the oil passages in the crankcase. Clean the oil passages before assembling the crankcase
halves.
SPECIFICATIONS
Unit: mm (in)
Crankshaft Connecting rod big end radial clear-
0 – 0.008 (0 – 0.0003) 0.05 (0.002)
ance
Connecting rod big end side clear-
0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032)
ance
Runout 0.03 (0.001) 0.08 (0.003)
Transmission Gear I.D. M4 20.000 – 20.018 (0.7874 – 0.7881) 20.05 (0.789)
M5 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)
C2, C3 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
Bushing O.D. C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)
C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)
Gear-to-bushing C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance C2 0.015 – 0.057 (0.0006 – 0.0022) 0.10 (0.004)
C3 0.015 – 0.057 (0.0006 – 0.0022) 0.10 (0.004)
Bushing I.D. C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
Mainshaft O.D. at M4 19.968 – 19.980 (0.7861 – 0.7866) 19.93 (0.785)
at M5 16.968 – 16.980 (0.6680 – 0.6685) 16.93 (0.667)
Countershaft O.D. at C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667)
at C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785)
at C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785)
Bushing-to-shaft C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Shift fork, shift Shift fork shaft O.D. 9.986 – 9.995 (0.3931 – 0.3935) 9.93 (0.391)
fork shaft Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)
TORQUE VALUES
Mainshaft bearing setting plate bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent to the threads.
Push plug bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply locking agent to the threads.
Gearshift spindle return spring pin 22 N·m (2.2 kgf·m, 16 lbf·ft) Apply locking agent to the threads.
11-3
TOOLS
Sliding hammer weight Bearing driver attachment, 32×35 Bearing driver attachment, 37×40
07741-0010201 07746-0010100 07746-0010200
Bearing driver attachment, 42×47 Bearing driver attachment, 52×55 Pilot, 12

07746-0010300 07746-0010400 07746-0040200
Pilot, 17 Pilot, 20 Pilot, 30

07746-0040400 07746-0040500 07746-0040700
Driver handle, 15×135L Bearing remover head, 12 Bearing remover shaft, 12

07749-0010000 07936-1660110 07936-1660120
11-4
TROUBLESHOOTING
Excessive noise
• Worn, sized or chipped transmission gear
• Worn or damaged transmission bearing
• Worn or damaged connecting rod bearing
• Worn connecting rod small end
• Worn crankshaft bearing
Hard to shift
• Bent shift fork
• Damaged shift drum guide groove
• Damaged shift fork guide pin
Transmission jumps out of gear
• Worn gear dogs or dog holes
• Worn shift drum guide groove
• Worn shift fork guide pin
• Worn gear shifter groove
• Worn shift fork shaft
11-5
CRANKCASE SEPARATION
GUIDE PLATE
– cylinder and piston (page 8-4)
– oil pump (page 4-4)
– kickstarter (page 9-21)
– primary drive gear (page 9-18)
– gearshift linkage (page 9-15)
– flywheel (page 10-6)
– starter motor (page 17-6)
– gear position switch (page 18-14)
– two bolts and cam chain guide setting plate
– cam chain guide CHAIN BOLTS
– cam chain
– bolt and push plug plate SPRING
BOLT
– spring and push plug
PUSH PLUG PLATE PUSH PLUG
– three bolts and crankshaft bearing setting plates SETTING PLATES BOLTS
– right crankcase bolt

BOLT
11-6
Loosen the thirteen left crankcase bolts in a crisscross BOLTS
pattern in 2 or 3 steps, and remove them.
Place the crankcase assembly with the right side down.

LEFT CRANKCASE
Do not ply the Carefully separate the left crankcase from the right
crankcase halves. crankcase while tapping them at several locations with
a soft hammer.
RIGHT CRANKCASE
Remove the dowel pins. DOWEL PINS
Remove the countershaft oil seal from the left

COUNTERSHAFT
crankcase.
OIL SEAL
11-7
TRANSMISSION
DISASSEMBLY
Separate the crankcase halves (page 11-6). SHIFT FORK SHAFTS SHIFT DRUM
Remove the shift fork shafts.
Remove the shift forks and shift drum.
SHIFT FORKS
Remove the mainshaft and countershaft as an COUNTERSHAFT
MAINSHAFT
assembly.
Disassemble the mainshaft and countershaft.

COUNTERSHAFT
Keep track of the disassembled parts (gears, bushings,
washers, and snap rings) by stacking them on a tool or
slipping them onto a piece of wire.
Clean disassembled parts in solvent thoroughly.
MAINSHAFT
INSPECTION
GEAR/BUSHING/SHAFT
Check the shifter groove for abnormal wear or damage.
SHIFTER GROOVE DOG SLOT
Check the gear dogs, dog slots and teeth for abnormal
wear or damage.
GEAR DOG
11-8
Measure the I.D. of each gear.
SERVICE LIMITS: M4: 20.05 mm (0.789 in)
M5: 17.04 mm (0.671 in)
C1: 20.55 mm (0.809 in)
C2, C3: 23.07 mm (0.908 in)
Measure the O.D. of each bushing.
SERVICE LIMITS: C1: 20.41 mm (0.804 in)

C2, C3: 22.95 mm (0.904 in)
Calculate the gear-to-bushing clearance.
SERVICE LIMITS: C1, C2, C3: 0.10 mm (0.004 in)
Measure the I.D. of each bushing.
SERVICE LIMITS: C1: 17.04 mm (0.671 in)
C2, C3: 20.07 mm (0.790 in)
Check the spline grooves and sliding surfaces for

abnormal wear or damage.
Measure the mainshaft and countershaft O.D. M5 M4
SERVICE LIMITS: M4: 19.93 mm (0.785 in)
M5: 16.93 mm (0.667 in)
C1: 16.93 mm (0.667 in)
C2: 19.94 mm (0.785 in)
C3: 19.94 mm (0.785 in)
Calculate the bushing-to-shaft clearance.
SERVICE LIMIT: C1, C2, C3: 0.10 mm (0.004 in)
C2 C3 C1
SHIFT DRUM/SHIFT FORK/SHAFT

Inspect the shift drum journals for scoring, scratches, or JOURNALS
evidence of insufficient lubrication.
Check the shift drum guide grooves for abnormal wear
or damage.
GUIDE GROOVES
11-9
Check the shift forks for deformation or abnormal wear.
Measure each shift fork claw thickness.
Measure I.D. of each fork.
Check the shift fork shafts for damage and straightness.

Measure the shift fork shaft O.D.
ASSEMBLY
Apply molybdenum oil solution to the gear and bushing
sliding surfaces.
CORRECT INCORRECT
Assemble all parts into their original positions.
• Check the gears for freedom of movement or
rotation on the shaft.
• Do not reuse worn snap ring which could easily spin
in the groove.
• Always install the thrust washers and snap ring with
the chamfered (rolled) edge facing away from the
thrust load.
• Install the snap ring so its ends aligns with the
grooves in the splines.
• Make sure the snap ring is fully seated in the shaft SNAP RING
groove after installing it.
11-10
MAINSHAFT
: Gear and bushing sliding surfaces SNAP RING

SPLINE WASHER
M4 GEAR (26T)
M1 GEAR (13T)
THRUST WASHER
MAINSHAFT
M3 GEAR (23T)
M2 GEAR (19T)
THRUST WASHER M5 GEAR (28T)
SPLINE WASHER SNAP RING

THRUST WASHER
THRUST WASHER
M3 GEAR (23T) M2 GEAR (19T)

M4 GEAR (26T) M5 GEAR (28T)
11-11
COUNTERSHAFT
C3 GEAR (30T) THRUST WASHER

: Gear and bushing sliding surfaces
C3 BUSHING
C4 GEAR (28T)
SPLINE WASHER
SNAP RING
C1 GEAR (40T)
THRUST WASHER
C1 BUSHING
THRUST WASHER
THRUST WASHER
C2 BUSHING
C2 GEAR (34T)
THRUST WASHER
COUNTERSHAFT C5 GEAR (26T)
THRUST WASHERS
SPLINE WASHER
THRUST WASHERS THRUST WASHER
SNAP RING
C3 BUSHING
C2 BUSHING
C1 BUSHING
C4 GEAR (28T) C5 GEAR (26T)
C1 GEAR (40T) C3 GEAR (30T) C2 GEAR (34T)
11-12
Apply molybdenum oil solution to the gear shifter
grooves.
Apply clean engine oil to the gear teeth and engage the
mainshaft and countershaft gears.
Install the mainshaft and countershaft assemblies as a

MAINSHAFT COUNTERSHAFT
set into the left crankcase.
Each shift fork has an identification marks; “R/L” for "C" MARK
right and left shift forks, and “C” for center shift fork.
"R/L" MARKS
Install the shift forks into the shifter gear grooves with
the marks facing up (left crankcase side). SHIFT DRUM
Apply engine oil to the shift drum journals and guide
grooves in the and install the shift drum.
Install the shift fork guide pins into the shift drum guide
grooves.
SHIFT FORKS
11-13
Apply engine oil to the shift fork shafts and insert them
through the shift forks into the right crankcase. SHIFT FORK SHAFTS
Assemble the crankcase (page 11-17).
CRANKSHAFT
REMOVAL
Remove the crankshaft from the right crankcase.
CRANKSHAFT
INSPECTION
Set the crankshaft in a stand or V-blocks and measure
the runout using a dial indicator.
47.5 mm (1.87 in) 43.0 mm (1.69 in)
Measure the side clearance between the connecting

rod big end and crank weight with a feeler gauge.
11-14
Measure the radial clearance at the connecting rod big
end in an X and Y directions.
Turn the outer race of the crankshaft bearing with your

BEARING
finger. The bearing should turn smoothly and quietly.
Also check that bearing inner races fit tightly in the
crankshaft.
Replace crankshaft if the outer race does not turn
smoothly, quietly or if the inner race fits loosely in the
crankshaft.
INSTALLATION
Apply 1 - 2 cc of molybdenum oil solution to the
connecting rod big end bearing.
Install the crankshaft into the right crankcase.
CRANKSHAFT
CRANKCASE BEARING
INSPECTION
– transmission (page 11-8)
– crankshaft (page 11-14)
Turn the inner race of each crankcase bearing with your
finger. The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
crankcase.
Replace any bearing if the inner race does not turn
smoothly, quietly or if the outer race fits loosely in the
crankcase.
11-15
RIGHT CRANKCASE BEARING
REPLACEMENT
CRANKSHAFT BEARING
Remove the crankcase bearing inner race. CRANKSHAFT BEARING
Press the crankshaft bearing out of the crankcase.
INNER RACE
Lubricate a new bearing with molybdenum oil solution.
ATTACHMENT DRIVER
Press a new crankcase bearing into the crankcase
using the special tools.
TOOLS:
Driver 07749-0010000 BEARING
Attachment, 52 x 55 mm 07746-0010400
Pilot, 30 07746-0040700
Install a new crankcase bearing inner race.
PILOT
TRANSMISSION BEARING
Remove the bolts and mainshaft bearing setting plates MAINSHAFT BEARING
BOLTS/ PLATES
from the crankcase.
Drive the mainshaft and countershaft bearings out of
the crankcase.
COUNTERSHAFT BEARING
Apply engine oil to new bearings.

DRIVER
Drive the bearings in the crankcase with the marked
side facing up, using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm07746-0010200
(mainshaft side) BEARING
Attachment, 42 x 47 mm07746-0010300
(countershaft side)
Pilot, 17 mm 07746-0040400
PILOT ATTACHMENT
11-16
Apply locking agent to the setting plate bolt threads.
Install the mainshaft bearing setting plates and bolts, BOLTS
and tighten the bolts.
PLATES
LEFT CRANKCASE BEARING

REPLACEMENT
Drive the countershaft bearing out of the crankcase.
MAINSHAFT BEARING BEARING REMOVER
Remove the mainshaft bearing from the crankcase
using the special tools.
TOOLS:
Remover head, 12 mm 07936-1660110
Remover shaft, 12 mm 07936-1660120
Remover weight 07741-0010201
COUNTERSHAFT BEARING
Apply engine oil to new bearings.

DRIVER
Drive the bearings in the crankcase with the marked
side facing up, using the special tools.
TOOLS:
Mainshaft bearing: BEARING
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
Countershaft bearing:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
ATTACHMENT PILOT
CRANKCASE ASSEMBLY
Apply grease to new countershaft oil seal lips and install
COUNTERSHAFT
them into the left crankcase.
OIL SEAL
GEARSHIFT
SPINDLE OIL SEAL
11-17
Clean the left and right crankcase mating surfaces
thoroughly, being careful not to damage them.
Apply liquid sealant to the mating surface (shadowed
area) of the left crankcase except the oil passage area
as shown.
Install the two dowel pins. DOWEL PINS
Install the left crankcase over the right crankcase.

LEFT CRANKCASE
RIGHT CRANKCASE
Install the thirteen left crankcase bolts, and tighten them BOLTS
in a crisscross pattern in 2 or 3 steps.
11-18
Install the right crankcase bolt and tighten it.
BOLT
When installing the Install the bearing retainer plates and bolts. PLATES PLATE BOLT
retainer plate, pull
Tighten the bolts securely.
the crankshaft and Hook
hook the plate tab
to the crankshaft
bearing groove as
shown.
BOLTS CRANKSHAFT
Apply molybdenum oil solution to the push plug entire

SPRING
surface. PUSH PLUG
Install the push plug and spring by aligning the tapered
surfaces of the plug and crankshaft bearing outer race.
OUTER
RACE
Apply locking agent to the push plug bolt threads.
Install the push plug plate and bolt, and tighten the bolt. BOLT
PLATE
11-19
Install the cam chain and cam chain guide.
GUIDE PLATE
Install the setting plate with the two bolts and tighten the
bolts.
– gear position switch (page 18-14)
– starter motor (page 17-11)
– flywheel (page 10-10)
– gearshift linkage (page 9-16)
– primary drive gear (page 9-18)
– kickstarter (page 9-21)
– oil pump (page 4-6)
– cylinder and piston (page 8-8)
– cylinder head (page 7-25) BOLTS
CHAIN
11-20
12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING
SYSTEM COMPONENTS····························· 12-2 FRONT WHEEL (DRUM BRAKE TYPE) ····12-18
SERVICE INFORMATION ···························· 12-4 FRONT DRUM BRAKE (Type 1, 3, 4, 6) ····12-22
TROUBLESHOOTING·································· 12-6 FORK···························································12-26
HANDLEBAR ··············································· 12-7 STEERING STEM········································12-33
FRONT WHEEL (DISC BRAKE TYPE)······ 12-13 12
12-1
SYSTEM COMPONENTS
DRUM BRAKE TYPE
12 N·m (1.2 kgf·m, 9 lbf·ft)
23 N·m (2.3 kgf·m, 17 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
52 N·m (5.3 kgf·m, 38 lbf·ft)
12-2
DISC BRAKE TYPE
12 N·m (1.2 kgf·m, 9 lbf·ft)
23 N·m (2.3 kgf·m, 17 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
30 N·m (3.1 kgf·m, 22 lbf·ft)
52 N·m (5.3 kgf·m, 38 lbf·ft)
12-3
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• Raise the front wheel off the ground by supporting the frame securely when servicing the front wheel, suspension and steering
stem. A hoist or equivalent is required to support the motorcycle.
• Disc brake type: A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a
contaminated disc with a high quality brake degreasing agent.
Drum brake type: A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a
contaminated drum with a high quality brake degreasing agent.
• After the front wheel installation, check the brake operation by applying the brake lever.
• For hydraulic brake system (Type 2, 5), see Hydraulic Disc Brake section (page 14-2).
SPECIFICATIONS
Unit: mm (in)
Cold tire Driver only 200 kPa (2.00 kgf/cm2, 29 psi) –
pressure Driver and passenger 200 kPa (2.00 kgf/cm2, 29 psi) –
Front brake Lever freeplay 10 – 20 (0.4 – 0.8) –
(Type 1, 3, 4, 6) Drum I.D. 130.0 – 130.3 (5.12 – 5.13) 131 (5.2)
Fork Spring free length 485 (19.1) 453 (17.8)
Tube runout – 0.20 (0.008)
Recommended fork fluid Fork fluid –
Fluid level 147 (5.8) –
Fluid capacity 159 ± 2.5 cm3 (5.4 ± 0.08 US oz, 5.6 ±
–
0.09 lmp oz)
TORQUE VALUES
Front axle nut 52 N·m (5.3 kgf·m, 38 lbf·ft) U-nut
Front brake disc bolt (Type 2,5) 42 N·m (4.3 kgf·m, 31 lbf·ft) ALOC bolt: replace with a new one.
Front spoke (Type 3, 6) 3.7 N·m (0.38 kgf·m, 2.7 lbf·ft)
Front brake arm nut (Type 1, 3, 4, 6) 10 N·m (1.0 kgf·m, 7 lbf·ft)
Handlebar holder bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Clutch lever pivot bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Clutch lever pivot nut 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)
Rearview mirror lock nut 34 N·m (3.5 kgf·m, 25 lbf·ft)
Fork socket bolt 20 N·m (2.0 kgf·m, 15 lbf·ft) Apply locking agent to the threads.
Fork cap 22 N·m (2.2 kgf·m, 16 lbf·ft)
Bottom bridge pinch bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Top bridge pinch bolt 23 N·m (2.3 kgf·m, 17 lbf·ft)
Brake caliper mounting bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt: replace with a new one.
Steering bearing adjustment nut – For tightening sequence; See page 12-37
Steering stem nut – For tightening sequence; See page 12-37
12-4
TOOLS
Spoke wrench, 5.8×6.1 Bearing driver attachment, 37×40 Bearing driver attachment, 42×47
07701-0020300 07746-0010200 07746-0010300
Pilot, 12 Bearing remover shaft, 9×200L Remover head, 12

07746-0040200 07746-0050100 07746-0050300
Oil seal remover Driver handle, 15×135L Lock nut wrench, 5.7×50
07748-0010001 07749-0010000 07916-3710101
Ball race remover, 29×240L Inner driver, 24×30×275L

07944-1150001 07946-GC40000
12-5
TROUBLESHOOTING
Hard steering
• Steering bearing adjustment nut too tight
• Worn or damaged steering head bearings
• Worn or damaged steering head bearing races
• Damaged steering stem
• Insufficient tire pressure
• Faulty front tire
Steers to one side or does not track straight
• Bent fork leg
• Damaged or loose steering head bearings
• Worn wheel bearings
• Bent front axle
• Wheel installed incorrectly
• Bent frame
• Worn swingarm pivot components (page 13-20)
Front wheel wobbles
• Bent rim
• Worn or damaged wheel bearings
• Faulty front tire
• Loose or broken spokes (spoke wheel type)
• Loose axle fasteners
Wheel turns hard
• Faulty wheel bearings
• Bent front axle
• Brake drag (page 14-4)
Soft suspension
• Weak fork springs
• Low fluid level in fork
• Wrong type of fluid in fork
• Low tire pressure
Stiff suspension
• Bent fork tubes
• Fork slider binds
• High fluid level in fork
• Incorrect fluid weight (high viscosity)
• Clogged fork fluid passage
• High tire pressure
Front suspension noise
• Loose fork fasteners
• Worn fork tube or guide bushing
• Low fluid level in fork
12-6
HANDLEBAR
REMOVAL
The right rearview Remove the following:
mirror lock nut has – four wire bands
left-hand threads. – rearview mirrors MIRRORS
BANDS
– screw and right side handlebar weight

WEIGHT
SCREW
Disc brake type – brake light switch connectors Disc brake type only: MASTER CYLINDER
only. – two bolts, holder and master cylinder (keep the
reservoir upright to prevent air from entering the HOLDER
hydraulic system)
CONNECTORS BOLTS
– two screws (and separate the right handlebar

SWITCH
switch)
SCREWS
12-7
– throttle cable (disconnect from the throttle grip)
– right handlebar switch SWITCH
– throttle grip
GRIP
THROTTLE
CABLE
Drum brake type – brake lever bracket bolt (only loosen)

only. Drum brake type only:
BOLT
– screw and left side handlebar weight

– handlebar grip GRIP
WEIGHT
SCREW
– clutch switch connectors

– two screws (and separate the left handlebar switch) SWITCH
CONNECTORS
SCREWS
12-8
– choke cable (disconnect from the choke lever)
– left handlebar switch SWITCH LEVER
– choke lever
CABLE
– clutch cable (by sliding the dust cover off and

loosening the lock nut and adjuster) LEVER BRACKET
– clutch lever bracket bolt (only loosen) LOCK NUT
– clutch lever bracket BOLT
ADJUSTER
CLUTCH CABLE DUST COVER
– two screws and handlebar cover

COVER
SCREWS
– four bolts, handlebar cover stay and handlebar

STAY HANDLEBAR
holders
– handlebar
Drum brake type Remove the front brake lever bracket from the
only. handlebar.
BOLTS
HOLDERS
12-9
INSTALLATION
• Route the cables, hose and wires properly (page 1-

16).
Drum brake type Set the front brake lever bracket to the handlebar.
STAY HANDLEBAR PUNCH
only.
MARKS
Align the punch Install the handlebar, handlebar cover stay and holders
mark on the with the punch marks facing forward.
handlebar with the Tighten the front bolts first, then tighten the rear bolts.
with the top edge of
the lower holder.
Align
HOLDERS
Install the handlebar cover and tighten the two screws.

COVER
SCREWS
Set the clutch lever bracket to the handlebar.

LEVER BRACKET
Align the slit of clutch lever bracket with the punch mark
on the handlebar, and tighten the bracket bolt.
BOLT
Apply grease to the cable end and cable rolling area.
Connect the clutch cable and adjust it (page 3-22). Align
CLUTCH CABLE
Install the choke lever onto the handlebar.

Apply grease to the cable end and cable rolling area. SWITCH LEVER
Connect the throttle cable to the throttle grip pipe.
Connect the choke cable to the choke lever.
Align the locating Install the left handlebar switch by setting the switch
pin with the hole in housing ends into the choke lever groove.
the handlebar.
Align
CABLE
12-10
Install the screws and tighten the front screw first, then
tighten the rear screw. SWITCH
Connect the clutch switch connectors.
CONNECTORS
SCREWS
Clean the inside surface of the left handlebar grip and

the outside surface of the handlebar. HANDLEBAR GRIP
Apply Honda Bond A or equivalent to the inside surface
of the handlebar grip and to the outside surface of the
handlebar.
Allow the adhesive Wait 3 – 5 minutes and install the grip. Rotate the grip
to dry for an hour for even application of the adhesive.
before using.
LEFT HANDLEBAR
Install the left handlebar weight and tighten the screw.
WEIGHT
SCREW
Drum brake type Align the slit of brake lever bracket with the punch mark
only. on the handlebar, and tighten the bracket bolt. Drum brake type only: LEVER
BRACKET
Align
BOLT
12-11
Install the throttle grip onto the handlebar.
Apply grease to the cable end and cable rolling area. SWITCH
Connect the throttle cable to the throttle grip pipe.
Install the right handlebar switch by aligning the locating
pin with the hole on the handlebar.
Align
GRIP
THROTTLE
CABLE
Install the screws and tighten the front screw first, then
SWITCH
tighten the rear screw.
SCREWS
Disc brake type Install the brake master cylinder and holder with the Disc Brake type
type:only: MASTER CYLINDER
only. "UP" mark facing up.
Align the edge of the master cylinder with the punch HOLDER
mark on the handlebar and tighten the upper bolt first, "UP"
then tighten the lower bolt.
Connect the brake light switch connectors.
Align
CONNECTORS BOLTS
Install right handlebar weight and tighten the screw.

WEIGHT
SCREW
12-12
The right rearview Install each rearview mirror and tighten the lock nut to
mirror has left-hand the specified torque. MIRRORS
threads.
Secure the wires with the wire bands.
– throttle operation (page 3-6)
– choke operation (page 3-6)
BANDS
FRONT WHEEL (DISC BRAKE TYPE)

REMOVAL
Remove the screw and disconnect the speedometer
cable/O-ring.
Remove the nut cap and loosen the axle nut.
NUT
Raise the front wheel off the ground and support the
motorcycle securely.
Remove the axle nut.
Do not operate the Pull the axle out and remove the front wheel.
brake lever after
removing the wheel.
To do so will cause
difficulty in fitting the
brake disc between
the brake pads. CAP SCREW
CABLE/O-RING
Remove the side collar and side collar cover.
SIDE COLLAR COVER
SIDE COLLAR
INSPECTION
AXLE
Set the axle in V-blocks. Turn the axle and measure the
runout using a dial indicator.
Actual runout is 1/2 of the total indicator reading.
12-13
WHEEL RIM
Check the rim runout by placing the wheel in a turning
stand.
Spin the wheel slowly and read the runout using a dial
indicator.
SERVICE LIMITS:
Axial: 1.0 mm (0.04 in)
Radial: 1.0 mm (0.04 in)
WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
hub.
Replace the Remove and discard the bearings if they do not turn
bearings in pairs. smoothly, quietly, or if they fit loosely in the hub.
DISASSEMBLY
SPEEDOMETER
– speedometer gearbox GEAR
– dust seal
– speedometer gear retainer
RETAINER
DUST SEAL
12-14
– four bolts and brake disc
BRAKE DISC
– dust seal BOLTS
DUST SEAL
Install the remover head into the bearing.

From the opposite side of the wheel, install the remover REMOVER SHAFT
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 12 mm 07746-0050300
Bearing remover shaft 07746-0050100
REMOVER HEAD
ASSEMBLY
DISC BOLTS
42 N·m (4.3 kgf·m, 31 lbf·ft) DUST SEAL
BEARING
(6301U)
BEARING (6301U)
BRAKE DISC
DUST SEAL
DISTANCE
COLLAR SPEEDOMETER GEAR RETAINER
12-15
Pack new bearing cavities with grease.
Drive in a new right side (brake disc side) bearing
squarely with the sealed side facing up until it is fully
DRIVER
seated.
Install the distance collar.
Drive in a new left side (gear box side) bearing squarely
with the sealed side facing up.
TOOLS: ATTACHMENT
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
PILOT
BEARING
Do not get grease Install the brake disc with the stamp facing out.
BRAKE DISC
on the brake disc or Install new disc bolts and tighten them in a crisscross BOLTS
stopping power will pattern in several steps.
be reduced.
Apply grease to the lips of a new dust seal.
Install the dust seal as specified.
7.0 - 8.0 mm
(0.28 - 0.31 in)
DUST SEAL
Install the gear retainer, aligning the locating tabs with

the grooves in the hub.
RETAINER
Apply grease to the lips of a new dust seal. DUST SEAL
Install the dust seal so that it is flush with the wheel hub.
Align
Apply 3 g of grease to the speedometer gear teeth and

0.2 - 0.3 g to inner surface, and install the washers and SPEEDOMETER
gear. GEAR
Install the gear box so the tabs on the retainer and slots
on the gear are aligned.
TABS
12-16
INSTALLATION
Install the side collar cover and side collar.
SIDE COLLAR COVER
SIDE COLLAR
Be careful not to Place the wheel between the fork legs while inserting
damage the brake the brake disc between the pads in the caliper so the
pads. groove in the gear box is aligned with the stopper.
Insert the axle from the right side and temporary tighten
the axle nut.
Align
AXLE
Coat a new O-ring with grease and install it into the

cable groove. O-RING
Connect the speedometer cable by aligning the groove
with the blade.
Align
Install the speedometer cable setting screw and tighten

it.
Tighten the axle nut.
NUT
Install the nut cap securely.
With the front brake applied, pump the suspension up
and down several times and check brake operation.
CAP SCREW
CABLE
12-17
FRONT WHEEL (DRUM BRAKE TYPE)
REMOVAL
Remove the screw and disconnect the speedometer
cable. SCREW SPEEDOMETER CABLE
Disconnect the brake cable by removing the adjusting
nut, and remove the brake cable and joint pin.
Remove the nut cap and loosen the axle nut.
Raise the front wheel off the ground and support the
motorcycle securely.
Remove the axle nut. CAP
Pull the axle out and remove the front wheel.
Remove the brake panel.
ADJUSTING
NUT
AXLE BRAKE
JOINT PIN NUT CABLE
Remove the side collar and side collar cover.
COLLAR COLLAR COVER
INSPECTION
AXLE
12-18
WHEEL RIM
Check the rim runout by placing the wheel in a turning
stand.
Spin the wheel slowly and read the runout using a dial
indicator.
SERVICE LIMITS:
Axial: 1.0 mm (0.04 in)
Radial: 1.0 mm (0.04 in)
WHEEL BEARING
The bearings should turn smoothly and quietly.
hub.
bearings in pairs. smoothly, quietly, or if they fit loosely in the hub.
DISASSEMBLY
• For brake panel service, refer to front drum brake

(page 12-22). DUST SEAL
Remove the dust seal.
Install the remover head into the bearing.

From the opposite side of the wheel, install the remover REMOVER SHAFT
shaft and drive the bearing out of the wheel hub.
bearing.
TOOLS:
REMOVER HEAD
12-19
ASSEMBLY
BEARING (6301U) DISTANCE

COLLAR
BEARING (6301U)
DUST SEAL
WHEEL CENTER ADJUSTMENT (type 3, 6)

Adjust the hub position so that the distance from the left
end surface of the hub center to the side of rim is 6.5 ±
1 mm (0.3 ± 0.04 in) as shown.
Tighten the spokes in 2 or 3 progressive steps.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300

Check the rim runout (page 12-19).
6.5 ± 1 mm (0.3 ± 0.04 in)
BASE
POINT
WHEEL ASSEMBLY
Drive in a new left side (brake drum side) bearing
seated. DRIVER
Drive in a new right side bearing squarely with the
sealed side facing up.
TOOLS: ATTACHMENT
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
PILOT
BEARING
12-20
Install the dust seal as specified. 7.0 - 8.0 mm
(0.28 - 0.31 in)
DUST SEAL
INSTALLATION
Do not get grease Install the brake panel by aligning the speedometer BRAKE PANEL
on the brake drum gear tabs with the grooves in the hub.
and shoe linings or
stopping power will
be reduced.
Align
Install the side collar and side collar cover.
COLLAR COLLAR COVER
Install the wheel between the fork legs and align the
groove of the brake panel with the boss on the left fork BRAKE PANEL
leg.
Insert the front axle through the fork and wheel from the AXLE NUT
right side.
Install the axle nut and tighten it.
Align
12-21
Apply grease to a speedometer cable seal lips.
Connect the speedometer cable by tightening the
SCREW SPEEDOMETER CABLE
screw.
Install the brake cable into the brake panel and connect
it with the joint pin and adjusting nut.
Install the nut cap securely.
Adjust the brake lever freeplay and check the brake
operation (page 3-19).
CAP
ADJUSTING
NUT
BRAKE
JOINT PIN CABLE
FRONT DRUM BRAKE (Type 1, 3, 4, 6)

REMOVAL
Remove the wheel and the brake panel (page 12-18).
INSPECTION
Measure the front brake drum I.D.
DISASSEMBLY
Always replace the Expand the brake shoes and remove them from the
brake shoes in brake panel. SHOES
pairs.
Remove the shoe springs from the brake shoes. SPRINGS
12-22
– dust seal GEAR AND WASHER
– speedometer gear
– washer
DUST SEAL
– nut and bolt

– brake arm
NUT
BRAKE ARM
BOLT
– wear indicator
– return spring BRAKE CAM
– brake cam INDICATOR
– felt seal
FELT SEAL
SPRING
12-23
ASSEMBLY
*1: 3 g to gear teeth/0.2 - 0.3 g to inner surface
BRAKE SHOES *2: Gear oil
DUST SEAL
SPEEDOMETER GEAR *1
WASHER
SHOE SPRINGS
WEAR INDICATOR
BRAKE ARM
BRAKE CAM
*2 FELT SEAL
RETURN
SPRING
BRAKE ARM NUT
BOLT
10 N·m (1.0 kgf·m, 7 lbf·ft)
Apply grease to the brake cam sliding surface and

install it into the brake panel.
Apply gear oil to the felt seal and install it onto the brake
SPRING
panel.
INDICATOR
Install the return spring by inserting the spring end into
the hole in the brake panel.
Install the wear indicator by aligning the wide tooth with
the wide groove in the brake cam.
Align
FELT SEAL
HOLE
12-24
Install the brake arm by aligning the punch marks.
Install the bolt from the opposite side of the punch mark SPRING
and tighten the nut. Align
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) NUT
Hook the return spring onto the brake arm.
BRAKE ARM
BOLT
Apply 3 g of grease to the speedometer gear teeth and GEAR
0.2 - 0.3 g to inner surface. Install the washer and gear.
WASHER
Apply grease to the lips of a new dust seal. Install the

dust seal so that it is flush with the brake panel.
Apply 0.2 - 0.3 g of grease to the anchor pin and brake
cam sliding surfaces.
DUST SEAL
Assemble the brake shoes and springs in the direction

SHOES Up
as shown.
Install the shoe assembly onto the brake panel so the
spring ends are facing up (wheel side).
Wipe any excess grease from the brake cam and
anchor pin.
Install the front wheel (page 12-21).
SPRINGS
12-25
FORK
REMOVAL
– front wheel Disc brake type only:
(disc brake type; page 12-13)
(drum brake type; page 12-18)
– front fender (page 2-5)
Disc brake type Remove the two bolts and brake caliper from the right BOLTS
only: fork leg.
Support the caliper
so it does not hang
from the brake
hose. Do not twist
the brake hose.
CALIPER
When the fork is ready to be disassembled, loosen the

fork cap, but do not remove it. FORK CAP
Loosen the top bridge pinch bolt/nut.
PINCH
BOLT NUT
Loosen the bottom bridge pinch bolts while supporting

the fork leg.
Pull the fork leg down and remove it out of the fork FORK
bridges.
PINCH
BOLT
DISASSEMBLY
Hold the fork slider in a vise with soft jaws or shop
towels.
Loosen the socket bolt, but do not remove it yet.
SOCKET BOLT
12-26
The fork cap is Remove the following:
under spring – fork cap FORK CAP
pressure; use care – O-ring
when loosening it.
O-RING
– fork spring
Pour out the fork fluid by pumping the fork tube up and
FORK SPRING
down several times.
– socket bolt
– sealing washer SEALING WASHER
SOCKET BOLT
– fork piston
– rebound spring
REBOUND
SPRING
FORK PISTON
12-27
– fork tube
– oil lock piece
FORK TUBE
OIL LOCK PIECE
– dust seal
– stopper ring DUST SEAL STOPPER RING
– oil seal
TOOL:
Oil seal remover 07748-0010001 OIL SEAL
OIL SEAL
REMOVER
INSPECTION
FORK SPRING
Measure the fork spring free length.
12-28
FORK TUBE/SLIDER/PISTON
Check the fork tube, slider, oil lock piece and fork piston OIL LOCK PIECE
for score marks, and excessive or abnormal wear. FORK TUBE
Check the fork piston ring for wear or damage. FORK SLIDER
Check the rebound spring for fatigue or damage.
Replace any damaged component if necessary.
PISTON
RING
REBOUND SPRING FORK PISTON
Set the fork tube in V-blocks and measure the fork tube
runout with a dial indicator.
Actual runout is 1/2 the total indicator reading.
ASSEMBLY
FORK TUBE FORK CAP
DUST SEAL
22 N·m (2.2 kgf·m, 16 lbf·ft)
STOPPER RING
PISTON
RING
OIL SEAL
O-RING
FORK SLIDER
SEALING WASHER
FORK FORK SPRING
PISTON
REBOUND
SPRING
SOCKET BOLT
20 N·m (2.0 kgf·m, 15 lbf·ft) OIL LOCK PIECE
12-29
Wrap vinyl tape around the fork tube top end to avoid
DRIVER
damaging the oil seal lip.
HANDLE
Apply fork fluid to a new oil seal lip. Install the oil seal
with the marking facing up.
Drive the oil seal until the stopper ring groove is visible.
TOOLS:
Driver 07749-0010000
Attachment, 42×47 07746-0010300
OIL SEAL
ATTACHMENT
Install the stopper ring into the groove in the fork slider, DUST SEAL
being careful not to scratch the fork tube sliding surface. STOPPER
RING
Coat the lips of a new dust seal with fork fluid and install
it.
Before assembly, wash all parts with a high-flash or

FORK TUBE
non-flammable solvent and wipe them off completely.
Install the rebound spring and fork piston into the fork
tube. REBOUND
SPRING
FORK PISTON

– rebound spring (onto the fork piston)
– fork piston (into the fork tube)
– oil lock piece (onto the fork piston) REBOUND SPRING
Install the fork tube into the fork slider.
OIL LOCK PIECE
FORK PISTON
FORK TUBE
12-30
Apply locking agent to the fork socket bolt threads.
Install the socket bolt with a new sealing washer.
WASHER
SOCKET BOLT
Pour the specified amount of the fork fluid into the fork
tube.
FLUID CAPACITY:
159 ± 2.5 cm3 (5.4 ± 0.08 US oz, 5.6 ± 0.09 lmp oz)
Slowly pump the fork tube several times to remove any
trapped air from the lower portion of the fork tube. 147 mm
(5.8 in)
Compress the fork tube fully. Measure the oil level from
the top of the fork tube.
FLUID LEVEL: 147 mm (5.8 in)
Pull the fork tube up and install the fork spring with the
tightly wound coil side facing down.
Down
Tighten the fork cap Coat a new O-ring with fork fluid and install it into the FORK CAP
after installing the fork cap groove.
fork tube into the Hold the fork cap securely and install it into the fork
fork bridges. tube, being careful not to cross-thread the cap.
O-RING
12-31
Hold the fork slider in a vise with soft jaws or shop
towels.
Tighten the socket bolt to the specified torque.
SOCKET BOLT
INSTALLATION
Install the fork tube into the bottom and top bridges.
Align the top of the fork tube with the upper surface of FORK CAP
the top bridge. TOP BRIDGE
Tighten the bottom bridge pinch bolts.
Align
Tighten the top bridge pinch bolts and nuts.
Tighten the fork cap to the specified torque if it was
removed.
– front wheel PINCH FORK CAP
(disc brake type; page 12-17) BOLTS
NUT
Disc brake type Install the brake caliper with new mounting bolts and Disc brake type only:
only: tighten the bolts.
BOLTS
CALIPER
12-32
STEERING STEM
REMOVAL
– front wheel
(disc brake type; page 12-13)
– headlight case (page 2-3)
– speedometer (page 18-6)
– handlebar (page 12-7)
Disconnect the connectors from the wire harness.
CONNECTORS
Remove the two bolts and headlight stay.

BOLTS
HEADLIGHT STAY
Loosen the steering stem nut and top bridge pinch

bolts.
STEM NUT
PINCH BOLTS
Loosen the bottom bridge pinch bolts while supporting

the fork leg. STEM NUT/WASHER TOP BRIDGE
Pull the fork leg down and remove it out of the fork
bridges.
Remove the following: BACK
– bottom bridge pinch bolts and headlight cover stay PLATE
– stem nut and washer
– top bridge
– headlight back plate FORK
Remove the stem nut and washer.
Remove the top bridge and headlight back plate.
STAY PINCH BOLT
12-33
Loosen the steering bearing adjustment nut.
TOOL:
Stem socket wrench 07916-3710101
While holding the steering stem, remove the adjustment
nut. SOCKET
WRENCH
– steering stem
– upper inner race
– upper steering bearing
– lower steering bearing
ADJUSTMENT
NUT
UPPER INNER RACE
UPPER BEARING
STEM LOWER BEARING
Always replace the Remove the upper and lower outer races using the
bearings and races special tool. BALL RACE
as a set. REMOVER
TOOL:
Ball race remover 07944-1150001
BALL RACE
REMOVER
12-34
Install the stem nut onto the stem to prevent the threads DUST SEAL
from being damaged when removing the inner race. AND WASHER
Remove the lower inner race with a chisel or equivalent NUT
tool, being careful not to damage the stem.
Remove the dust seal and washer.
INNER RACE
INSTALLATION
• Route the wires, hose and cables properly (page 1-16).
ADJUSTMENT NUT
DUST SEAL UPPER INNER RACE
WASHER
UPPER OUTER
RACE UPPER STEERING
BEARING (21)
STEERING STEM
LOWER OUTER RACE
LOWER STEERING
BEARING (21)
grease with extreme pressure agent

(recommended: EXCELIGHT EP2
manufactured by KYODO YUSHI,
japan or Shell ALVANIA EP2 or LOWER INNER RACE
equivalent)
12-35
• Use multi-purpose grease with extreme pressure

agent for the steering bearings and dust seals:
– Excelite EP2 (Kyodo Yushi) or
– Alvania EP2 (Shell) or equivalent INNER DRIVER
Apply grease to the lips of a new lower dust seal.
Install the washer and lower dust seal onto the steering
stem.
Press a new lower bearing inner race using the special
tool. INNER RACE
TOOL: DUST SEAL

Inner driver 07946-GC40000
WASHER
Drive in new upper and lower bearing outer races into
the steering head pipe.
DRIVER
TOOLS:
Driver 07749-0010000
Bearing driver attachment,07746-0010200 ATTACHMENT
37×40
UPPER OUTER RACE
LOWER OUTER RACE
ATTACHMENT
DRIVER
Apply 3 g (0.1 oz) of grease to each new bearing and fill

it up. UPPER INNER RACE
Attach the lower steering bearing balls onto the stem.
Attach the upper steering balls onto the upper outer
race.
UPPER BEARING
Insert the steering stem into the steering head pipe, and (21 BALLS)
install the following while holding the stem.
– upper inner race
– adjustment nut (and temporarily tighten it)
LOWER BEARING
(21 BALLS)
STEM
12-36
1. Tighten the adjustment nut to the initial torque.
SOCKET WRENCH
TOOL:
Stem socket wrench 07916-3710101
ADJUSTMENT
NUT
2. Turn the steering stem left and right, lock-to-lock

several times to seat the bearings.
Completely loosen the adjustment nut.
ADJUSTMENT
NUT
3. Retighten the adjustment nut to the specified torque.

SOCKET WRENCH
ADJUSTMENT
NUT

STEM NUT/WASHER TOP BRIDGE
– headlight back plate
– top bridge
– stem nut and washer
– bottom bridge pinch bolts and headlight cover stay BACK
Temporarily install the fork legs into the bottom and top PLATE
bridges.
FORK
STAY PINCH BOLT
12-37
Tighten the stem nut.
STEM NUT
Move the steering stem lock-to-lock and make sure the
steering stem moves smoothly without play or binding.
Align the top of the fork tube with the upper surface of
the top bridge.
Tighten the bottom bridge pinch bolts. TOP BRIDGE
Tighten the top bridge pinch bolts and nuts. Align
PINCH
BOLTS
NUTS
Install the headlight stay by setting its boss into

grommet of bottom bridge. BOLTS
Tighten the two bolts.
HEADLIGHT STAY
12-38
Route the wire Connect the following:
harness properly
– ignition switch 2P connector
(page 1-16).
– right handlebar switch 2P connector
– left handlebar switch 3P connector
– right handlebar switch Brown wire connector
– left handlebar switch Black, Light blue and Orange
wire connectors
– lighting switch Blue/white wire connector
– front brake light switch Green/yellow wire connector
– clutch switch Green connector
– handlebar (page 12-7)
– speedometer (page 18-6)
– headlight case (page 18-17) CONNECTORS
12-39
MEMO
13. REAR WHEEL/BRAKE/SUSPENSION
SYSTEM COMPONENTS····························· 13-2 REAR DRUM BRAKE ·································13-14
SERVICE INFORMATION ···························· 13-4 BRAKE PEDAL/CENTERSTAND···············13-16
TROUBLESHOOTING·································· 13-6 SHOCK ABSORBER ··································13-19
REAR WHEEL ·············································· 13-7 SWINGARM·················································13-20
13
13-1
SYSTEM COMPONENTS
29 N·m (3.0 kgf·m, 21 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
22 N·m (2.2 kgf·m, 16 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft)
13-2
13-3
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
• A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with
a high quality brake degreasing agent.
• Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
• For drive chain information, see Maintenance section (page 3-14).
SPECIFICATIONS
Unit: mm (in)
Cold tire pres- Driver only 225 kPa (2.25 kgf/cm2, 33 psi) –
sure Driver and passenger 225 kPa (2.25 kgf/cm2, 33 psi) –
Drive chain Size/link 428H/112 –
Slack 15 – 25 (0.6 – 1.0) –
Rear brake Pedal freeplay 20 – 30 (0.8 – 1.2) –
Drum I.D. 130.0 – 130.3 (5.12 – 5.13) 131 (5.2)
TORQUE VALUES
Rear brake arm nut 10 N·m (1.0 kgf·m, 7 lbf·ft) U-nut
Driven sprocket bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Rear axle nut 59 N·m (6.0 kgf·m, 44 lbf·ft) U-nut
Shock absorber upper mounting bolt 29 N·m (3.0 kgf·m, 21 lbf·ft)
Shock absorber lower mounting bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Rear brake stopper arm nut 22 N·m (2.2 kgf·m, 16 lbf·ft)
Rear spoke (Type 3, 6) 3.7 N·m (0.38 kgf·m, 2.7 lbf·ft)
Swingarm pivot nut 59 N·m (6.0 kgf·m, 44 lbf·ft) U-nut
13-4
TOOLS
Spoke wrench, 5.8×6.1 Bearing driver attachment, 32×35 Bearing driver attachment, 37×40
07701-0020300 07746-0010100 07746-0010200
Bearing driver attachment, 42×47 Pilot, 15 Pilot, 25

07746-0010300 07746-0040300 07746-0040600
Bearing remover shaft, 9×200L Remover head, 15 Driver handle, 15×135L

07746-0050100 07746-0050400 07749-0010000
13-5
TROUBLESHOOTING
Rear wheel wobbles
• Bent rim
• Worn or damaged rear wheel bearings
• Faulty rear tire
• Worn or damaged swingarm bushings
• Bent frame or swingarm
• Axle fastener not tightened properly
• Loose or broken spokes (spoke wheel type)
Wheel turns hard
• Faulty wheel bearings
• Bent axle
• Drive chain too tight (page 3-14)
• Brake drag (page 14-4)
Soft suspension
• Incorrect suspension adjustment
• Weak shock absorber springs
• Oil leakage from damper unit
Stiff suspension
• Incorrect suspension adjustment
• Bent shock absorber damper rod
• Damaged suspension or swingarm pivot bushings
• Bent swingarm pivot or frame
• High tire pressure
Steers to one side or does not track straight
• Drive chain adjusters not adjusted equally
• Bent axle
• Bent frame
• Worn swingarm pivot components
Rear suspension noise
• Loose suspension fasteners
• Worn or damaged suspension pivot bushings
• Faulty shock absorber
13-6
REAR WHEEL
REMOVAL
ROD
Disconnect the brake rod by removing the adjusting nut,
and remove the spring and joint pin.
JOINT PIN
SPRING
ADJUSTING NUT
Disconnect the stopper arm from the brake panel by

removing the following.
WASHER COTTER PIN
– cotter pin
– nut
– washer
– rubber seat
– joint bolt
NUT
STOPPER ARM
BOLT
RUBBER SEAT
Loosen the axle nut.

COLLAR
Loosen the both drive chain adjuster lock nuts and AXLE NUT
adjusting bolts so the wheel can be moved all the way
forward.
Move the wheel forward for maximum chain slack. ADJUSTER
Remove the axle nut and washer. PLATE AXLE
Derail the drive chain from the driven sprocket.
– axle LOCK NUT
– both adjusters and adjuster plates
– collar WASHER
– rear wheel
ADJUSTING BOLT ADJUSTER
Remove the brake panel assembly from the wheel hub.

BRAKE PANEL
13-7
Remove the side collar from the driven flange.
SIDE COLLAR
INSPECTION
AXLE
Actual runout is 1/2 the total indicator reading.
WHEEL BEARING
The bearings should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the hub
or driven flange.
bearings in pairs. smoothly, quietly, or if they fit loosely in the hub or
driven flange.
Replace the bearings if necessary (page 13-9).
WHEEL RIM
Check the wheel rim runout by placing the wheel in a
turning stand.
Spin the wheel slowly by hand, and read the runout
using a dial indicator.
SERVICE LIMITS: Radial: 1.0 mm (0.04 in)
Axial: 1.0 mm (0.04 in)
13-8
DISASSEMBLY
If you will replace Remove the driven flange assembly from the wheel.
the driven sprocket, LOCK
bend down the lock PLATE
plates and loosen
the four bolts.
DUST SEAL
DRIVEN FLANGE LOCK

ASSEMBLY PLATE
Remove the O-ring and the rubber dampers.

RUBBER DAMPERS
Replace the rubber Check the rubber dampers for deterioration or damage.
dampers as a set.
O-RING
Remove the sleeve.

SLEEVE

– four bolts/nuts
– lock plates LOCK
– driven sprocket PLATE
– dust seal DUST SEAL
DRIVEN LOCK BOLTS/

SPROCKET PLATE NUTS
13-9
Drive the bearing out of the driven flange.
BEARING
Install the bearing remover head into the wheel bearing.

From the opposite side of the wheel, install the bearing REMOVER HEAD
remover shaft and drive the bearing out of the wheel
hub.
bearing.
TOOLS:
REMOVER SHAFT
BEARING
ASSEMBLY
LOCK PLATE
BEARING (6302U) SLEEVE
BEARING (6202U)
DAMPER
RUBBERS
BOLTS
DRIVEN 34 N·m (3.5
FLANGE kgf·m, 25 lbf·ft)
LOCK PLATE
DRIVEN
SPROCKET
NUT
DISTANCE COLLAR DUST SEAL
BEARING (6004UU) SIDE COLLAR

O-RING
13-10
WHEEL CENTER ADJUSTMENT (Type 3, 6)
Adjust the hub position so that the distance from the left
end surface of the hub center to the side of rim is 2.0 ±
1 mm (0.08 ± 0.04 in) as shown. 2.0 ± 1 mm (0.08 ± 0.04 in)
Tighten the spokes in 2 or 3 progressive steps.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300

Check the rim runout (page 13-8).
WHEEL ASSEMBLY
Drive in a new right side (brake drum side) bearing
seated. DRIVER
Drive in a new left side bearing with the sealed side
facing up.
TOOLS:
Driver 07749-0010000 BEARING
Attachment, 37×40 (brake drum07746-0010200
side)
Attachment, 32×35 (left side) 07746-0010100
Pilot, 15 mm 07746-0040300 ATTACHMENT PILOT

Drive in a new driven flange bearing squarely with the
sealed side facing up until it is fully seated.
TOOLS: DRIVER
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 25 mm 07746-0040600
BEARING
ATTACHMENT PILOT

Install the dust seal so that it is flush with the wheel hub. LOCK
PLATE
Install the following: DUST SEAL
– driven sprocket
– lock plates
– four bolts
– four nuts
Temporary tighten the bolts.
DRIVEN LOCK BOLTS

SPROCKET PLATE
13-11
Install the sleeve into the new driven frange bearing.
SLEEVE
Install the rubber dampers as shown.

RUBBER DAMPERS
Coat a new O-ring with grease and install it into the
groove.
O-RING
Install the driven flange assembly to the wheel hub.

LOCK
Tighten the sprocket bolts in a crisscross pattern in PLATE
several steps if they were removed.
Bend up the lock plate tabs against the bolts as shown
so that the bolts cannot be loosed.
DRIVEN FLANGE LOCK BOLTS/

ASSEMBLY PLATE NUTS
INSTALLATION
Install the left side collar.
SIDE COLLAR
13-12
Do not get grease Install the brake panel assembly into the wheel hub.
BRAKE PANEL
on the brake drum
and shoe linings.
Place the rear wheel in the swingarm and install the

drive chain onto the final driven sprocket. COLLAR
AXLE NUT
Install the both adjusters and adjuster plates to the
swingarm.
Insert the axle from the left side through the swingarm,
collar and rear wheel. ADJUSTER
Install the axle nut and washer. PLATE AXLE
WASHER
ADJUSTER
Connect the stopper arm to the brake panel with the

joint bolt. Install the rubber seat, washer and nut and
WASHER COTTER PIN
tighten the nut to the specified torque.

Install a new cotter pin into the joint bolt.
NUT
STOPPER ARM
BOLT
RUBBER SEAT
Install the joint pin into the brake arm.

Install the spring onto the brake rod. ROD
Push down the brake pedal and install the brake rod
into the joint pin. JOINT PIN
Install the adjusting nut.
Adjust the drive chain slack (page 3-15).
Adjust the brake pedal freeplay (page 3-20).
SPRING
ADJUSTING NUT
13-13
REAR DRUM BRAKE
REMOVAL
Remove the rear wheel and the brake panel (page 13-
7).
INSPECTION
Measure the rear brake drum I.D.
DISASSEMBLY
Always replace the Expand the brake shoes and remove them from the
brake shoes in brake panel.
pairs.
Remove the shoe springs from the brake shoes.
PANEL
SHOES
SPRINGS

– nut and bolt
– brake arm
NUT
BRAKE ARM
BOLT
13-14
– wear indicator
– brake cam
– felt seal BRAKE CAM
INDICATOR FELT SEAL
ASSEMBLY
*: Gear oil
BRAKE CAM
WEAR INDICATOR
SPRINGS
BOLT
BRAKE SHOES
*
FELT SEAL BRAKE PANEL
NUT
BRAKE ARM 10 N·m (1.0 kgf·m, 7 lbf·ft)
Apply 0.2 - 0.3 g of grease to the brake cam sliding

surface and install it into the brake panel.
BRAKE CAM
13-15
Apply gear oil to the felt seal and install it onto the brake
panel. BRAKE CAM
Install the wear indicator by aligning the wide tooth with
the wide groove in the brake cam.
Align
INDICATOR
FELT SEAL
Install the brake arm by aligning the punch marks.

BRAKE ARM
Install the bolt from the punch mark side and tighten the
nut.
NUT
Align
BOLT
Apply 0.2 - 0.3 g of grease to the anchor pin and brake

cam sliding surfaces.
Assemble the brake shoes and springs in the direction
as shown. PANEL
Install the shoe assembly onto the brake panel so the
spring ends are facing up (wheel side). SHOES
Wipe any excess grease from the brake cam and

anchor pin.
Install the rear wheel (page 13-12).
SPRINGS
BRAKE PEDAL/CENTERSTAND
REMOVAL
Place the motorcycle on its sidestand.
Retract the centerstand. ROD
Disconnect the brake rod by removing the adjusting nut,

JOINT PIN
and remove the spring and joint pin.
SPRING
ADJUSTING NUT
13-16
– centerstand return spring
RETURN SPRING
– centerstand return spring plate

PLATE
– brake light switch rod

PIVOT SHAFT COTTER PIN
– brake pedal return spring
– cotter pin
RETURN
– pivot shaft and washer
SPRING
– brake pedal WASHER
– centerstand
ROD
BRAKE PEDAL
CENTERSTAND
– cotter pin and washer

– brake rod COTTER PIN
WASHER
PEDAL
BRAKE ROD
13-17
INSTALLATION
Connect the brake rod to the brake pedal, then install
the washer and a new cotter pin as shown. COTTER PIN
WASHER
PEDAL
BRAKE ROD
Apply grease to the pivot shaft sliding surface.

Place the centerstand and brake pedal in the frame.
Insert the pivot shaft from the left side through the
frame, centerstand and brake pedal.
PIVOT SHAFT
CENTERSTAND
Install the washer and new cotter pin into the pivot
PIVOT SHAFT COTTER PIN
shaft.
Install the following as shown:
– brake pedal return spring
WASHER
– brake light switch rod
RETURN
ROD SPRING
Install the centerstand return spring plate by setting its

hole and boss of the frame. PLATE
13-18
Install the centerstand return spring.
RETURN SPRING
Install the joint pin into the brake arm.

Install the spring onto the brake rod. ROD
Push down the brake pedal and install the brake rod
into the joint pin. JOINT PIN
Install the adjusting nut.
Adjust the brake pedal freeplay (page 3-20).
SPRING
ADJUSTING NUT
SHOCK ABSORBER
Place the motorcycle on its centerstand and support the
WASHER/COLLAR
swingarm.
– rear carrier (page 2-6)
– upper mounting bolt, washer and collar
– lower mounting bolt
– shock absorber UPPER LOWER
MOUNTING MOUNTING
Installation is in the reverse order of removal. BOLT BOLT
TORQUE:
Lower mounting bolt
34 N·m (3.5 kgf·m, 25 lbf·ft)
Upper mounting bolt SHOCK
ABSORBER
29 N·m (3.0 kgf·m, 21 lbf·ft)
INSPECTION
Do not disassemble Visually inspect the shock absorber for wear or
the shock absorber. damage. SHOCK ABSORBER
Replace the shock
absorber as an
assembly. – damper rod for bending or damage
– damper unit for leakage or other damage
– bushings for wear or damage
Check for smooth damper operation.
13-19
SWINGARM
REMOVAL
Remove the following: CHAIN COVER
– muffler (page 2-9)
– rear wheel (page 13-7)
– two bolts and drive chain cover
BOLTS
Remove the shock absorber lower mounting bolts.

SHOCK
Release the both shock absorber lower mounts from ABSORBER
the swingarm.
LOWER
MOUNTING BOLT
Remove the swingarm pivot bolt/washer and swingarm.
BOLTS WASHER
DISASSEMBLY
Remove the chain slider by releasing the bosses from
the holes of the swingarm.
BOSSES
HOLES
CHAIN SLIDER
13-20
ARM
– cotter pin
– nut COTTER PIN, NUT
– washer AND WASHERS
– spring washer
– joint bolt
– brake panel stopper arm
BOLT
INSPECTION
Check the pivot bushings for wear, deterioration or
damage.
BUSHINGS
Check the chain slider for wear or damage.

LIMIT GROOVE
The chain slider must be replaced if it is worn to the
wear limit groove.
13-21
ASSEMBLY
Note the installation Install the following:
direction of the – brake panel stopper arm
stopper arm. – joint bolt
– spring washer
– washer
– nut
Tighten the nut to the specified torque.
Install a new cotter pin into the joint bolt.
Install the chain slider by setting the bosses into the holes in the swingarm securely.
NUT
22 N·m (2.2 kgf·m, 16 lbf·ft) WASHER SPRING WASHER
BOLT
CHAIN SLIDER
COTTER PIN
STOPPER ARM
SWINGARM
INSTALLATION
Apply grease to the swingarm pivot bolt.
SWINGARM
Set the swingarm into the frame through the drive chain
and insert the pivot bolt with washer from the left side. BOLT
WASHER
13-22
Align the shock absorber lower mounts side hole and
thread hole of the swingarm, then temporary tighten the SHOCK
shock absorber lower mounting bolts. ABSORBER
LOWER
MOUNTING BOLT
Install the chain cover, aligning the locating tab of the
cover with the slit in the swingarm. Align
CHAIN COVER

Install the rear wheel (page 13-12).
Install the muffler (page 2-10).
Tighten the shock absorber lower mounting bolts to the
specified torque.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) LOWER
MOUNTING
BOLT
BOLTS
13-23
MEMO
14. HYDRAULIC DISC BRAKE
SYSTEM COMPONENTS····························· 14-2 BRAKE PADS/DISC······································14-7
SERVICE INFORMATION ···························· 14-3 MASTER CYLINDER ··································14-10
TROUBLESHOOTING·································· 14-4 BRAKE CALIPER ·······································14-14
BRAKE FLUID REPLACEMENT/

AIR BLEEDING ············································ 14-5
14
14-1
SYSTEM COMPONENTS
34 N·m (3.5 kgf·m, 25 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
30 N·m (3.1 kgf·m, 22 lbf·ft)
14-2
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
Spilled brake fluid will severely damage the plastic parts and painted surface. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid as they may not be compatible.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always check brake operation before riding the motorcycle.
SPECIFICATIONS
Unit: mm (in)
Specified brake fluid DOT 3 or DOT 4 –
Brake pad wear indicator – To the groove
Brake disc thickness 3.8 – 4.2 (0.15 – 0.17) 3.5 (0.14)
Brake disc runout – 0.10 (0.004)
TORQUE VALUES
Caliper bleed valve 8 N·m (0.8 kgf·m, 5.9 lbf·ft)
Master cylinder reservoir cap screw 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
Brake caliper mounting bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt: replace with a new one.
Front brake light switch screw 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
Brake lever pivot bolt 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
Brake lever pivot nut 6.0 N·m (0.6 kgf·m, 4.4 lbf·ft)
Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Brake caliper slide pin 18 N·m (1.8 kgf·m, 13 lbf·ft) Apply locking agent to the threads.
Pad pin 18 N·m (1.8 kgf·m, 13 lbf·ft)
Pad pin plug 2.5 N·m (0.25 kgf·m, 1.8 lbf·ft)
Rear view mirror lock nut 34 N·m (3.5 kgf·m, 25 lbf·ft)
TOOL
Snap ring pliers
07914-SA50001
14-3
TROUBLESHOOTING
Brake lever soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pads/disc
• Worn caliper piston seal
• Worn master cylinder piston cups
• Worn brake pads/disc
• Contaminated caliper
• Contaminated master cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Bent brake lever
Brake lever hard
• Clogged/restricted brake system
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Bent brake lever
Brake drags
• Contaminated brake pads/disc
• Misaligned wheel
• Badly worn brake pads/disc
• Warped/deformed brake disc
• Clogged/restricted fluid passage
• Sticking caliper piston
14-4
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Turn the handlebar until the master cylinder reservoir is
level before removing the reservoir cap. SCREWS
Remove the screws, reservoir cap, set plate and
diaphragm.
RESERVOIR
CAP
SET PLATE
DIAPHRAGM
Connect a bleed hose to the bleed valve.

Loosen the bleed valve and pump the brake lever until
no more fluid flows out of the bleed valve.
Tighten the bleed valve.
BLEED HOSE
BLEED VALVE
BRAKE FLUID FILLING/AIR BLEEDING

Close the bleed valve.
BRAKE BLEEDER
Fill the reservoir with DOT 3 or DOT 4 brake fluid from a
sealed container.
Follow the Connect a commercially available brake bleeder to the
manufacturer’s bleed valve.
operating Operate the brake bleeder and loosen the bleed valve.
instructions.
Check the fluid level often while bleeding the brake to
prevent air from being pumped into the system.
If air enters the Perform the bleeding procedure until the system is
bleeder from completely flushed/bled.
around the bleed
Close the bleed valve and operate the brake lever. If it
valve threads, seal
still feels spongy, bleed the system again. BLEED VALVE
the threads with
teflon tape.
14-5
If a brake bleeder is not available, use the following
procedure: BRAKE LEVER
Connect a bleed hose to the bleed valve.
Pressurize the system with the brake lever until lever
resistance is felt.
Do not release the 1. Squeeze the brake lever, open the bleed valve 1/4
lever until the bleed turn and then close it.
valve has been
2. Release the brake lever slowly and wait several
closed.
seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding the system completely, tighten the bleed
valve.
Fill the reservoir to the upper level line with DOT 3 or
DOT 4 brake fluid. UPPER LINE
(CASING LEDGE)
Install the diaphragm, set plate and reservoir cap and

tighten the screws. SCREWS
RESERVOIR
CAP
SET PLATE
DIAPHRAGM
14-6
BRAKE PADS/DISC
BRAKE PADS REPLACEMENT
Check the brake Push the caliper pistons all the way in to allow
fluid level in the installation of new brake pads.
master cylinder
reservoir as this
operation causes
the fluid level to
rise.
Remove the pad pin plugs.

PAD PIN PLUGS
Loosen the pad pins.

BRAKE CALIPER
Remove the caliper mounting bolts and brake caliper.
BOLTS
PAD PINS
Pull the pad pins out of the caliper while pushing in the
pads against the pad spring. PAD PINS
14-7
Remove the brake pads.
BRAKE PADS
Make sure the pad spring is installed in position.
PAD SPRING
Always replace the Install new brake pads into the caliper so their ends are
brake pads in pairs positioned onto the bracket as shown.
to ensure even disc BRAKE PADS
pressure.
Install the pad pin by pushing the pads against the pad
spring to align the pad pin holes of the pads and caliper. PAD PINS
14-8
Install the brake caliper and new mounting bolts.
Tighten the brake caliper mounting bolts. BRAKE CALIPER

Tighten the pad pins. BOLTS
Operate the brake lever to seat the caliper pistons
against the pads.
PAD PINS
Install and tighten the pad pin plugs.

PAD PIN PLUG
BRAKE DISC INSPECTION

Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness at several points.
Measure the brake disc runout with a dial indicator.

Check the wheel bearings for excessive play, if the
warpage exceeds the service limit.
Replace the brake disc if the wheel bearings are
normal.
Refer to Front Wheel/Brake/Suspension/Steering
section for brake disc replacement (page 12-13).
14-9
MASTER CYLINDER
DISASSEMBLY
Drain the brake fluid from the hydraulic system (page
14-5). MIRROR
The right rearview Remove the following:
mirror lock nut has – brake light switch connectors
left-hand threads. – rearview mirror CONNECTORS
When removing the – oil bolt and sealing washers

MASTER CYLINDER
oil bolt, cover the – brake hose HOLDER
end of the hose to – two bolts
prevent – holder WASHERS
contamination. – master cylinder
OIL BOLT
HOSE
BOLTS
– pivot nut and bolt

– brake lever BOLT
LEVER NUT
– screw and brake light switch

– piston boot SWITCH
SCREW
BOOT
14-10
– snap ring
PLIERS SNAP RING
TOOL:
Snap ring pliers 07914-SA50001
– master piston
– spring
Clean the master cylinder, reservoir and master piston
in clean brake fluid.
MASTER PISTON
SPRING
INSPECTION
Check the master cylinder and piston for scoring,
scratches or damage.
Check the piston cups and boot for wear, deterioration
or damage.
Check the spring for fatigue or damage.
14-11
ASSEMBLY
SCREWS
1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
SNAP RING
MASTER
BOOT PISTON
SPRING
PIVOT BOLT
1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
MASTER
CYLINDER
PISTON
CUPS
BRAKE LIGHT
SWITCH
BRAKE LEVER
PIVOT NUT SCREW

6.0 N·m (0.6 kgf·m, 4.4 lbf·ft) 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
Coat the master piston and piston cups with clean

brake fluid. SPRING
Install the spring onto the master piston.

Do not allow the Install the master piston/spring into the master cylinder.
piston cup lips to
turn inside out.
MASTER PISTON
CUPS
Make sure the snap Install the snap ring into the groove in the master
ring is firmly seated cylinder with the chamfered side facing the piston. PLIERS SNAP RING
in the groove.
TOOL:
Snap ring pliers 07914-SA50001
14-12
Install the boot into the master cylinder and the piston
groove.
Apply silicone grease to the brake lever contacting
surface of the piston.
BOOT
Apply silicone grease to the brake lever pivot sliding

surface. BOLT
Install the brake lever and pivot bolt, and tighten it while
holding the pivot bolt.
Install the pivot nut and tighten it.
LEVER NUT
Install the brake light switch by aligning the locating pin

with the hole and tighten the screw. SWITCH
SCREW
BOOT
Align the edge of Install the master cylinder and holder with the “UP”
MASTER CYLINDER
the master cylinder mark facing up.
with the punch Tighten the upper bolt first, then tighten the lower bolt. BOLTS
mark on the Align
WASHERS
handlebar. Connect the brake hose to the master cylinder with the
Rest the hose joint oil bolt and new sealing washers. OIL BOLT
against the stopper. Tighten the oil bolt.
HOSE
HOLDER
("UP")
14-13
The right rearview Install the rearview mirror.
mirror lock nut has MIRROR
Tighten the rear view mirror lock nut to the specified
left-hand threads.
torque.
CONNECTORS
Connect the brake light switch connectors.
Fill and bleed the hydraulic system (page 14-5).
BRAKE CALIPER
REMOVAL
Drain the brake fluid from the hydraulic system (page
14-5). BRAKE HOSE BRAKE
CALIPER
When removing the Disconnect the brake hose from the brake caliper by
oil bolt, cover the removing the oil bolt and sealing washers.
end of the hose to
Remove the brake pads and brake caliper (page 14-7).
prevent OIL BOLT
contamination.
SEALING WASHERS
DISASSEMBLY
– caliper bracket
– pin boots
BRACKET
BOOTS
Place a shop towel over the piston.

Do not use high Position the caliper body with the piston facing down
pressure air or bring and apply small squirts of air pressure to the fluid inlet
the nozzle too close to remove the piston.
to the inlet.
14-14
Be careful not to Push the dust and piston seals in and lift them out.
damage the piston PISTON SEAL
Clean the seal grooves, caliper cylinders and piston
sliding surface.
with clean brake fluid.
DUST SEAL
INSPECTION
Check the caliper cylinders and pistons for scoring,
scratches or damage. CALIPER
PISTONS
14-15
ASSEMBLY
BLEED VALVE
*: Apply 0.02 g
8 N·m (0.8 kgf·m, 5.9 lbf·ft) BOOT
PAD PIN PLUGS
2.5 N·m (0.25 kgf·m, 1.8 lbf·ft)
PISTON SEALS *
DUST SEALS *
PAD PINS
18 N·m (1.8 kgf·m, 13 lbf·ft)
BOOT
CALIPER BODY
CALIPER BRACKET
PAD SPRING
CALIPER PISTONS
BRAKE PADS
Coat new dust seals with 0.02 g of clean brake fluid and
install them into the seal grooves in the caliper.
Coat new pistons with clean brake fluid and install them
into the caliper.
Coat the caliper piston with clean brake fluid and install SEALS
them into the caliper cylinders with the open side
toward the pads.
CALIPER PISTONS
Check the pin boots and replace them if they are hard,
deteriorated or damaged.
Install the boot into the caliper.
Apply silicone grease to the inside of the boots and
install the caliper bracket over the caliper body.
Make sure the boot ribs are seated into the boot BRACKET
grooves in the slide pins properly.
BOOTS
14-16
INSTALLATION
Install the brake pads and brake caliper (page 14-7).
BRAKE HOSE BRAKE
Connect the brake hose to the brake caliper with the oil
GROOVE CALIPER
bolt and new sealing washers.
Set the hose eyelet joint into the stopper groove and
tighten the oil bolt.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) OIL BOLT
Fill and bleed the hydraulic system (page 14-5).
SEALING WASHERS
14-17
MEMO
15. BATTERY/CHARGING SYSTEM
COMPONENT LOCATION ··························· 15-2 BATTERY ······················································15-5
SYSTEM DIAGRAM ····································· 15-2 CHARGING SYSTEM INSPECTION·············15-7
SERVICE INFORMATION ···························· 15-3 REGULATOR/RECTIFIER ····························15-8
TROUBLESHOOTING·································· 15-4 ALTERNATOR CHARGING COIL ················15-8
15
15-1
COMPONENT LOCATION
REGULATOR/RECTIFIER
IGNITION SWITCH
BATTERY
ALTERNATOR
SUB FUSE (15 A) MAIN FUSE (20 A)
SYSTEM DIAGRAM
To SWITCHES Bl R/Bl R/Bl R/W

SUB FUSE IGNITION SWITCH
15 A
R/W
MAIN FUSE
Y Y Y 20 A
Bl: Black
G: Green
Y Y Y R/W G R R: Red
Y: Yellow
W: White
ALTERNATOR
REGULATOR/RECTIFIER BATTERY
15-2
SERVICE INFORMATION
GENERAL
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charg-
ing.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
– If electrolyte gets on your skin, flush with water.
– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.
KEEP OUT OF REACH OF CHILDREN.
• Always turn OFF the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every two weeks.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions
contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2
– 3 years.
• Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and eventually die
out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage
does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level
goes down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the motorcycle.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge
the battery. Also, the battery life is lengthened when it is initially charged.
• When checking the charging system, always follow the steps in the troubleshooting (page 15-4).
• Alternator stator removal/installation (page 10-5).
• Ignition switch servicing (page 18-9).
BATTERY TESTING
Refer to the instruction of the Operation Manual for the recommended battery tester for details about battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
Recommended battery tester: BM210 or BATTERY MATE or equivalent
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 7 Ah
Current leakage 1 mA max.
Specific gravi- Fully charged 1.270 – 1.290
ty (20°C/68°F) Needs charging Below 1.230
Voltage Fully charged 13.0 – 13.2 V
(20°C/68°F) Needs charging Below 12.3 V
Charging current Normal 0.6 A/5 – 10 h
Quick 3 A/1 h
Alternator Capacity 0.16 kW/5,000 min-1 (rpm)
Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω
TORQUE VALUE
Battery holder bolt 1.8 N·m (0.18 kgf·m, 1.3 lbf·ft)
15-3
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. Battery Test
Check the battery condition using the recommended battery tester.
RECOMMENDED BATTERY TESTER: BM210 or BATTERY MATE or equivalent
Is the battery in good condition?
YES – GO TO STEP 2.
NO – Faulty battery
2. Current Leakage Test
Install the battery (page 15-5).
Check the battery current leakage test (Leak test;(page 15-7)).
Is the current leakage below 1 mA?
NO – GO TO STEP 3.
3. Current Leakage Test Without Regulator/Rectifier
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Is the current leakage below 1 mA?
YES – Faulty regulator/rectifier
NO – • Shorted wire harness
• Faulty ignition switch
4. Charging Voltage Inspection
Measure and record the battery voltage using a digital multimeter (page 15-6).
Start the engine.
Measure the charging voltage (page 15-7).
Compare the measurements to the results of the following calculation.
STANDARD: Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage
• CV = Charging Voltage
Is the measured charging voltage within the standard voltage?
YES – Intermittent failure (system is normal.)
5. Alternator Charging Coil Inspection
Measure the alternator charging coil resistance (page 15-8).
STANDARD: 0.1 – 1.0 Ω (20°C/68°F)
Is the alternator charging coil resistance within the standard value?
NO – Faulty charging coil
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
Perform the regulator/rectifier system inspection (page 15-8).
Are the measurements correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related wire
• Loose or poor contacts of related terminal
• Shorted wire harness
15-4
BATTERY
Remove the left side cover (page 2-4).
NUTS POSITIVE (+) CABLE TERMINAL
Turn the ignition switch to OFF. BOLT
Remove the bolt, nut and battery negative (–) cable
from the battery.
Remove the bolt, nut and battery positive (+) cable from
the battery. HOSE
Remove the battery holder bolt and open the battery
stay.
Remove the battery by disconnecting the battery
breather hose.
Connect the Install the battery in the reverse order of removal.
positive (+) terminal
first, and then the TORQUE:
negative (–) cable. BATTERY HOLDER BOLT: STAY
1.8 N·m (0.18 kgf·m, 1.3 lbf·ft) NEGATIVE (–) HOLDER
CABLE BATTERY BOLT
Make sure that the battery breather hose is correctly

positioned, and not kinked, trapped or bent in such
away as to obstruct the passage of the air.
• If the hose is blocked, the battery’s internal pressure
will not be relieved, the breather may come off, or
the battery crack as a result.
BATTERY INSPECTION
remove the battery (page 15-5).
DISTILLED WATER
Check for cracked or broken case or plates.
Check the plates for sulfation. UPPER
LEVEL LINE
Check each cell’s electrolyte level.
If low, remove the caps and add distilled water to bring
the level to the upper level line.
Replace the battery if damaged or sulfated.
• In order to obtain an accurate test reading when
checking the charging system, the battery must be
fully charged and in good condition. Perform the
following inspections and tests before attempting to
troubleshooting charging system problems. CAPS
15-5
SPECIFIC GRAVITY
• The battery electrolyte contains sulfuric acid. Avoid
contact with skin, eyes or clothing. HYDROMETER
The specific gravity must be checked with a hydro
meter.
Test each cell by drawing electrolyte into the
hydrometer.
SPECIFIC GRAVITY Fully charged: 1.270 – 1.290
(20°C/68°F): Under charged: Below 1.230 ELECTROLYTE
• If the difference in specific gravity between cells

exceeds 0.01, re-charge the battery. If the difference
in specific gravity is excessive, replace the battery.
• There is a charging in specific gravity of CAPS
approximately 0.007 per 10°C change in
temperature. Be sure to consider this when taking
measurements.
• Reading of the hydrometer’s fluid level should be SPECIFIC
GRAVITY
taken horizontally.
ELECTROLYTE
TEMPERATURE (°C)
VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (20°C/68°F):Fully charged: 13.0 – 13.2 V
Under charged: Below 12.3 V
(-) (+)
• When measuring the battery voltage after charging,
leave it for least 30 minutes, or the accurate results
cannot be obtained because the battery voltage
fluctuates just after charging.
BATTERY CHARGING
CHARGER
Turn power ON/ Connect the charger positive (+) cable to the battery
OFF at the charger, positive (+) terminal.
not at the battery Connect the charger negative (–) cable to the battery
terminals to prevent negative (–) terminal.
sparks.
CHARGING CURRENT/TIME: Normal: 0.6 A/5 – 10 h
Quick: 3 A/1 h
• Quick-charging should only be done in an

emergency; slow charging is preferred.
• For battery charging, do not exceed the charging
current and time specified on the battery. Using
BATTERY
excessive current or extending the charging time
may damage the battery.
15-6
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
(+) PROBE (-) PROBE
Turn the ignition switch to OFF and disconnect the
battery negative (–) cable from the battery.
Connect the ammeter (+) probe to the battery negative
(–) cable and the ammeter (–) probe to the battery
negative (–) terminal.
With the ignition switch turned to OFF, check for current
leakage.
• When measuring current using a tester, set it to a

high range, and then bring the range down to an
appropriate level. Current flow higher than the range
(-) CABLE
selected may blow out the fuse in the tester.
• While measuring current, do not turn the ignition
switch to ON. A sudden surge of current may blow
out the fuse in the tester.
CURRENT LEAKAGE: 1 mA max.

If the current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION
Be sure the battery is in good condition before
performing this test.
Warm up the engine to normal operating temperature
and stop it.
Connect the multimeter between the battery positive (+)
and negative (–) terminals. (-) (+)
• To prevent a short, make absolutely certain which

are the positive (+) and negative (–) terminals or
cables.
• Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.
Restart the engine and turn the headlight on.
Measure the voltage on the multimeter when the engine
runs at 5,000 min–1 (rpm).
STANDARD: Measured BV < Measured CV < 15.5 V
BV = Battery voltage
CV = Charging voltage
15-7
REGULATOR/RECTIFIER
SYSTEM INSPECTION
Disconnect the regulator/rectifier 6P connector, and 6P CONNECTOR
check it for loose contact or corroded terminals.
Check the following at the wire harness side connector
terminals.
Item Terminal Specification
Battery Red/White (+) Battery voltage should
charging line and Green (–) exist at all times.
Ground line Green and Continuity should exist
ground at all times.
Charging coil line inspection (page 15-8).
BOLTS
Disconnect the regulator/rectifier 6P connector.
Remove the two bolts and regulator/rectifier.
6P CONNECTOR
REGULATOR/
RECTIFIER
ALTERNATOR CHARGING COIL

INSPECTION
Disconnect the alternator 3P connector, and check it for
loose contact or corroded terminals.
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
STANDARD: 0.1 – 1.0 Ω (20°C/68°F)
Check for continuity between each Yellow wire terminal
of the alternator side connector and ground.
There should be no continuity.
If resistance is out of specification or if any wire has
continuity to ground, replace the alternator stator (page
10-5). 3P CONNECTOR
15-8
16. IGNITION SYSTEM
COMPONENT LOCATION ··························· 16-2 IGNITION SYSTEM INSPECTION ················16-5
SYSTEM DIAGRAM ····································· 16-2 IGNITION TIMING ·········································16-7
SERVICE INFORMATION ···························· 16-3 IGNITION COIL ·············································16-8
TROUBLESHOOTING·································· 16-4 ICM (IGNITION CONTROL MODULE)··········16-8
16
16-1
IGNITION SYSTEM
COMPONENT LOCATION
IGNITION SYSTEM
IGNITION SWITCH
ICM
BATTERY
IGNITION COIL
SPARK PLUG
IGNITION PULSE GENERATOR MAIN FUSE (20 A)
SYSTEM DIAGRAM
R/Bl R/W
IGNITION
SWITCH
R
MAIN FUSE
20 A
Bl/Y G Bl: Black
Bu: Blue
G: Green
G G Bu/Y Bu/Y G Bl/Y R/Bl R R: Red
Y: Yellow
IGNITION W: White
COIL
SPARK
PLUG
IGNITION ICM BATTERY

PULSE
GENERATOR
16-2
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
• The Ignition Control Module (ICM) may be damaged if dropped. Also if the connector is disconnected when current is flowing,
the excessive voltage may damage the ICM. Always turn the ignition switch to OFF before servicing.
• Use spark plug with the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
• When servicing the ignition system, always follow the steps in the troubleshooting chart (page 16-4).
• The ignition timing cannot be adjusted since the ICM is factory preset.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
• Ignition pulse generator removal/installation (page 10-5).
• Ignition switch servicing (page 18-9).
SPECIFICATION
ITEM SPECIFICATION
Ignition coil primary peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing ("F" mark) 8° BTDC at idle
TORQUE VALUE
TOOLS
Peak voltage adaptor
07HGJ-0020100
16-3
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system.
– Faulty spark plug
– Loose spark plug cap or spark plug wire connection
– Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
No spark at plug
Unusual condition Probable cause (check in numerical order)
Ignition coil pri- Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/DCV.
mary 2. Cranking speed is too slow. (Battery is undercharged.)
voltage 3. The sampling time of the tester and measured pulse were not syn-
chronized. (System is normal if measured voltage is over the stan-
dard voltage at least once.)
4. Poorly connected connectors or an open circuit in the ignition sys-
tem.
5. Faulty ignition coil.
6. Faulty ICM (in case when above No. 1 through 5 are normal).
No peak voltage. 1. Incorrect peak voltage adaptor connections. (System is normal if
measured voltage is over the specifications with reverse connec-
tions.)
2. Battery is undercharged. (Voltage drops largely when the engine is
started.)
3. Faulty ignition switch.
4. Loose or poorly connected ICM connector.
5. No voltage at the Red/black wire of the ICM.
6. Open circuit or poor connection in the Green wire of the ICM.
7. Faulty peak voltage adapter.
8. Faulty ignition pulse generator. (Measure the peak voltage.)
9. Faulty ICM (in case when above No. 1 through 8 are normal).
Peak voltage is normal, but no 1. Faulty spark plug or leaking ignition coil secondary current.
spark at the plug. 2. Faulty ignition coil.
Ignition pulse Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/DCV.
generator 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling time of the tester and measured pulse were not syn-
chronized. (System is normal if measured voltage is over the stan-
dard voltage at least once.)
4. Faulty ignition pulse generator (in case when above No. 1 through
3 are normal).
No peak voltage. 1. Faulty peak voltage adapter.
2. Faulty ignition pulse generator.
16-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark at the plug, check all connections
for loose or poor contact before measuring the peak
voltage.
• Use a commercially available digital multimeter with
an impedance of 10 MΩ/DCV minimum.
• The display value differs depending upon the
internal impedance of the multimeter.
• If using the Imrie diagnostic tester (model 625),
follow the manufacturer’s instructions.
Connect the peak voltage adaptor to the digital
multimeter, or use the Imrie diagnostic tester. DIGITAL MULTIMETER
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MW/DCV minimum)
PEAK VOLTAGE ADAPTOR
IGNITION COIL PRIMARY PEAK

VOLTAGE INSPECTION
• Check all system connections before this inspection.

Poor connected connectors can cause incorrect
readings.
• Check that the cylinder compression is normal and
the spark plug is installed correctly in the cylinder
head.
Disconnect the spark plug cap from the spark plug.
KNOWN GOOD SPARK PLUG
Connect a known good spark plug to the spark plug cap
and ground it to the cylinder head as done in a spark
test.
16-5
IGNITION SYSTEM
With the connector connected, connect the Imrie
IGNITION COIL CONNECTOR
diagnostic tester or peak voltage adaptor probes to the
ignition coil primary wire terminal and body ground.
(–) PROBE
TOOL:
(impedance 10 MΩ/DCV minimum)
CONNECTION: Black/yellow (–) – Body ground (+)

Turn the ignition switch to ON.
Crank the engine with the starter motor and read
ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is lower than the standard value, (+) PROBE PEAK VOLTAGE ADAPTOR
follow the checks described in the troubleshooting chart
(page 16-4).
IGNITION PULSE GENERATOR PEAK
VOLTAGE
• Check that the cylinder compression is normal and

the spark plug is installed correctly in the cylinder
head.
Remove the ICM (page 16-8).
Green (–) ICM 4P CONNECTOR
Connect the Imrie diagnostic tester or adaptor probes to
the wire harness side 4P connector terminals.
TOOL:
(impedance 10 MΩ/DCV minimum)
CONNECTION: Blue/yellow (+) – Green (–)

Shift the transmission into neutral. Blue/yellow (+)
Crank the engine with the starter motor and read the
ignition pulse generator peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ICM 4P connector
is abnormal, measure the peak voltage at the ignition
pulse generator side.
Disconnect the ignition pulse generator 2P connector
and connect the tester probes to the ignition pulse
generator side 2P connector terminals.
CONNECTION: Blue/yellow (+) – Green (–)
In the same manner as at the ICM connector, measure
the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnormal 2P CONNECTOR
and the one measured at the ignition pulse
generator is normal, the wire harness has an open
or short circuit, or loose connection.
• If both peak voltages are abnormal, follow the
checks described in the troubleshooting chart (page
16-4).
16-6
IGNITION SYSTEM
IGNITION TIMING
Warm up the engine. TIMING HOLE CAP
Stop the engine and remove the timing hole cap and O-
ring.
O-RING
Read the Connect a timing light to the spark plug wire.

instructions for
Start the engine, let it idle and check the ignition timing.
timing light
operation.
TIMING LIGHT
The ignition timing is correct if the "F" mark on the INDEX NOTCH
flywheel aligns with the index notch on the left
crankcase cover.
"F" MARK
timing hole cap. TIMING HOLE CAP
Install the timing hole cap and tighten it.

O-RING
16-7
IGNITION SYSTEM
IGNITION COIL
Remove the fuel tank (page 2-5). CONNECTOR
Disconnect the ignition coil primary wire connector.
Remove the plug cap from the spark plug and release
the plug wire from the wire holder and the clamp.
HOLDER
PLUG CAP
Remove the two bolts, ground terminal and ignition coil.

Route the spark Installation is in the reverse order of removal. BOLTS
plug wire properly
(page 1-16).
IGNITION COIL GROUND TERMINAL
ICM (IGNITION CONTROL MODULE)

ICM 4P CONNECTOR
Release the ICM from the stays of the frame.
Disconnect the ICM 4P connector and remove the ICM.
STAYS
16-8
IGNITION SYSTEM
POWER/GROUND LINE INSPECTION
Remove the ICM (page 16-8).
4P CONNECTOR
Turn the ignition switch "ON".
Measure the voltage between the ICM 4P connector of
the wire harness side.
CONNECTION: Red/Black (+) – Green (–)
There should be battery voltage with the ignition switch
"ON".
If there is no voltage with the ignition switch "ON",
check the following:
– Wire harness between the battery and ICM
– Ignition switch
– Main fuse 20 A
Turn the ignition switch "OFF".
Disconnect the ICM 4P connector.
Check for continuity between the ICM 4P connector of
the wire harness side.
CONNECTION: Green – Body ground
There should be continuity at all time.
If there is no continuity, check the open circuit in green
wire.
16-9
MEMO
17. ELECTRIC STARTER
COMPONENT LOCATION ··························· 17-2 STARTER MOTOR········································17-6
SYSTEM DIAGRAM ····································· 17-2 STARTER RELAY·······································17-12
SERVICE INFORMATION ···························· 17-3 NEUTRAL DIODE ·······································17-14
TROUBLESHOOTING·································· 17-4
17
17-1
ELECTRIC STARTER
COMPONENT LOCATION
ELECTRIC STARTER
STARTER SWITCH
CLUTCH SWITCH
STARTER RELAY SWITCH

BATTERY
IGNITION SWITCH
MAIN FUSE (20 A)
DIODE
GEAR POSITION SWITCH
STARTER MOTOR SUB FUSE (15 A)
SYSTEM DIAGRAM
R
STARTER
RELAY
SWITCH
BATTERY
G/R Y/R
R R/W R/Bl
MAIN FUSE IGNITION
20 A SWITCH
Y/R Bl R/Bl
STARTER SWITCH SUB FUSE 15 A
STARTER
MOTOR
2 3
Lg/R
1 4
G/R
Bl: Black
G: Green DIODE Lg/R 5
Lg: Light green N GEAR
R: Red POSITION
Y: Yellow G/R G SWITCH
W: White
CLUTCH SWITCH
17-2
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.
• Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting (page 17-4).
• A weak battery may be unable to turn the starter motor quick enough, or supply adequate ignition current.
• Starter clutch servicing (page 10-6)
• Ignition switch servicing (page 18-9)
• Starter switch inspection (page 18-11)
• Clutch switch inspection (page 18-12)
• Gear position switch servicing (page 18-13)
SPECIFICATIONS
Unit: mm (in)
Starter motor brush length 10.00 – 10.05 (0.394 –0.396) 3.5 (0.14)
TORQUE VALUE
Starter motor case bolt 4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
17-3
ELECTRIC STARTER
TROUBLESHOOTING
NOTE:
• The starter motor should operate when the transmission is in neutral or when the clutch lever is squeezed.
Starter motor does not turn
1. Fuse Inspection
Check for blown main fuse (20 A) or sub-fuse (15 A).
Is the fuse blown?
YES – Replace the fuse.
2. Battery Inspection
Make sure the battery is fully charged and in good condition.
Is the battery in good condition?
NO – Charge or replace the battery (page 15-5).
3. Battery Cable Inspection
Check the battery cables for loose or poorly connected terminal, and for an open circuit.
Is the battery cable in good condition?
NO – • Loose or poorly connected battery cables.
• Open circuit in the battery cable.
4. Starter Motor Cable Inspection
Check the starter motor cable for loose or poorly connected terminal, and for an open circuit.
Is the starter motor cable in good condition?
NO – • Loose or poorly connected starter motor cable.
• Open circuit in the starter motor cable.
5. Starter Relay Switch Operation Inspection
Check the operation of the starter relay switch (page 17-12).
Does the starter relay switch click?
6. Starter Motor Inspection
Connect the starter motor terminal to the battery positive (+) terminal directly. (A large amount of current
flows, so do not use a thin wire.)
Does the starter motor turn?
YES – Faulty starter relay switch.
NO – Faulty starter motor.
7. Relay Coil Ground Line Inspection
Check the ground line of the starter relay switch (page 17-12).
Is the ground line normal?
NO – • Faulty neutral diode (page 17-14).
• Faulty gear position switch (page 18-13).
• Faulty clutch switch (page 18-12).
• Loose or poor contact of the related connector terminal.
• Open circuit in the wire harness.
17-4
ELECTRIC STARTER
8. Relay Coil Power Input Line Inspection
Check the power input line of the starter relay switch (page 17-12).
Is the power input line normal?
NO – • Faulty ignition switch (page 18-9).
• Faulty starter switch (page 18-11).
• Loose or poor contact of the related connector terminal.
• Open circuit in the wire harness.
9. Starter Relay Switch Inspection
Check the function of the starter relay switch (page 17-13).
Does the starter relay switch function properly?
NO – Faulty starter relay switch.
YES – Loose or poor contact of the starter relay switch connector.
Starter motor turns, but the engine turns slowly

• Low battery voltage
• Poorly connected battery cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected ground cable terminal
Starter motor turns, but engine does not turn

• Faulty starter clutch
• Damaged or faulty starter gear train
Starter relay switch clicks, but engine does not turn

• Crankshaft does not turn due to engine problems
17-5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
Disconnect the negative (–) cable from the battery MOTOR CABLE RUBBER CAP
(page 15-5).
Slide the rubber cap off the starter motor terminal, and NUT
remove the starter motor terminal nut and starter motor
cable.
(–) CABLE
Remove the mounting bolts, battery (–) cable and
starter motor from the crankcase.
BOLTS STARTER MOTOR

Remove the O-ring from the starter motor.
O-RING
DISASSEMBLY/INSPECTION
– motor case bolts
– O-rings
– setting plates
BOLTS, SETTING PLATES, O-RING

If the shims are – front cover
SHIM FRONT COVER
installed, record the – seal ring
location and – shim(s)
number of them.
SEAL RING
17-6
ELECTRIC STARTER
– rear cover
SEAL RING
– seal ring
– armature
ARMATURE REAR COVER

Check the oil seal and bushing in the front cover for
deterioration, wear or damage. BUSHING
OIL SEAL
Do not use emery Check the commutator bars of the armature for COMMUTATOR BARS
or sand paper on discoloration.
the commutator.
Check for continuity between pairs of commutator bars. CONTINUITY:

There should be continuity.
17-7
ELECTRIC STARTER
Check for continuity between each commutator bar and NO CONTINUITY:
the armature shaft.
Check for continuity between the insulated brush and CONTINUITY:

cable terminal.
Check for continuity between the insulated brush and

NO CONTINUITY:
rear cover as shown.
Remove the brushes from the brush holder.
Measure the brush length.

Remove the brush holder.
BRUSH HOLDER
17-8
ELECTRIC STARTER
CABLE TERMINAL INSULATOR PLATE
– nut
– insulators
– O-ring
– cable terminal
– Insulator plate
NUT
O-RING INSULATORS
Check the bushing in the rear cover for wear or BUSHING
damage.
ASSEMBLY
INSULATOR PLATE NUT INSULATORS
CABLE TERMINAL
O-RING
BRUSH HOLDER REAR COVER
ARMATURE
SHIM(S)
SEAL RING
MOTOR CASE
SETTING PLATES
SEAL RING
O-RINGS FRONT COVER

MOTOR CASE BOLTS
4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
17-9
ELECTRIC STARTER
CABLE TERMINAL INSULATOR PLATE
– Insulator plate
– cable terminal
– new O-ring
– insulators
– nut
NUT
O-RING INSULATORS
Install the brush holder into the rear cover by aligning BRUSH HOLDER
Align
the cutouts with the insulator plate.
Install the brushes into the brush holder.
BRUSHES REAR COVER
Install the armature into the rear cover while pushing

the brushes into the brush holder. ARMATURE
REAR COVER
Install a new seal ring onto the motor case.

SEAL RING
While holding the armature tightly to prevent the
magnet of the motor case from pulling the armature
against it, install the motor case over the armature and
into the rear cover.
The coil may be damaged if the magnet pulls the

armature and hits the case.
MOTOR CASE
17-10
ELECTRIC STARTER
Install the same number of shims in the same locations
SHIM FRONT COVER
as noted during disassembly if they are installed.
Install a new seal ring onto the motor case.
Install the front cover.
SEAL RING
Align the index lines on the motor case, rear cover and
front cover.
Align
Install the motor case bolts with the setting plates and
SETTING PLATES
new O-rings and tighten them to the specified torque. O-RINGS
CASE BOLTS
INSTALLATION
Coat a new O-ring with clean engine oil and install it into
the starter motor groove.
O-RING
17-11
ELECTRIC STARTER
Install the starter motor into the left crankcase cover MOTOR CABLE RUBBER CAP
and onto the crankcase.
Route the wire Install the mounting bolts with the battery (–) cable, and NUT
harness properly tighten the bolts.
(page 1-16).
Install the starter motor cable and terminal nut onto the (–) CABLE
motor terminal and tighten the nut as specified.
Install the rubber cap over the motor terminal properly.
Connect the negative (–) cable to the battery (page 15-
5).
BOLTS STARTER MOTOR

BATTERY
NEGATIVE
(–) CABLE
45º
STARTER
MOTOR
CABLE
STARTER RELAY
OPERATION INSPECTION
STARTER RELAY SWITCH
Turn the ignition switch to ON and push the starter
switch.
The coil is normal if the starter relay switch clicks.
If you don't hear the switch click, inspect the relay
switch circuits (page 17-12).
CIRCUIT INSPECTION
2P CONNECTOR
Disconnect the starter relay switch 2P (Black)
connector, and check it for loose contact or corroded
terminals.
GROUND LINE
Check for continuity between the Green/red wire
terminal of the wire harness side connector and ground.
If there is continuity when the transmission is in neutral
or when the clutch lever is squeezed, the ground line is
normal.
17-12
ELECTRIC STARTER
POWER INPUT LINE
Measure the voltage between the Yellow/red wire
terminal (+) of the wire harness side connector and
ground (–).
If the battery voltage appears only when the starter
switch is pushed, the power input line is normal.
FUNCTION INSPECTION
Remove the starter relay switch (page 17-13).
Connect an ohmmeter to the starter relay switch cable STARTER RELAY
terminals. SWITCH
Connect the fully charged 12 V battery to the 2P black
connector terminals.
CONNECTIONS: Battery (+) terminal – Yellow/red
Battery (–) terminal – Green/red
There should be continuity between the cable terminals
while the battery is connected, and no continuity when
the battery is disconnected.
Install the starter relay switch (page 17-13).
BATTERY
STAYS
Disconnect the negative (–) cable from the battery
(page 15-5).
Disconnect the starter relay switch 2P (Black)
connector.
Release the starter relay switch from the stays of the
frame.
2P CONNECTOR
Remove the rubber covers from the starter relay switch.

STARTER RELAY SWITCH NUTS
Remove the nuts, battery cable, starter motor cable and
starter relay switch.
Route the wire Installation is in the reverse order of removal.
harness properly
(page 1-16).
CABLES COVERS
17-13
ELECTRIC STARTER
NEUTRAL DIODE
INSPECTION
NEUTRAL DIODE
Remove the neutral diode from the wire harness.
Check for continuity between the diode terminals.

When there is continuity, a small resistance value will
register.
If there is continuity in one direction, the neutral diode is
normal. A B
Install the neutral diode in the reverse order of removal. A
NEUTRAL DIODE
17-14
18. LIGHTS/METERS/SWITCHES
COMPONENT LOCATION ··························· 18-2 HANDLEBAR SWITCH ·······························18-10
SERVICE INFORMATION ···························· 18-3 CLUTCH SWITCH ·······································18-12
HEADLIGHT ················································· 18-4 BRAKE LIGHT SWITCH ·····························18-12
BRAKE/TAILLIGHT······································ 18-5 GEAR POSITION SWITCH ·························18-13
TURN SIGNAL LIGHT·································· 18-5 FUEL GAUGE/FUEL LEVEL SENSOR ······18-15
SPEEDOMETER··········································· 18-6 HORN ··························································18-17
TACHOMETER············································· 18-8 TURN SIGNAL RELAY ······························18-18
IGNITION SWITCH ······································· 18-9
18
18-1
COMPONENT LOCATION
DISC BRAKE TYPE SHOWN:
FRONT BRAKE LIGHT SWITCH
IGNITION SWITCH RIGHT HANDLEBAR

LEFT HANDLEBAR SWITCHES
SWITCHES
SPEEDOMETER
FUEL LEVEL SENSOR
TURN SIGNAL RELAY
CLUTCH SWITCH
HORN
REAR BRAKE LIGHT SWITCH
18-2
SERVICE INFORMATION
GENERAL
• Be sure to install the dust cover after replacing the bulb.
• Check the battery condition before performing any inspection that requires proper battery voltage.
• A continuity test can be made with the switches installed on the motorcycle.
• The following color codes are used throughout this section.
Bl: Black G: Green Lg: Light green R: Red

Bu: Blue Gr: Gray O: Orange W: White
Br: Brown Lb: Light blue P: Pink Y: Yellow
SPECIFICATIONS
ITEM SPECIFICATION
Bulbs Headlight (Hi/low beam) 12 V - 35/35 W
Position light 12 V - 3 W
Brake/tail light 12 V - 21/5 W
Turn signal light 12 V - 10 W x 4
Instrument light 12 V - 1.7 W x 3
Turn signal indicator 12 V - 1.7 W x 2
High beam indicator 12 V - 1.7 W
Gear position indicator LED x 5
Neutral indicator 12 V - 1.7 W
Fuse Main 20 A
Sub 15 A
Fuel level sensor resistance Full 4 – 10 Ω
(20°C/68°F) Empty 90 – 108 Ω
TORQUE VALUES
Fuel level sensor mounting nut 10 N·m (1.0 kgf·m, 7 lbf·ft)
Ignition switch mounting bolt 24 N·m (2.4 kgf·m, 18 lbf·ft) ALOC bolt: replace with a new one.
TOOLS
Peak voltage adaptor
07HGJ-0020100
18-3
HEADLIGHT
Remove the headlight case (page 2-3).
Disconnect the headlight wire connectors (Blue, White, HEADLIGHT STAY
Green, Brown). Align
Remove the two bolts and headlight from the headlight HEADLIGHT
stay.
Install the headlight by aligning the tabs and slots of the
headlight stay.
Install the two bolts and tighten it.
Route the wire Connect the headlight wire connectors (Blue, White,
harness properly Green, Brown).
(page 1-16).
Install the headlight case (page 2-3).
Check the headlight aim (page 3-21)
WIRE CONNECTORS BOLTS
HEADLIGHT BULB REPLACEMENT

RETAINER
Remove the dust cover.
Unhook the retainer and remove the bulb socket.
DUST COVER SOCKET
Push the bulb in, turn it counterclockwise and remove it.

SOCKET
If you touch the bulb with your bare hands, clean it with
cloth moistened with alcohol to prevent early bulb
failure.
Install the new bulb in the reverse order of removal.
BULB
18-4
POSITION LIGHT BULB
REPLACEMENT
Pull the position light bulb socket out of the headlight.
Pull the bulb out of the socket and replace it with a new
one.
Install the bulb socket into the headlight securely.
Install the headlight case (page 2-3).
SOCKET BULB
BRAKE/TAILLIGHT
BULB REPLACEMENT
Remove the seat (page 2-4).
Turn the bulb socket clockwise and remove it.
Push the bulb in, turn it counterclockwise and remove it
from the bulb socket.
Install the new bulb in the reverse order of removal.
BULB
SOCKET
TURN SIGNAL LIGHT

BULB REPLACEMENT
Remove the screw and turn signal light lens.
SCREW LENS
Push the bulb in, turn it counterclockwise and remove it
from the turn signal light unit.
Replace the bulb with a new one.
removal.
BULB
18-5
SPEEDOMETER
POWER/GROUND LINE INSPECTION
Remove the headlight (page 18-4).
Disconnect the speedometer 3P connector of the
speedometer wire harness.
Turn the ignition switch to " " and measure the voltage
between the main wire harness side connector terminal.
CONNECTION: Black (+) – Green (–)
There should be battery voltage.
Turn the ignition switch to " ".
Check for continuity between the wire harness side
connector terminal and ground.
CONNECTION: Green – Body ground
3P CONNECTOR
CONNECTORS
Disconnect the following connectors:
– 6P connector
– 3P connector
– Brown wire connector
– Light blue wire connector
– Orange wire connector
– Yellow/green wire connector
Disconnect the speedometer cable.

Remove the two nuts, washers and speedometer.
Route the wire Install the speedometer in the reverse order of removal.
harness properly
(page 1-16).
NUTS/ SPEEDOMETER
SPEEDOMETER WASHER CABLE
18-6
DISASSEMBLY/ASSEMBLY
– two screw and lower cover
– screw, O-ring and knob
– screws and speedometer sub harness
– screws and meter case
– screws/washers, fuel meter, speedometer and
tachometer
Assembly is in the reverse order of disassembly.
TACHOMETER
UPPER CASE
SPEEDOMETER
FUEL METER SPEEDOMETER

SUB HARNESS
O-RING
KNOB
METER CASE
SCREWS LOWER COVER

PLUG
Br, G Y/G Bl Y/W
G Br, G
SCREWS/WASHERS
Bl
SB, G O, G
GEAR POSITION Br, G Lg, Bl
Bu, G
INDICATER
18-7
BULB REPLACEMENT
Remove the speedometer lower cover (page 18-7).
SOCKET
Pull the bulb socket out of the speedometer case.
Pull the bulb out of the socket and replace it with a new
one.
removal.
BULB
TACHOMETER
INSPECTION
Check that the speedometer power/ground lines are
normal (page 18-6). DIGITAL MULTIMETER
Connect the peak voltage adaptor to the digital

multimeter, or use the Imrie diagnostic tester.
TOOL:
(impedance 10 MW/DCV minimum)
• Use a commercially available digital multimeter with

an impedance of 10 MΩ/DCV minimum. PEAK VOLTAGE ADAPTOR
• The display value differs depending upon the
internal impedance of the multimeter.
• If using the Imrie diagnostic tester (model 625),
follow the manufacturer’s instructions.
Connect the peak voltage adaptor or Imrie diagnostic
GREEN
tester probes to the wire harness side connector
terminals.
CONNECTION: Yellow/green (+) – Green (–)
Start the engine and measure the peak voltage.
PEAK VOLTAGE: 100 V minimum
– If the measured value is normal, check the Black,
Green and Yellow/green wires in the meter harness
for open circuit.
If the meter harness is normal, replace the
tachometer (page 18-6). WIRE CONNECTOR
– If the value is 0 V, check the Yellow/green wire for (YELLOW/GREEN)
continuity between the speedometer and ICM.
18-8
IGNITION SWITCH
INSPECTION
Disconnect the ignition switch 2P connector.
Check for continuity between the ignition switch side
connector terminals in each switch position.
Continuity should exist between the color coded wires as follows:
2P CONNECTER
IGNITION SWITCH
BAT 1 BAT 2
COLOR R/Bl R/W
IGNITION SWITCH
BOLTS IGNITION SWITCH
– headlight case (page 2-3)
– handlebar cover (page 12-9)
Disconnect the ignition switch 2P connector.
Remove the two bolts and pull the speedometer
forward.
Remove the two ignition switch mounting bolts and
ignition switch from the top bridge.
harness properly
(page 1-16)
Replace the TORQUE:
mounting bolts with IGNITION SWITCH MOUNTING BOLT:
new ones. 4.2 N·m (0.43 kgf·m, 3.1 lbf·ft)
MOUNTING BOLTS 2P CONNECTOR
18-9
HANDLEBAR SWITCH
LEFT HANDLEBAR SWITCH
INSPECTION
Disconnect the left handlebar switch 3P connector, and
Light blue, Orange, Black and Blue/white wire
connectors.
CONNECTORS
Check for continuity between the wire terminals of the

switch side connectors in each switch position.
Continuity should exist between the color coded wire terminals as follows:
PASSING SWITCH DIMMER SWITCH
TURN SIGNAL
LIGHT SWITCH HORN SWITCH
PASSING SWITCH DIMMER SWITCH
BAT H1 HL HI LO
FREE
PUSH (N)
COLOR Bl Bu
COLOR Bu/W Bu W
HORN SWITCH TURN SIGNAL LIGHT SWITCH
BAT HO R WR L
FREE
PUSH N
COLOR Bl Lg
COLOR Lb Gr O
18-10
RIGHT HANDLEBAR SWITCH
INSPECTION
RIGHT HANDLEBAR
Disconnect the right handlebar switch 2P connector, SWITCH 2P CONNECTOR
and Brown and Blue/white wire connectors.
WIRE CONNECTORS WIRE CONNECTORS

(BLUE/WHITE) (BROWN)
Check for continuity between the wire terminals of the
LIGHTING SWITCH
switch side connectors in each switch position.
Continuity should exist between the color coded wire
terminals as follows:
STARTER SWITCH
STARTER SWITCH
ST BAT
FREE
PUSH
COLOR Y/R Bl
LIGHTING SWITCH
BAT TL HL
COLOR Bl Br Bl/W
18-11
CLUTCH SWITCH
INSPECTION
Disconnect the clutch switch connectors and check for
continuity between the switch terminals.
There should be continuity with the clutch lever
squeezed and no continuity with the lever released.
BRAKE LIGHT SWITCH

FRONT
DRUM BRAKE TYPE (Type 1, 3, 4, 6)
Disconnect the front brake light switch (Green/Yellow
and Black) wire connectors and check for continuity
between the switch side connectors.
There should be continuity with the front brake lever
WIRE
CONNECTORS
BRAKE LEVER
DISC BRAKE TYPE (Type 2, 5)

Disconnect the front brake light switch connectors and
check for continuity between the switch terminals.
There should be continuity with the front brake lever
FRONT BRAKE LIGHT SWITCH
18-12
REAR
2P CONNECTOR
Disconnect the rear brake light switch 2P connector and
check for continuity between the switch side connector
terminals.
There should be continuity with the rear brake pedal
depressed and no continuity with the pedal released.

INSPECTION
Turn the ignition switch "ON", and shift the transmission
GEAR POSITION INDICATORS
into each gear position.
Check the operation of gear position and neutral
indicator lights at each gear position.
If all the indicator bulbs are normal but the gear position
indicator does not light, check as follows:
NEUTRAL INDICATOR

6P CONNECTOR
Disconnect the gear position switch 6P connector.
Check for continuity at the switch side connector
terminals.
There should be continuity in each gear position as
follows:
Gear position Connection
Neutral Light green/red – ground
1st Light green/pink – ground
2nd Light green/brown – ground
3rd Light green/green – ground
4th Light green/yellow – ground
5th Light green/black – ground
18-13
REMOVAL
6P CONNECTOR GEAR POSITION
SWITCH WIRE
– left side cover (page 2-4)
Disconnect the gear position switch 6P connector and
release the gear position switch wire from the clamp.
CLAMP
Remove the gear position switch wire from the left

crankcase cover.
Remove the upper side bolt and gear position switch
from the collar.
Remove the O-ring from the gear position switch.
O-RING BOLT
GEAR POSITION
SWITCH
Remove the bolt and collar from the left crankcase.
Remove the O-ring from the collar. COLLAR O-RING
BOLT
INSTALLATION
collar groove. COLLAR
Install the collar to the left crankcase.
O-RING
18-14
gear position switch groove. SLOT SPRING PIN
Install the gear position switch by aligning the spring pin
with the slot in the shift drum.
GEAR POSITION
SWITCH O-RING

Route the wire Route the gear position switch wire into the left
harness properly crankcase cover as shown.
(page 1-16).
BOLTS
GEAR POSITION
SWITCH
Route the wire Secure the gear position switch wire with the clamp and
harness properly connect the gear position switch 6P connector. 6P CONNECTOR GEAR POSITION
(page 1-16). SWITCH WIRE
– left side cover (page 2-4)
(page 3-11).
CLAMP
FUEL GAUGE/FUEL LEVEL SENSOR

SYSTEM INSPECTION
Check that the speedometer power/ground lines are
normal (page 18-6).
FUEL LEVEL SENSOR

2P CONNECTOR
18-15
With the fuel level sensor 2P connector disconnected, FUEL GAUGE
turn the ignition switch to " " and check the fuel gauge.
The gauge needle should move to "E".
Turn the ignition switch to " " and connect the wire
harness side connector terminals with a jumper wire.
Turn the ignition switch to " " and check the fuel
gauge.
The gauge needle should move to "F".
• If the fuel gauge needle moves properly, check the
fuel level sensor (page 18-16).
• If the fuel gauge needle does not move properly,
check the Yellow/white wire in the wire harness, and
Black, Green and Yellow/white wire in the meter
harness.
If the wires are normal, replace the fuel gauge (page
18-6).
FUEL LEVEL SENSOR REMOVAL
NUTS
Remove the four nuts.
Be careful not to Remove the rubber gasket and fuel level sensor.
FUEL LEVEL SENSOR
damage the float
arm.
RUBBER
GASKET
FUEL LEVEL SENSOR INSTALLATION
Coat a new rubber gasket with engine oil and install it
FUEL LEVEL SENSOR
onto the fuel tank.
Be careful not to Install the fuel level sensor.
damage the float
arm.
RUBBER
GASKET
18-16
Install the four nuts and tighten them.
NUTS
Install the fuel tank (page 2-5).
FUEL LEVEL SENSOR INSPECTION

Remove the fuel level sensor (page 18-16).
Measure the resistance between the fuel level sensor
connector terminals in each float position. FULL
FLOAT POSITION FULL EMPTY
Resistance (20°C/68°F) 4 – 10 Ω 90 – 108 Ω
Install the fuel sensor (page 18-16).
EMPTY
HORN
LEFT SIDE
Disconnect the wire connectors from the horn.
Remove the bolt and horn. CONNECTORS

harness properly
(page 1-16)
BOLT
HORN
18-17
RIGHT SIDE
Disconnect the wire connectors from the horn.
Remove the bolt and horn. BOLT
Route the wire Install the horn and tighten the bolt.
harness properly Connect the wire connectors with their drain holes
(page 1-16) facing down.
HORN CONNECTORS
DRAIN HOLES CONNECTORS
INSPECTION
The inspect Disconnect the wire connectors from the horn.
procedure is same LEFT SIDE SHOWN:
Connect the fully charged 12 V battery to the horn
for both sides.
terminals.
The horn is normal if it sounds when the 12 V battery is
connected across the horn terminals.
TURN SIGNAL RELAY

SYSTEM INSPECTION
Remove the left side cover (page 2-4). TURN SIGNAL RELAY
Disconnect the 2P connector from the turn signal relay
and connect the 2P connector terminals with a jumper
wire.
Turn the ignition switch to " " and operate the turn
signal light switch.
• If the turn signal lights come on, replace the turn
signal relay with a new one.
• If the turn signal lights do not come on, check the
following:
– turn signal light bulb
– turn signal light switch (page 18-10)
– wire harness for open circuit
2P CONNECTOR
18-18
19. WIRING DIAGRAM
TYPE 1, 3, 4, 6·············································· 19-2 TYPE 2, 5·······················································19-3
19
19-1
STARTER. FRONT BRAKE REAR BRAKE STARTER RELAY
LIGHTING IGNITION LIGHT SWITCH LIGHT SWITCH REGULATOR/ TURN SIGNAL
19-2
SWITCH SWITCH RECTIFIER RELAY
R
BATTERY
BAT
TL
HL
ST
BAT1
BAT2
12V 7AH
SUB MAIN
FUSE 6P 2P FUSE
15A Bl 20A
Y
Y
Y
Bl
Bl
Bl
Bl
Bl
Br
Gr
Y/R
Y/R
G/Y
G/Y
G/R
R/Bl
R/Bl
R/W
R/W
R/W
STARTER
Bu/W
MOTOR
MINI
MINI 2P MINI Bl 2P
RIGHT FRONT TURN GROUND
Bl Lb
WIRING DIAGRAM
SIGNAL LIGHT (ENGINE)
2P
Bl
G G
Y/R
G/Y
G/R
R/W
(12V10W)
WIRING DIAGRAM
Bu/W
TYPE 1, 3, 4, 6
Bl MINI
FUEL METER Y/W Y/R Y/R
2P
G Bl Bl
RIGHT REAR TURN
Bu/W
Bl SIGNAL LIGHT
TACHOMETER Y/G Y/G Y/G (12V10W)
G MINI
R/Bl R/Bl Lb Bl
2P
2P
R/W R/W G G
Br
G
G/Y G/Y
METER LIGHT Br Bl
Bl
(12V1.7Wx3) G Bl G
G/Y G/Y
Br
G G
G Br G/Y G/Y
Br
Br Br Br Br Br Br
Lg/Bl G G
Lg/Y Bl Bl BRAKE/TAILLIGHT
GEAR POSITION (12V21/5W)
3P MINI
Lg/G Y/W Y/W
INDICATOR Lg/Br
Lg/P
Bl
Lb Lb G G
2P
Lg/Bl Lg/Bl O O O Bl
HIGH BEAM INDICATOR Bu Lg/Y Lg/Y MINI
(12V1.7W) G Lg/G Lg/G Bl LEFT REAR TURN
Lg/Br Lg/Br SIGNAL LIGHT
6P MINI
Lg/P Lg/P (12V10W)
RIGHT TURN Lb Lg/R Lg/R
SIGNAL INDICATOR G
(12V1.7W)
NEUTRAL INDICATOR Bl Lb Lb Bl/Y Bl/Y

(12V1.7W) Lg/R Lb
G
O O
LEFT TURN O
O
SIGNAL INDICATOR G IGNITION COIL
(12V1.7W)
SPARK
PLUG
G G
Bu Bu
HEADLIGHT Bu Lg Lg
(12V35/35W) W W Gr Gr
3P MINI
G/R G/R
Bl
G
G
G
POSITION LIGHT
Y
Y
Y
G
G
Br Br
Y/W
Lg/P
Lg/R
Lg/Y
Bu/Y
Lg/G
Lg/Bl
Lg/Br
(12V3W)
2P MINI 3P 6P MINI
LEFT FRONT TURN 2P MINI
Bl O
2P
SIGNAL LIGHT G G
(12V10W)
Y
Y
Y
O
G
G
G
G
G
G
Bl
W
Lb
Lg
Gr
Lg
Lg
Bu
G/R
G/R
MINI
R/Bl
Bl/Y
Y/W
Lg/P
Lg/R
Lg/R
Lg/Y
Bu/Y
Lg/G
Bu/Y
Lg/Bl
Lg/Br
Bu/W
Bl
T2P 4P
L
R
1 2 3 4
HI
HL
LO
HO
WR
BAT
N 5
DIODE
TURN SIGNAL. PASSING. CLUTCH IGNITION
DIMMER. HORN SWITCH SWITCH HORN HORN FUEL LEVEL IGNITION CONTROL
SENSOR PULSE MODULE
GENERATOR
ALTERNATOR
GEAR POSITION
SWITCH
Bl BLACK Br BROWN
Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE
G GREEN Lg LIGHT GREEN
R RED P PINK
IGNITION SWITCH STARTER SWITCH LIGHTING SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH PASSING SWITCH W WHITE Gr GRAY
BAT1 BAT2 ST BAT BAT TL HL HL HI LO R WR L BAT HO BAT H1 COLOR COMB : GROUND/MARKING
FREE FREE FREE
PUSH (N) N PUSH PUSH
COLOR R/W R/Bl COLOR Y/R Bl COLOR Bl Lg COLOR Bl Bu
COLOR Bl Br Bu/W COLOR Bu/W Bu W COLOR Lb Gr O
STARTER. FRONT BRAKE REAR BRAKE STARTER RELAY
LIGHTING IGNITION LIGHT SWITCH LIGHT SWITCH REGULATOR/ TURN SIGNAL
SWITCH SWITCH RECTIFIER RELAY
R
BATTERY
BAT
TL
HL
ST
BAT1
BAT2
12V 7AH
SUB MAIN
FUSE 6P 2P FUSE
15A Bl 20A
TYPE 2, 5
Y
Y
Y
Bl
Bl
Bl
Bl
Bl
Br
Gr
Y/R
Y/R
G/Y
G/Y
G/R
R/Bl
R/Bl
R/W
R/W
R/W
STARTER
Bu/W
MOTOR
MINI
MINI 2P MINI Bl 2P
RIGHT FRONT TURN GROUND
SIGNAL LIGHT Bl Lb (ENGINE)
2P
Bl
G G
Y/R
G/Y
G/R
R/W
(12V10W)
Bu/W
Bl MINI
FUEL METER Y/W Y/R Y/R
2P
G Bl Bl
RIGHT REAR TURN
Bu/W
Bl SIGNAL LIGHT
TACHOMETER Y/G Y/G Y/G (12V10W)
G MINI
R/Bl R/Bl Lb Bl
2P
2P
R/W R/W G G
Br
G
G/Y G/Y
METER LIGHT Br Bl
Bl
(12V1.7Wx3) G Bl G
G/Y G/Y
Br
G G
G Br G/Y G/Y
Br
Br Br Br Br Br Br
Lg/Bl G G
Lg/Y Bl Bl BRAKE/TAILLIGHT
GEAR POSITION (12V21/5W)
3P MINI
Lg/G Y/W Y/W
INDICATOR Lg/Br
Lg/P
Bl
Lb Lb G G
2P
Lg/Bl Lg/Bl O O O Bl
HIGH BEAM INDICATOR Bu Lg/Y Lg/Y MINI
(12V1.7W) G Lg/G Lg/G Bl LEFT REAR TURN
Lg/Br Lg/Br SIGNAL LIGHT
6P MINI
Lg/P Lg/P (12V10W)
RIGHT TURN Lb Lg/R Lg/R
SIGNAL INDICATOR G
(12V1.7W)
NEUTRAL INDICATOR Bl Lb Lb Bl/Y Bl/Y

(12V1.7W) Lg/R Lb
G
O O
LEFT TURN O
O
SIGNAL INDICATOR G IGNITION COIL
(12V1.7W)
SPARK
PLUG
G G
Bu Bu
HEADLIGHT Bu Lg Lg
(12V35/35W) W W Gr Gr
3P MINI
G/R G/R
Bl
G
G
G
POSITION LIGHT
Y
Y
Y
G
G
Br Br
Y/W
Lg/P
Lg/R
Lg/Y
Bu/Y
Lg/G
Lg/Bl
Lg/Br
(12V3W)
2P MINI 3P 6P MINI
LEFT FRONT TURN 2P MINI
Bl O
2P
SIGNAL LIGHT G G
(12V10W)
Y
Y
Y
O
G
G
G
G
G
G
Bl
W
Lb
Lg
Gr
Lg
Lg
Bu
G/R
G/R
MINI
R/Bl
Bl/Y
Y/W
Lg/P
Lg/R
Lg/R
Lg/Y
Bu/Y
Lg/G
Bu/Y
Lg/Bl
Lg/Br
Bu/W
Bl
T2P 4P
L
R
1 2 3 4
HI
HL
LO
HO
WR
BAT
N 5
DIODE
TURN SIGNAL. PASSING. CLUTCH IGNITION
DIMMER. HORN SWITCH SWITCH HORN HORN FUEL LEVEL IGNITION CONTROL
SENSOR PULSE MODULE
GENERATOR
ALTERNATOR
GEAR POSITION
SWITCH
Bl BLACK Br BROWN
Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE
G GREEN Lg LIGHT GREEN
R RED P PINK
IGNITION SWITCH STARTER SWITCH LIGHTING SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH PASSING SWITCH W WHITE Gr GRAY
BAT1 BAT2 ST BAT BAT TL HL HL HI LO R WR L BAT HO BAT H1 COLOR COMB : GROUND/MARKING
FREE FREE FREE
PUSH (N) N PUSH PUSH
COLOR R/W R/Bl COLOR Y/R Bl COLOR Bl Lg COLOR Bl Bu
COLOR Bl Br Bu/W COLOR Bu/W Bu W COLOR Lb Gr O
19-3
WIRING DIAGRAM
MEMO
20. TROUBLESHOOTING
ENGINE DOES NOT START OR POOR PERFORMANCE AT

IS HARD TO START ···································· 20-2 HIGH SPEED·················································20-6
ENGINE LACKS POWER ···························· 20-3 POOR HANDLING ········································20-6
POOR PERFORMANCE AT
LOW AND IDLE SPEED······························· 20-5
20
20-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
TROUBLESHOOTING
1. Fuel Line Inspection

Check fuel flow to the carburetor.
Does fuel reach the carburetor?
NO – • Clogged fuel hose or fuel strainer
• Clogged fuel valve
• Clogged fuel tank breather
2. Spark Plug Inspection
Remove and inspect the spark plug.
Is the spark plug wet?
YES – • Flooded carburetor
• Throttle valve open
• Dirty air cleaner
• Improper choke operation
3. Spark Test
Perform spark test.
Is there weak or no spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Broken or shorted spark plug wire
• Broken or shorted ignition coil
• Faulty Ignition pulse generator
• Faulty ICM
4. Engine Starting Condition
Start engine by following normal procedure.
Does the engine start then stops?
YES – • Improper choke operation
• Incorrectly adjusted carburetor
• Leaking carburetor insulator
• Improper ignition timing (Faulty ICM or ignition pulse generator)
• Contaminated fuel
5. Cylinder Compression
Test cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
20-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspection
Raise the rear wheel off the ground and spin it by hand.
Does the wheel spin freely?
NO – • Brake dragging
• Worn or damaged wheel bearings
• Bent axle
• Drive chain too tight
2. Tire Pressure Inspection
Check tire pressure.
Is the tire pressure low?
YES – • Faulty tire valve
• Punctured tire
3. Clutch Inspection
Accelerate rapidly from low to second.
Does the engine speed change accordingly when the clutch is engaged?
NO – • Worn clutch discs
• Warped clutch plates
• Weak clutch spring
• Sticking clutch lifter
• Additive in engine oil
4. Engine Condition Inspection
Accelerate lightly.
Does the engine speed increase?
NO – • Fuel/air mixture too rich or lean
• Restricted fuel flow
• Clogged muffler
• Excessive carbon build-up in combustion chamber
5. Engine Knocking Inspection
Accelerate or run at high speed.
Is the engine knocking?
YES – • Worn piston and cylinder
• Use of poor quality fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advanced (Faulty ICM or ignition pulse generator)
• Lean fuel mixture
6. Ignition Timing Inspection
Check ignition timing.
Is the ignition timing correct?
NO – • Faulty ICM
• Faulty ignition pulse generator
20-3
TROUBLESHOOTING
7. Engine Oil Inspection
Check the oil level and condition.
Is the oil level correct and the oil in good condition?
NO – • Oil level too high
• Oil level too low
• Contaminated oil
8. Spark Plug Inspection
Remove and inspect the spark plug.
Is the spark plug fouled or discolored?
YES – • Plugs not serviced frequently enough
• Incorrect spark plug heat range
• Incorrect spark plug gap
9. Cylinder compression Inspection
Test the cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Improper valve timing
10. Carburetor Inspection
Check the carburetor for clogging.
Is the carburetor clogged?
YES – Carburetor not serviced frequently enough
11. Lubrication Inspection
Remove cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
NO – • Faulty oil pump
• Clogged oil passage
• Clogged oil strainer screen
20-4
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Pilot Screw Inspection
Check carburetor pilot screw adjustment.
Is the adjustment correct?
NO – See page 5-16.
2. Intake Air Leak Inspection
Check for leaking carburetor insulator.
Is the carburetor insulator manifold leaking?
YES – • Loose carburetor insulator bands
• Damaged insulator
• Deteriorated or damaged insulator O-ring
3. Spark Test
Perform spark test.
Is the spark weak or intermittent?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Broken or shorted spark plug wire
• Faulty ignition coil
• Faulty ICM
20-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1. Fuel Line Inspection
Disconnect fuel line at carburetor.
Does fuel flow freely?
NO – • Clogged fuel line
• Faulty fuel valve
• Clogged fuel strainer
2. Carburetor Inspection
Check carburetor for clogging.
Is the carburetor clogged?
YES – Carburetor not serviced frequently enough
4. Valve Timing Inspection
Check valve timing.
Is the valve timing correct?
NO – Cam sprocket not installed properly.
5. Valve Spring Inspection
Check valve springs.
Are the valve springs weak?
YES – Faulty valve spring.
POOR HANDLING
Steering is heavy
• Steering bearing adjustment nut too tight
• Damaged steering head bearings
Either wheel is wobbling
• Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Damaged swingarm pivot bushing
• Bent frame
Motorcycle pulls to one side
• Front and rear wheels not aligned
• Bent fork
• Bent swingarm
• Bent axle
• Bent frame
• Faulty shock absorber
20-6
INDEX
INDEX
A Few Words About Safety··············································· 0-1 FUEL GAUGE/FUEL LEVEL SENSOR ························ 18-15
A
AIR CLEANER·································································· 3-7 FUEL LINE········································································ 3-5

AIR CLEANER HOUSING ················································ 5-5 FUEL STRAINER···························································· 5-17
AIR INJECTION PIPE····················································· 5-19 FUEL STRAINER SCREEN·············································· 3-5
ALTERNATOR CHARGING COIL·································· 15-8 FUEL TANK ······································································ 2-5
BATTERY GEAR POSITION SWITCH ·········································· 18-13
B G
BATTERY/CHARGING SYSTEM ······························ 15-5 GEARSHIFT LINKAGE··················································· 9-15

MAINTENANS···························································· 3-16 HANDLEBAR ·································································· 12-7
H
BRAKE CALIPER ························································· 14-14 HANDLEBAR SWITCH················································· 18-10

BRAKE FLUID (DISC BRAKE) ······································· 3-17 HEADLIGHT ··································································· 18-4
BRAKE FLUID REPLACEMENT/AIR BLEEDING ·········· 14-5 HEADLIGHT AIM ···························································· 3-21
BRAKE LIGHT SWITCH HEADLIGHT BACK PLATE ·············································· 2-3
LIGHTS/METERS/SWITCHES ································ 18-12 HEADLIGHT CASE··························································· 2-3
MAINTENANS···························································· 3-21 HORN ··········································································· 18-17
BRAKE PAD/DISC·························································· 14-7 ICM (IGNITION CONTROL MODULE) ··························· 16-8
I
BRAKE PADS WEAR (DISC BRAKE)···························· 3-18 IGNITION COIL······························································· 16-8

BRAKE PEDAL/CENTERSTAND································· 13-16 IGNITION SWITCH························································· 18-9
BRAKE SHOE WEAR (DRUM BRAKE) ························· 3-17 IGNITION SYSTEM INSPECTION ································· 16-5
BRAKE SYSTEM···························································· 3-19 IGNITION TIMING ·························································· 16-7
BRAKE/TAILLIGHT ························································ 18-5 INSULATOR INSTALLATION········································· 5-13
CABLE & HARNESS ROUTING····································· 1-16 INSULATOR REMOVAL··················································· 5-8
C
CAM CHAIN TENSIONER LIFTER ································ 7-26 KICKSTARTER······························································· 9-21

K
CAMSHAFT ······································································ 7-8 KICKSTARTER IDLE GEAR··········································· 9-19

CAMSHAFT HOLDER ···················································· 7-13 LEFT CRANKCASE COVER INSTALLATION ············· 10-11
L
CARBURETOR ASSEMBLY ·········································· 5-11 LEFT CRANKCASE COVER REMOVAL ······················· 10-4
CARBURETOR DISASSEMBLY/INSPECTION ··············· 5-8 LUBRICATION & SEAL POINTS···································· 1-14
CARBURETOR INSTALLATION ···································· 5-14 LUBRICATION SYSTEM DIAGRAM ································ 4-2
CARBURETOR REMOVAL ·············································· 5-6 MAINTENANCE SCHEDULE ··········································· 3-4
M
CHARGING SYSTEM INSPECTION······························ 15-7 MASTER CYLINDER···················································· 14-10

CHOKE OPERATION······················································· 3-6 MODEL IDENTIFICATION················································ 1-2
CLUTCH ··········································································· 9-8 NEUTRAL DIODE························································· 17-14
N
CLUTCH LIFTER ARM····················································· 9-6 NUTS, BOLTS, FASTENERS········································· 3-24

CLUTCH SWITCH ························································ 18-12 OIL PUMP········································································· 4-4
O
CLUTCH SYSTEM ························································· 3-21 PILOT SCREW ADJUSTMENT ······································ 5-16

P
COMPONENT LOCATION PISTON/CYLINDER INSTALLATION······························· 8-8

BATTERY/CHARGING SYSTEM ······························ 15-2 PRIMARY DRIVE GEAR ················································ 9-18
ELECTRIC STARTER················································ 17-2 REAR CARRIER······························································· 2-6
R
IGNITION SYSTEM ··················································· 16-2 REAR COWL ···································································· 2-6

LIGHTS/METERS/SWITCHES ·································· 18-2 REAR DRUM BRAKE ··················································· 13-14
CRANKCASE ASSEMBLY ··········································· 11-17 REAR FENDER ································································ 2-7
CRANKCASE BEARING ·············································· 11-15 REAR WHEEL ································································ 13-7
CRANKCASE SEPARATION ········································· 11-6 REGULATOR/RECTIFIER·············································· 15-8
CRANKSHAFT ····························································· 11-14 RIGHT CRANKCASE COVER INSTALLATION ············· 9-18
CYLINDER COMPRESSION············································ 7-6 RIGHT CRANKCASE COVER REMOVAL ······················· 9-5
CYLINDER HEAD··························································· 7-17 SEAT················································································· 2-4
S
CYLINDER HEAD COVER REMOVAL ···························· 7-6 SECONDARY AIR SUPPLY SYSTEM
CYLINDER/PISTON REMOVAL······································· 8-4 FUEL SYSTEM ·························································· 5-17
DRIVE CHAIN································································· 3-14 MAINTENANCE ························································· 3-13
D
DRIVE SPROCKET COVER ············································ 2-8 SERVICE INFORMATION 21

EMISSION CONTROL SYSTEMS ································· 1-29 ALTERNATOR/STARTER CLUTCH ·························· 10-3
E
ENGINE & FRAME TORQUE VALUES ························· 1-10 BATTERY/CHARGING SYSTEM······························· 15-3
ENGINE IDLE SPEED···················································· 3-13 CLUTCH/GEARSHIFT LINKAGE································· 9-3
ENGINE INSTALLATION ················································· 6-6 CRANKCASE/CRANKSHAFT/TRANSMISSION ······· 11-3
ENGINE OIL ··································································· 3-10 CYLINDER HEAD/VALVES ········································· 7-3
ENGINE OIL CENTRIFUGAL FILTER ··························· 3-12 CYLINDER/PISTON ····················································· 8-3
ENGINE OIL STRAINER SCREEN ································ 3-11 ELECTRIC STARTER ················································ 17-3
ENGINE REMOVAL ························································· 6-4 ENGINE REMOVAL/INSTALLATION··························· 6-3
EVAP CANISTER ··························································· 5-21 FRAME/BODY PANELS/EXHAUST SYSTEM············· 2-2
EVAP ONE WAY VALVE················································ 5-20 FRONT WHEEL/BRAKE/SUSPENSION/
EVAPORATIVE EMISSION CONTROL SYSTEM ········· 3-14 STEERING ································································· 12-4
EXHAUST PIPE/MUFFLER·············································· 2-9 FUEL SYSTEM ···························································· 5-3
FLYWHEEL/STARTER CLUTCH ··································· 10-6 HYDRAULIC DISC BRAKE ········································ 14-3
F
FOOTPEG BAR································································ 2-9 IGNITION SYSTEM···················································· 16-3

FORK············································································ 12-25 LIGHTS/METERS/SWITCHES··································· 18-3
FRONT DRUM BRAKE (Type 1, 3, 4, 6) ······················ 12-22 LUBRICATION SYSTEM ············································· 4-3
FRONT FENDER······························································ 2-5 MAINTENANCE ··························································· 3-2
FRONT WHEEL REAR WHEEL/BRAKE/SUSPENSION ······················ 13-4
DISC BRAKE TYPE ················································· 12-13 SERVICE RULES ····························································· 1-2
DRUM BRAKE TYPE··············································· 12-18 SHOCK ABSORBER ···················································· 13-19
21-1
INDEX
SIDE COVER···································································· 2-4 FUEL SYSTEM·····························································5-2
SIDESTAND HYDRAULIC DISC BRAKE ········································14-2
FRAME/BODY PANELS/EXHAUST SYSTEM············· 2-8 REAR WHEEL/BRAKE/SUSPENSION ······················13-2
MAINTENANS···························································· 3-22 SYSTEM DIAGRAM
SPARK PLUG ··································································· 3-8 BATTERY/CHARGING SYSTEM ·······························15-2
SPECFICATIONS ELECTRIC STARTER ················································17-2
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER ······ 1-6 IGNITION SYSTEM ····················································16-2
SPECIFICATIONS TACHOMETER ·······························································18-8
T
ALTERNATOR/STARTER CLUTCH···························· 1-6 THROTTLE OPERATION ·················································3-6

BATTERY/CHARGING SYSTEM································· 1-9 TORQUE VALUES··························································1-10
CRANKCASE/CRANKSHAFT/TRANSMISSION ········· 1-7 TRANSMISSION ·····························································11-8
CYLINDER HEAD/VALVES ········································· 1-5 TROUBLESHOOTING
CYLINDER/PISTON····················································· 1-5 ALTERNATOR/STARTER CLUTCH ··························10-3
ELECTRIC STARTER·················································· 1-9 BATTERY/CHARGING SYSTEM ·······························15-4
FRONT WHEEL/BRAKE/SUSPENSION/STEERING ·· 1-7 CLUTCH/GEARSHIFT LINKAGE ·································9-4
FUEL SYSTEM ···························································· 1-5 CRANKCASE/CRANKSHAFT/TRANSMISSION········11-5
GENERAL ···································································· 1-4 CYLINDER HEAD/VALVES··········································7-5
HYDRAULIC DISC BRAKE·········································· 1-8 CYLINDER/PISTON ·····················································8-3
IGNITION SYSTEM······················································ 1-9 ELECTRIC STARTER ················································17-4
LIGHTS/METERS/SWITCHES ···································· 1-9 ENGINE DOES NOT START OR
LUBRICATION SYSTEM ············································· 1-5 IS HARD TO START ··················································20-2
REAR WHEEL/BRAKE/SUSPENSION························ 1-8 ENGINE LACKS POWER···········································20-3
SPEEDOMETER ···························································· 18-6 FRAME/BODY PANELS/EXHAUST SYSTEM ·············2-2
STARTER MOTOR························································· 17-6 FRONT WHEEL/BRAKE/SUSPENSION/
STARTER RELAY SWITCH ········································· 17-12 STEERING ·································································12-6
STATOR/IGNITION PULSE GENERATOR···················· 10-5 FUEL SYSTEM·····························································5-4
STEERING HEAD BEARINGS ······································· 3-25 HYDRAULIC DISC BRAKE ········································14-4
STEERING STEM························································· 12-32 IGNITION SYSTEM ····················································16-4
STORAGE TANK······························································ 5-6 LUBRICATION SYSTEM ··············································4-3
SUSPENSION ································································ 3-23 POOR HANDLING······················································20-6
SWINGARM·································································· 13-20 POOR PERFORMANCE AT HIGH SPEED················20-6
SYSTEM COMPONENTS POOR PERFORMANCE AT
ALTERNATOR/STARTER CLUTCH·························· 10-2 LOW AND IDLE SPEED ·············································20-5
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER REAR WHEEL/BRAKE/SUSPENSION ······················13-6
SYSTEM······································································· 9-2 TURN SIGNAL LIGHT·····················································18-5
CRANKCASE/CRANKSHAFT/TRANSMISSION ······· 11-2 TURN SIGNAL RELAY ·················································18-18
CYLINDER HEAD/VALVES ········································· 7-2 VALVE CLEARANCE························································3-9
V
CYLINDER/PISTON····················································· 8-2 WHEELS/TIRES······························································3-24

W
ENGINE REMOVAL/INSTALLATION ·························· 6-2 WIRING DIAGRAM

FRONT WHEEL/BRAKE/SUSPENSION/ Type 1, 3, 4, 6 ·····························································19-2
STEERING ································································· 12-2 Type 2, 5 ·····································································19-3
21-2

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A Few Words About Safety

Improper set-up or pre-delivery service can create

For Your Safety

Failure to properly follow instructions and precau-

Important Safety Precautions

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

© Honda Motor Co., Ltd.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use silicone grease.

Use fork or suspension fluid.

SERVICE RULES ··········································· 1-2 FRONT WHEEL/BRAKE/SUSPENSION/

LUBRICATION SYSTEM HYDRAULIC DISC BRAKE

FUEL SYSTEM SPECIFICATIONS················ 1-5 BATTERY/CHARGING SYSTEM

CYLINDER/PISTON SPECIFICATIONS ········ 1-6 ELECTRIC STARTER SPECIFICATION ········1-9

CLUTCH/GEARSHIFT LINKAGE/ LIGHTS/METERS/SWITCHES

ALTERNATOR/STARTER CLUTCH TORQUE VALUES ········································1-10

EMISSION CONTROL SYSTEMS ················1-29

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

The carburetor identification number is stamped on the right side of the

CARBURETOR IDENTIFICATION NUMBER

FUEL SYSTEM SPECIFICATIONS

CYLINDER HEAD/VALVES SPECIFICATIONS

CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SPECIFICATIONS

REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

HYDRAULIC DISC BRAKE SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATION

ENGINE & FRAME TORQUE VALUES

RIGHT HANDLEBAR CLUTCH SWITCH

FRONT BRAKE LIGHT

HEADLIGHT SUB HARNESS

DISC BRAKE TYPE

FRONT BRAKE LIGHT

THROTTLE CABLE CHOKE CABLE

MAIN WIRE HARNESS HEADLIGHT SUB HARNESS

FRONT BRAKE LIGHT

DISC BRAKE TYPE

CLUTCH CABLE FRONT BRAKE HOSE RIGHT HANDLEBAR

FRONT BRAKE LIGHT

FRONT BRAKE CABLE

FRONT BRAKE LIGHT

IGNITION COIL WIRE

MAIN WIRE HARNESS

SUB FUSE REAR BRAKE LIGHT MAIN FUSE WIRE

VACUUM HOSE CHOKE CABLE

ONE WAY VALVE-TO

CRANKCASE BREATHER HOSE CARBURETOR AIR

EVAP AIR JOINT HOSE

EVAP DRAIN HOSE

EVAP BREATHER HOSE

BATTERY BREATHER HOSE

REAR BRAKE LIGHT STARTER MOTOR 45º

MAIN WIRE SPARK PLUG WIRE

AIR SUPPLY HOSE