RT erateIMPORTANT SAFETY NOTICE REIN iciaees» cron pest of eecooenal ey or uae atm wee e@ CAUTION sich piney sia wig Mtl a toned NOTE: hoes oration | i elf ad eon coc: ay Neb Asn rane ek Won. We neers eerie eae! 6 could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, | ‘might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recammended by Honda, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected,HOW TO USE THIS MANUAL This service manual describes the service procedures for the TRX450S/FM and TRXA5ESIFE. Follow the Maintenance Schedule (Seetion 3) recom: mendations to ensure that the vehicle is in peak ‘operating condition and the emission levels are within the standards set by the California Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removaljinstallation of components that may be required to perform service describad in the following sections. ion 4 through 23 describe parts of the vehicle, iped according to location 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 assembly or system illustration, service information and troubleshooting for the section, The subsequent pages give detailed procedure. It you are not familiar with this vehicle, read the Technical Features in section 24. If you do not know the source of the trouble, go to section 25, Troubleshooting ee ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR 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 PERMISSION. 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 CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM "ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/CYLINDER/PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKSHAFT/BALANCER/ TRANSMISSION FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/SUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM Gi REAR DRIVING MECHANISM - BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER ENGINE AND DRAIVE TRAIN CHASSIS LIGHTS/METERS/SWITCHES ELECTRIC SHIFT PROGRAM (ESP) -g SELECTABLE 4WD SYSTEM (After ‘01) ELECTRICAL | WIRING DIAGRAM __ TECHNICAL FEATURES | TROUBLESHOOTING | INDEXSYMBOLS The symbols used throughout this manual show specific service procedur pertaining to these symbols, it would be explained specifically in the toxt without the use of the symbols, Replace the part(s) with new one(s) before assembly. Use recommended 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, NLGI #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 % mélybdenum disulfide, NLGI #2 or equivalent). Example: Molykote®BR-2 plus, 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 @ locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 3 or DOT 4 brake fiuid. Use the recommended brake fluid unless otherwise specified. fm aah Po Rhos Use Fork or Suspension Fluid. Parmemmnyntornuca nine @& e@ oe © 6 ©1. GENERAL INFORMATION GENERAL SAFETY 11 LUBRICATION & SEALPOINTS — 1-18 SERVICE RULES 1-2 CABLE & HARNESS ROUTING 1-21 MODEL IDENTIFICATION 13 EMISSION CONTROL SYSTEMS 1-37 SPECIFICATIONS 14 EMISSION CONTROL TORGUESALUES 4-13. INFORMATION LABEL 1-38 TOOLS 1-16 GENERAL SAFETY CARBON MONOXIDE Ifthe engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area, i The exhaust contains poisonous carbon monoxide gas that can 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, GASOLINE Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work ares or where gasoline is stored. Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS am Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. USED ENGINE OIL ORM Used engine oll may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oll on a daily basis, itis still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP ‘OUT OF REACH OF CHILDREN. BRAKE FLUID CAUTION: Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designad to minimize the hazard caused by airborne asbestos fivers. a Inhaled asbestos fibers have been found to cause respiratory disease and cancer.GENERAL INFORMATION BATTERY HYDROGEN GAS & ELECTROLYTE I + The battery gives off explosive gases; keep sparks. flames ‘ond cigarettes away. Provide adequate ventilation when charging + 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 = electrolyte gets in your eyes, flush with water for at least 15 minutes and cal a physician immediately. + Electrolyte is poisonous. = If swallowed, drink large quantities of water oF milk ‘and follow with milk of magnesia or vegetable oil and calla physicion. KEEP QUT OF REACH OF CHILDREN. SERVICE RULES 1 Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's design specifications may cause damage to the vehicle. 2, Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. install new gaskets, O-rings, cotter pins, and lock plates when reassembling 5. When tightening bolts or nuts, begin with the larger diamotor or inner bolt first. Then tighten to the specified torque diagonally in ineremental steps unless a particular sequence is specified, 6, Clean parts in cleaning solvent upon disassemb ny sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation snd operation. {8 Route all cable and harness routing as shown on pages 1-21 through 1-29 Cable and Harness Routing. 1-2MODEL IDENTIFICATION ©o TRX 450S/FM : GENERAL INFORMATION ‘TRX 450ES/FE : The frame serial number is stamped on the front of the frame. he x "\ [CARBURETOR NUMBER, The carburetor identification numbers are stampod on the left side of the carburetor body as shown. ENGINE SERIAL NUMBER The engine serial number is stamped on upper side. of the rear crankcase viewed from the left side. COLOR LABEL The color label is attached to the frame under the ‘seat as shown. When ordering color-coded parts, always specify the designated color cade. 1-3GENERAL INFORMATION SPECIFICATIONS [1 '98~ "01: TRXAS0ES -GehienAL: Alter ‘01: TRXASOFE ire ‘SPECIFICATION DIMENSIONS | Overall length (98-01) 4.961 mm (7.2 in) (after ‘01) 1,963 mm (77-3 in) Overall width (98-01) 41,186 mm (45.5 in) (ater ‘o1) 1,381 mm (45.3 in) Overall height 1/148 mm (45.9 in) Wheelbase (98 -'01) 411271 mm (60.9 in) (after ‘01) 1.274 mm (60.2 in) Front tread (38-01) 912 mm (35.9 in} (after 0) 910 mm (35.8 in} Roar tread ‘905 mm (35.6 in) Seat height (98-"01) ‘860 mm (33.3 in} (after ‘01) 854 mm (33.6 in} Footbag height (98-"01) 327 mmm (12 in) [333 mm (13.1 in) (after 00) 329 mm (73,0 in} [336 mm (13.2 in} Ground clearance (38-01) 192 mm (76in) (after 01) 198 mm (7.7 in) Dry weight (38 -'01) 260 kg (575 lbs) [2685 kg (886 Ibs!) ‘after 01) 264 kg (582 ths) (270 kg (595 Ibs) Curb weight (38~"01) 270 kg (595 tbs) (276 kg (608 Ibs!) {after 01) 274 kg (604 ths) (280 kg (617 Ibs)] Maximum weight capacity FRAME Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Roar dampor Front tire size Roar tire size Front rim size Rear rim size Tire brand (DUNLOP) FR/RR Front brake Rear brake Toe Caster angle Camber angle Trail length Fuel tank capacity Fuel tank reserve capacity 220 kg (486 Ibs) Double cradle Double wish-bone 150 mm (6.91 in} Double tube Swingarm 1150 mm (6.91 in) Double tube AT 25 X 8-12 8% AT 25 X 10-12 12X60 AT 12X75 AT KT401C/‘98 ~ 01: KTAO5C, After ‘01 KT128 Hydraulic drum brake Mechanical drum brake Toe-out: 35 mm (1-3/8 in) s on" 7 mm (9/32 in) 12.0 € (3.18 US gal, 2.64 Imp gal) 2.7 20.71 US gal, 0.58 Imp gal) 1-4;- GENERAL (Cont'd) GENERAL INFORMATION ITEM SPECIFICATION Bore and stroke Displacement ENGINE 90.0 X 68.0 mm (3.54 X 2.68 in) 432.6 cm (26.40 cu-in) | intake valve closes 45° ABDC ) | Exhavet vale opens ae eBpe i Saas a ‘ee ars 2 tau aass Bn ve er ooehis Seren Starting system Charging system Regulator/rectitier Lighting system Starter motor and emergensy recoil starter Triple phase output alternator SCR shorteditriple phase full-wave rectification BatteryGENERAL INFORMATION 7 LUBRICATION SYSTEM Wem Engine oil capacity At draining Unit: mm (in) STANDARDS SERVICE LIMIT | At disassembly 2.02 (2.10 US qt, 1.76 Imp at) | 2.7 2 (2.88 US at, 2.38 Imp at) Throttle lever free play _ t 2.11221 US at 1.85 Imp at _— Recommended engin HONDA GNA 4stroke oil or equivalent motor ci {API service classification SF or SG | pump rotor Tip clearance 0.18 (0.008) 0.20 (0.008) Body clearance 0.15~0.21 (0.006 0.008) 0.25 0.010) Sido clearance (0.02. 0.09 (0.001 0.008) Tost (0.008 FUEL SYSTEM trem. SPECIFICATIONS Carburetor identification numé ="01 : VESIA ‘itor 01: esac Main jet inital #130 | ‘High altitude setting #20 Slow jet — = #45 [Jet needle clip position - 3rd groove from 4 Pilot serew [initial opening 2-5/8 turns out | High att —_ ‘I Float level - Engine icle speed 308.0 mm V8 - 5/6) Starting enrichment (SE) valve distance 10-11 mm (0.39 ~ 0.43 in) ©GENERAL INFORMATION > CYLINDER HEAD/VALVES/CAMSHAFT unit mn ind mem ‘STANDARDS SERVICE LIMIT [Cylinder | Decompressor effected 539 — 834 KPa (65-85 kgllem, compression | ee [78-121 psi) at 450 rpm Decompressor not effected 1.200 — 1,442 kPa (125-145 kgm, _ 178 206 psi at 450 rom Valve, Valve clearance iW [10.15 0.006) Valve quide | 0.15 0.006) Valve siom 0.0. 5.475 - 5.490 (0.2188 — 0.2161) 5.45 (0.278) ‘5455 -5.470 (0.2148 0.2154) 5.43.0. Vaive guide 10. 5.500 - 6512 (02165 -0.2170) 5.525 (0.2178) 5500-8512 (02165 -0.2170) 525 (02 0.010 - 0.037 (0.0004 ~0.0015) 0.12 (0.005) | (0,030 - 0.057 (0.0012 - 0.0022) 0.14 (0.006) Valve seat width 1.2 (0.005) 7.5 (0.06) Valve spring Inner 36.85 (1.457) 35.64 (1.411) free length [Outer 41.67 (1.683) 40.42 (1.591) Rocker arm/ | Racker arrn 0. 12.000 12.018(0.4724-0.4731) | 12.05 (0.474) shaft Rocker arm shaft O.. 11.964—11.984(0.4710— 0.4718) | 11.92 (0.469) 10.016 ~ 0.054 (0.0006 0.002) 1.06 (0.003) Camshaftand [Cam lobe height IN 36.4291 - 36.4291 (1.43421 - 1.44051) | 36.25 (1.427), eam follower Ex 36.2670 96.4270 (1.42783 — 1.43131) | 36.10 (1.421) Cam follower 0. IWEX 22.457 ~ 22.482 (0.8845-0.8851) | 22.45 (0.884) Cam follower bore 0.0._|IWEX 22,510 22.526 (0.962-0.6868) | 22.54 (0.887) Cam follower to bore clearance 0,028 ~0.059 (0.0011 0.0023) 0.07 (0,003) Unit: rm Gn p CYLINDER/PISTON Tre STANDARDS SERVICE Lr Cylinder 10. 90.00 - 90.01 (3.543 ~ 3.544) 90.10 (3.547) Taper _ a 0.10 (0,004) Out of ound = 0:10 (0.004) [Warpage —__ [0.10 (0.004) son, Piston mark decion Tmo ——— ston rings, [Aton 0.0. 30.945 60.065 3411-36418) | B990@599 piston pin [Piston 0.0. mensurement point | 10 mm (0.4 in rom bottom of skirt = Piston pin bora LD. 1.002 19.008 (0.7481 -0.7483) | 190810750 Piston pin O.D. - 18.994 19.000 (0.7478 0.7480) | 18.96 0.746) Petrie plton pin dearance 62002-0014 0.0001 o.0008) | 0.120.029) Piston ring-toving [Ton 0.030 - 0.060 (0.0011-0.0020) [0.09 (0.0) gression Second | 0.015 =0.45 (0.0008 - 0.0018) | 0.090.008) Piston tng end ge [Top 2015 - 0.30 (0.008 - 0.012) 050002 Second | 000 0.480 0012-0018) 08 (002) Oi side ril_| 0.20 0.70 0008 - 0.026) | Cynder piston clesance 0.036 - 0.086 (0.0014 0.0022) | 6.10 (0.008) Connecting rod small end LO. 18.020 19.041 (07488 - 0.7488) | 1807 (0.7508) [Connecting rd t piston pin clearance 2020-0047 (00008-00018) | 0.102.004 — 1-7GENERAL INFORMATION 7 CLUTCH/GEARSHIFT LINKAGE aterm. tn ITEM ‘STANDARDS SERVICE LiMiT Change clutch | Spring fee length 2228) EXETTED Bless 262-278 (0.108 0.09) 2.3 (0.09) iate warpage — [0.20 10.008) Clutch outer guide OD. __| 27950~77.580 (1.1007 1.1016) | 27.82 (1.098) iD. | 22.000 72.021 (0.8661 - 0.8670) | 22.05 0.668) ‘Maincha 0.0 at outer guide 21.972 21,993 (0.8650 0.659) | 21.93 (0.69) Centrifugal | Drum LD. —__| 140.0 740.2 (6.51 - 5.52) [140.4 (5.53) eluteh ‘Weight lining thickness 3.0 (0.12 [2.0 (0.08 ‘Clutch spring height 3.1(0.12) [29510116 ah eihesery fale 218 (085) 725 088) Primary arive [ LD. 27.000 ~ 27.021 (7.0690 10658) | 27.05 (1.065) gear Crankshaft O10. at dive gear 26.959 ~ 76.980 (1.0614 ~ 1.0622) | 26.93 (1.060) 1-8 e @ ®GENERAL INFORMATION a > CRANKSHAFT/TRANSMISSION Aa tmeticy TEM STANDARDS: ‘SERVICE LIMIT Crankshaft, | Side clearance 0.05 — 0.65 (0.002 - 0.026) 0.80 (0.031) Radial clearance 0.006 0.018 (0.0002 - 0.0007) 0.05 (0,002) Runout — 0.05 (0.002) Transmission | Gear LD. me 25,000~ 25.021 (09843-09851) | 25.05 (0.586), Ms _ 20,000 — 20.021 (0.7874 — 0.7882) 25.05 (0.986) 1.02. 26,020 28.061(7.1081— 1.1040) | 28.07 (1.105), cr 26,021 ~ 28.067(7.1082— 1.1040) | 28.07 (7.105) | Reverse ile 18,000 18.021 (0.7087 0.7095) | 18.08 (0.711) ‘shat O0. M4 ~S~*d« 2.969 27.980 (0.8645 0.8664) | 21.99 (0.883) M5 16.983 — 16.994 (0.6686 - 0.6691) 16.95 (0.667) Reverse idle 13.966 13.984 (0.5496 0.5506) | 12.03 (0.548) (Gear bushing | 27.984 = 28,005 (1.1017 - 1.1026) 27.93 (1.100) 277.999 - 78.000 (1.1018 1.1026) [2793 (1.10 71.979 ~ 78.000 (1.1015 1.1024) | 2793,(1.10 ib. | 22.000- 22.021 0.661 0.8070) | 7205 868) 0.0. 24.959 - 24.980 (0.9826 - 0.9835) 24.93 (0.981) ws [uD. | 17.016 17.094 (0.6690 - 0.67061 | 1706 (0672) 0.0. | 19.966 19.8840 7661 0.7668) 1993 0785), R 1D. | 14.000 14.025 0.8616 0.8622) | 14.05 0.863) 0.0. | 17.966 17.964 7073-0 7080) 1793 0.706) Gears Ma 02020 - 0.062 (00008-00024) [0.10 (0004) bushing Ms 0.016 0.085 10.0006 0.0022) [0.10 0004) clearance ci 10.015 ~ 0.057 (0.0006 0.0022) [0.10 (0.008) a (0020 0062 (00008-00024) [0.10 0.004) cr 10.020 0.06210.0008-0.0024) [0.10 (0004) 3 (2018-0057 (00006-00022) [0.10 (0.004) Revers dle | 0.016 0.055 «0.0006 0.0022) [0.10 (0.004) Busting ton Me 01020 0.067 00008-00028) 0.10 0.008) | shottclesrance [M5 "0.022 0.081 (0.0009 0.0020) | 0.10 (0.004) Reverse idle | 0.016 0.058 (0.0006 0.0023) [0.10 (0.008) Shift fork, Fork At 13.000 - 13.021 (0.5118 - 0.5126) 13.04 (0.513) shot Claw thickness | 499-500 0.194 -0.197) [450 0.177 Fork shah 00. 12.966 - 12964 05105-05112) 1298 0510)GENERAL INFORMATION > FRONT WHEEL/SUSPENSION/STEERING Hee It rem STANDARDS SERVICE LIMIT Minimum tre wead depth = 401 Cold tte pressure [5k 10.28 kpc 3.6 psi 229 (0.22 aller, 3.2 ps — 28 KPa (0.28 kote, 4.0 psi) 25 KPa (0.25 kgler, 3.6 psi) ad anc boron a alin 3652 10/148 2000 Tos Too out 35+ 16 mm [881976 in) = - REAR WHEEL/SUSPENSION See rem STANDARDS SERVICE LT Minimum tre weed depth = [ior Cold tire pressure ‘Standard 25 kPa (0.25 kaliem®, 3.6 psi) Minimum [22 kPa (0.22 katiem’, 32 psi) Maximum - 28 kat/om’, 4.0 psi) With cargo 75 Pa (0.25 ken, 3.6 psi = Gas Unit: mm dn) Trem STANDARDS SERVICE LIMT Front broke | Drum LD. — “| 160.0 16.30 161.0638) Lining thickness | 4.0 (0.16) - 2.0 (0.08) Brake panel warpage 0.4 (0.02) Ea poe cal soon 05 (0.02) | Water soa ip fonath T0108 [20.0 (0.79) Master cylinder LD. 14.000 14.043 (05572-08629) | 14.055 (0.553) amar pbian OO 13.957 Tabs i 5486=0.5506) [1.546 15080) Wheel cylinder LD. 19.050 19.102 (0.7500-0.7520) | 19.12 (0.753) Wheel cylinder piston OD. 18.997 - 19.090 (0.7479 0.7492) | 188110741) [Rearbate [orm io. Tessa) 01638) (Citeg titel 5.0 (0.20) To the indicator - FRONT DRIVING MECHANISM conn in) eM SERVICE LIM ana aemnaany | na a = At disassembly 200 om (6.76 US 02, 7.02 Imp oz) = minendod Hypoid gear ol SAF 460 _ Clutch ‘spring free height 2.85 (0,104), __| Clutch dis thickness z "2: -2.8(6.106 0.110) i 8 2.3-2.4(0.081-0084) (0.08) Pinion gear. a 12,000 - 12.018 (0.4724 04731) | 12.0 (0478) Pinion gear shaft. 11973 11.984 (04714-04718) | 1.75 0.463) Sliptorque 17-26 Nem 17-25 4g 12-18 — | Gear backlash 105 ~ 0.0 (0.002 - 0.012) 040 (0.016) —.] A 1-10GENERAL INFORMATION Unit: mm (in) 7 FRONT DRIVING MECHANISM (‘98 - ‘01) ireM STANDARDS: SERVICE LIMIT | oil capacity Alter draining __| 190 cm? (6.4 US 07, 67 Imp oz) ‘At disassombly 200 om’ (6.8 US 02,7.01mp oz) Recommended oil Hypoid gear oll SAE #80 ‘Clutch spring free height 2.66 (0.104) Clutch dise thickness A | 2.7-2.8 (0.106 0.110) oe - 8 2.3-2.4 (0.091 - 0.094) 2.1 (0.08) Pinion gearl.D. 12,000 - 12.018 (0.4724 ~ 0.4731) 12,05 (0.474) Pinion gear shaft O.D. 973 11,984 (0.4714 0.4778) 11.78 (0.463) __| Slintorque 17-25 Nem (17-25 4h 12-186) = Gear backlash i 0.05 - 0.30 (0,002 - 0.012) 10.40 (0.016) - FRONT DRIVING MECHANISM (After 01) oe ITEM ‘STANDARDS ‘SERVICE LIMIT — “tee eae nee — Sores | " _[Risraamany — [ase i600 8:7 mp oe 5 [Recommendedol | Hypo oar ol SAE 00 == Gearbactlash 405 - 0.25 (0.002 -0.010) [e008 [Bsektsh ciference oziecv | Slip torque TOW Nem (45-178 Kghem, | 2 Nem (L2G L_ 10-13 bi | sie Face tam to-housing dstanc 63-6.7 (025-026) 63(0.25) Differential housing cap desth | ass 2.65 0.376 0.300) 955 (0378) Cone epring feo height 28.0111 260.10) ie wen fk ; REAR DRIVING MECHANISM rem STANDARDS SERVICE LIMIT Rear axle runout — — = 300012) Rearfinal | Oil capacity After draining 80 cm? (3.0 US 07, 321 Imp o2) ative a eckaaonin Wher aa lieot an lan == Recommended ol Hypoid gear oll SAE #80 = | Gear backlash 0.05 - 0.30 (0.002 - 0.012) 0.40 (0.016) - BATTERY/CHARGING SYSTEM vrem SPECIFICATIONS Bawery | Capacity 12V-12 AH Current teakage nam Voltage Fully charged wo-wev | | ao'cwet) | Needs charging Below 12.3V — Charging current | Normal [ 7 Quick | Altemator | Capacity Charging col resistance GOTISEA amar [is a rectifier Fleguiatad valtageGENERAL INFORMATION ote nm ay [IGNITION SYSTEM rem SPECIFICATIONS w ‘Spark plug | Standard DPATEA-S(NGK) | _ X22EPR— U9 IDENSO) Farsalt ina BaowiPoNTH_——|—beaiea se avant [eater Us DENCY [Fone na awad aa, ——| benicar —| ~SchePn cus ewech ‘Spark plug gap — 7 0.8 - 0.9 mm (0,03 - 0.04 in) 2 Tae we O07 Vmi ms~«@ ‘Ignition timing 10° BTDC at 1,400 rpm 30° BTDC at 5.900 rpm Unit: mm (in) [ELECTRIC STARTER =. | ii eee] ' rem STANDARDS ‘SERVICE LIMIT Starter motor brush length 12.5 (0.49) [3.0 (0.35) | LIGHTS/METERS/SWITCHES iTeM’ ‘SPECIFICATIONS Bue aan ce 1BV29R6WK2 Atwr'o1 | av 20c0W x2 1V-5W 8 eo Bake ight (Aher01 Quebec provnes oni ‘2V-21ce Indicator (llReverse/Neutra [Fase Tai tse — | Sub fuse s0 | 16AX2, 10AX 2 | a ON || MOTOR FUSE (TRX450 ES/FE only) 1BAX2, 10AX3 A 1-12GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE Nem (gto, tte) FASTENER TYPE [Nem (kgfom,tbftt) 5 mm hex bolt and nut 5(05,36 | 5 mmscrew 4 (0.4, 2.9) 6 mm hex bolt and nut 1011.0.71 | 6mm screw 909, 65) 8 mm hex bolt and nut 22122, 16) | 6 mm flange bolt (8 mm head) 8 (03,65) 30mm hex bolt and nut 34138,25) | 6 mm flange bolt (10 mm head) and nut 12(12, 9) 32mm hex bolt and nut 54155, 40) | 8 mm flange bolt and nut 2 (27, 20) 10 mm flange bolt and nut 38 (40, 29) = Torque specificatons listed below are for important fasteners. + Others should be tightened to standard torque values listed above. NOTES: 1. Apply sealant to the threads. 2, Apply a locking agent to the threads. 3 Stake. 44. Apply oll to the threads and flange surface. 5. Apply clean engine oil to the O-ring, 6. Apply grease to the threads and flange surface. 7, ALOC bolt: replace with a new ona. 8. Do not reuse; replace with a new one. 8, Castle nut: Tighten to the specified torque then tighten to position suitable for cotter pin hole direction. ENGINE THREAD DIA, ‘TORQUE rem oy ee Nem (kgfem, thf) REMARKS Maintenance: il drain bott 1 2 29 (25,18) Oil filter cover flange bolt 3 6 101.0, 7) ‘Spark plug i 12 181.8, 13) Timing hole cap 1 14 10(1.0.7), Valve adjuster lock nut 2 6 471.7, 12) Clutch adjusting serew lock nut 1 8 22 (2.2, 16), Lubrication System: il pump rotor side plate screw 1 5 40.40, 2.9) Relief valve cap 1 14 19(19,14) | NOTE2 Fule System: Carburetor cover serew 1 5 4(0.4.29) Starting enrichment (SE) valve nut 1 4 3(03, 1.8) Insulator band screw (After ‘01) 1 5 $(0.4,29) Cylinder Head/Valves/Camshaft: Gylinder head fiange cap nut 3 10 39(4.0,29| | NOTE 4 Camshaft bearing retainer bolt 1 8 26(2.7,20) | NOTE2 Cam spracket flange dowel bo!t 2 q 20(2.0,14) | NOTE2 Cam chain tensioner lifter sealing screw 1 6 $(0.4.2.9) Cam chain tensioner mounting bolt 2 6 32(12,9) | NOTE? locker arm holder flange cap nut 3 10 39(4.0,29| | NOTE 4 Rocker arm shaft flange bolt 1 6 7(0.7, 5.1) Clutch/Gearshitt Linkage: Gearshift return spring pin 1 8 2222.16) | NOTE2 Shift drum stopper arm bolt 1 6 1211.2.) Gearshift A arm bolt i 8 252, 18) Centrifugal clutch outer lock nut 1 20 118 (120,87) NOTE3.4 Clutch spring bolt 4 6 1211.2, 9) Change cluteh center lock nut 1 18 108 (11.0,80) | NOTES.4 Drum shitter and guide plate bolt (98 -‘01) 1 6 12112,8) | NOTE {aiter 07) 1 6 16116, 12) | NOTE2 1-13GENERAL INFORMATION y ENGINE (Cont'd) ‘THREAD DIA. TORQUE ves oy (mm) Nem (kgf-m, ibfett) | REMARKS Recoil Starter: | Recoil pulley flange bolt 1 2 108 (11,0,80) | NOTES Alternator/Starter Cluteh’ Starter one-way clutch socket bolt 6 8 3113.1.22) | NOTE2 Stator socket bolt 3 6 10(1.0,7) Ignition System: Ignition pulse generator socket bolt 2 5 6 (06,43) | NOTE2 Lights/Meters/Switehes: Neutraljreverse (or gear position) switch ‘mounting bolt 1 6 12(1.2,8) | NOTE2 il thermo sensor 1 12 18(18, 13) Angle sensor (TRX@S0ES only) 2 6 L 6106.43) rp FRAME THREAD DIA. TORQUE ce ar (mm) (Nem (kafom, wrt) | REMARKS Frame/Body Panels/Exhaust System: Muffler band bolt 2 8 2323.1) Exhaust pipe protector bolt 3 6 22(2.2, 16) Heat protector bolt 2 6 22 (2.2.16) Heat guard bolt 4 6 20(2.0, 14) Step bar mounting bolt 4 8 3218.3, 24) Cooling fan shroud special bolt 4 6 18(1.8, 13) Fue! tank rear bracket bolt 4 6 18 (1.8,13) Carrier mounting bolt '38~"01) 14 8 32 (3.3, 24) (after ‘01) “4 8 373.8, 27) Fuel System: Fuel valve mounting bolt 2 6 309,65) Fue! level gauge mounting bolt 2 6 12(1.2,9) By-starter cap special bolt H 4 2.3.(0.23,1.8) (Cluteh/Gearshitt Linkage: Gearshift pedal bolt ('98 -'01) 1 6 1616, 121 (after 01) 1 6 20(2.0, 14) Engine Mounting: Lower engine mounting bolt (right) 1 10 5415.5, 40) Lower engine mounting bolt (left) 1 10 54.5.5, 40) Upper engine hanger bolt 1 10 54 (5.5, 40) Upper engine hanger bracket bolt B 8 32.3.3, 24) Lower engine hanger bracket bolt 2 8 32.3.3, 24) Front Wheol/Susponsion/Steering: Throttle case cover 3 4 4 (04,25) Handlebar lower holder nut 2 10 39(4.0,2) | NOTES Steoring shaft U-nut 1 “ 108 (11.0,80) | NOTE6 Tie-t0d ball joint self lock nut 4 ” 54.5.5, 40) Tie-rod lock nut 4 2 5415.5, 40) Steering shaft holder flange bolt 2 8 328.3, 24) Upper/iower arm pivot self lock nut 8 10 4445 33) | NOTES Knuckle bal joint castle nut (98 —‘01) 4 rr 29(3.0,22| | NOTES (After ‘01) 4 ” 32033,24 | NOTES Shock absorber upper mounting self lock nut 2 10 44(65,33) | NOTES Shock absorber lower mounting self lock nut 2 10 44(465,33) | NOTES Damper rod lock nut 2 10 37(38,27) | NOTE2 Front wheel nut 8 10 64165, 47) Front whee! hub castle nut 2 16 78 (8.0.58) | NOTES 1-14 e ee 6GENERAL INFORMATION r FRAME (Cont'd) ery | THREAD DIA. TORQUE Tee ary tone) Akot-m, Ibert) REMARKS —— = | ‘Rear Wheel/Suspension: | Fear axle castle nut 2 20 137 (14.0, 101) | NOTES Rear wheal nut a 10 54 (65,47) ‘Shock absorber lower mounting self lock nut 1 10 44 (45,33) | NOTES ‘Shock absorber upper mounting self lock nut 2 10 39 (40,29) | NOTES Shock absorber lower mounting bolt 1 10 44 (45, 33) Damper rad lock nut 2 10 37(38,27) | NOTE2 Swingarm left pivot bolt 1 30 113 (11.5, 83) Swingarm right pivot bolt (98 ~‘01) 1 30 4(0.40,29) (After 01) 1 | 30 10(1.0,7) Swintarm right pivot lock nut 1 30 113 (11.5, 83) Rear axle housing and swingarm nut a | 10 44 (45,33) | NOTES Skid plate flange bolt 3 8 82 (3.3, 24) Brakes: Rear brake arm pinch bolt/nut 1 8 20(2.0, 14) Rear brake panel drain bolt (‘98 ~ 01) 1 2 34 (35, 25) ater 01) 1 2 12 (1.2.8), Master cylinder reservoir cap screw 2 4 2 (0.20, 1.4) Master cylinder holder SH bolt 2 6 12 (1.2.9), Brake laver pivot bolt 1 6 110.10, 0.7) Brake lever pivot lock nut 1 6 6106, 4.3) Brake hose oil bolt 4 10 34 (3.5, 25) Brake hose clamp flange bolt 2 6 1211.2.9) Brake panel flange bolt 8 8 29(3.0,22) | NOTER Whee! cylinder bolwasher 4 6 8108, 5.8) Wheel cylinder nut 4 8 17 (47, 12) Wheel cylinder oil pipe 4 10 16 (1.6, 12), Broke bleeder valve 2 8 6106. 4.3) Breather hose clamp (knuckle) 2 8 323.3, 24) Brake hose 2-way joint 2 a 3515.11) Front Driving Mechanism: Differential case mounting bolvinut, 10 mm 2 10 48 (45,33), amm 1 8 22 (2.2, 16), Differential case cover flange bolt, 8 mm 6 8 25 (2.6, 19), 10mm 2 10 49(5.0, 36) NOTE 2 Pinion joint nut '98~“01) 1 16 108 (11.0,80) | NOTE 2 Pinion bearing lock nut ('98-'01) a 6a 98(10.0,72) | NOTES Differential gear case drain bolt 1 8 12(1.2,9) Differential gear case cover oll cap 1 30 12(1.2,9) Differential case cap torx bolt (38 -'01) 6 8 32(33,24) | NOTE7 Differential case UBS bolt (98-01) 6 8 49 (6.0, 36), Differential ring gear bolt (After ‘01) 6 8 4950.36) | NOTES ‘Speed sensor mounting bolt (After 01) 2 e 1011.0, 7), Final clutch speed sensor mounting bolt (After‘01) 2 6 10(1.0,7) Final clutch mounting bolt (After ‘01) 3 8 25 (2.6, 19) Final clutch cover bolt (After ‘01), 2 6 70.7.5) 3F Driving Mechanism: Gear case caver flange bolt, 8 mm 6 8 25 (2.6, 19) 10mm 2 10 49(6.0.36) | NOTE2 Pinion joint nut ('98~'01) 1 16 108 (11.0, 80) | NOTE 2 Pinion bearing lock nut 1 64 98 (10.0,72) | NOTE3 Gear case drain bolt 1 8 121.2. 9) Gear case cover oil check bolt 1 8 1201.2, 9 Gear case cover oll cap 1 30 121.2.9) 1-15(GENERAL INFORMATION TOOLS NOTES: 1. Newly designed tool. 2. Equivalent commercially available in U.S.A. 3. Not available in U.S.A, 4. Alternative tool. DESCRIPTION Carburetor oat level gauge Flywheel holder Rotor puller Remover weight Valve guide driver, 5.5 mm Attachment, 37 X 40 mm Attachment, 42 X 47 mm ‘Attachment, 82 $5 mm ‘Attachment, 62 X 68 mm Attachment, 72 X 75 mm Attachment, 24 X 26 mm Attachment, 22 X 24 mm (After ‘01 Driver, 22 mm LD. ‘Attachment, 15 mm .D. Driver, 40:mm LD. ‘Attachment, 25 mm |.D. (98-01) ‘Attachment, 30 mm {,D. (After 01) Pilot. 10 mm Pilot, 16 mm (After “01 Pilot. 17 mm Pilot, 20 mm Pilot, 25 mm Pilot, 30 mm Pilot. 35 mm Pilot, 40 mm Pilot. 22 mm Pilot, 28 mm Pilot. 14 mm (After “01) Driver Valve spring compressor Valve seat cutter ‘Soat cutter, 29 mm (46° EX) Seat cutter, 35 mm (45° IN) Flat cutter, 30 mm (32° EX) Flat cutter, 35 mm (32° IN) Interior cutter, 30 mm (60° EX) Interior cutter, 37.5 mm (60° IN) Cutter holder, 55 mm ‘Swingarm lock nut wrench Snap ring pliers. Lock nut wrench, 30 64 mm ('38~"01) TOOL NUMBER (07401 - 0910000 (07728 - 0040000 (07733 - 0020001 (07741 - 0010201 0742 - 0010100 07746 - 0010200 (97746 - 0010300 (07746 - 0010400 (07746 - 0010500 07746 - 0010800 (07746 - 0010700 9746 - 0010800 (97746 - 0020100 07746 ~ 0020200 (0746 - 0030100 0746 ~ 0030200 07746 - 0030300 (0746 - 0040100 0746 - 0040300 07746 - 0040400 0746 ~ 0040500 0746 - 0040600 0746 — 0040700 0746 - 0080800 07746 - 0040900 07746 - 0041000 07746 - 0081100 07746 - 0041200 107749 - 0010000 07757 -0010000 07780 - 0010300 ‘0780 - 0910400 07780 - 0912200 (07780 - 0912300 (97780 - 0914000 (07780 ~ 0014100 0781 - 0010101 07908 - 4890003 07914 ~ 3230001 07916 - MB00002 REMARKS. NoTE2 NOTE &: (07933 - 3950000 (U.S.A. only) NOTE 07936 - 371020 or 07936 ~ 3770200 NoTE 2 NOTE 4 07916 - miao0001 REF. SEC, 5 0 10 8.13 18 (Atter’01) 7 1,12,13 8.11 10,11, 12,14 516 14,18 " 10,17 5 8 a 15,18 18.18 15.18 10 15 8,11, 13,14 14,12 " 2 n " n 14,15 15 8, 10,11,12, 13, 14, 15, 16 1-16GENERAL INFORMATION DESCRIPTION Bearing remover set = Remover handle ~ Bearing remover, 20 mm = Remover weight Remover handle Bearing remover, 17 mm. Cluteh puller Attachment | Attachment, 28 X 30 mm Driver handle attachment Oil seal driver (After 01) Driver attachment il seal driver Assombly collar Assembly shaft Threaded adapter Valve guide reamer, 6.5 mm Clutch holder Inspection adaptor Peak voltage adapter Pinion puller set ~ Shaft puller ~ Pinion puller base Adjustable bearing puller (After ‘01) Remover shaft (After 01) Oil seal driver attachment Clutch center holder Differential inspection tool Ball joint remover, 28 mm Pilot, 32 mm Bal joint installer base Recoil pulley holder Pinion holder ('98- 01) Ball joint remover/installer Universal bead breaker ‘TOOL NUMBER (07936 - 3710001 07936 - 3710100 (07936 - 3710600 0741 -0010201 (07936 - 3710100 (07936 ~ 3710300 (07933 - HA80000 (07945 ~ 3330300 07946 - 1870100 07949 - 3710001 (07965 - KEB0100 (07985 - KE80200 07965 - M1C70100 07965 - vM00100 07965 - Vivi00200 07966 - vim00300 (07984 - 2000007 o7GMB- HATO101 07GMy - MLB0100 ‘O7HGJ - 0020100 o7HMC - MMB0101, (07931 - ME4000 o7HMC - MMB0110 O7JAC- PHaDt01 O7JAC - PH80200, ‘O7AD ~ PHBO101 (07JMB - MN50300 O7KMK -HC50101 o7MAC- $L00200, ‘07MAD ~ PR90Z00 O7HAF ~ SF10720 (07SMB - HMI70100 o7SMB - HM70200 (O7WMIF - HN0O100 GN-AH-958-8B1 | Notes NOTE 4: 07836 - 3710204 or 07936 - 3710200 NOTE 4 07833 - HE30008 NOTE & (0748 - 0010400 NOTE 4, 07947 - KA50100, NOTE & 07931 ~ ME40108 ang (07931 ~ HB3020A (U.S.A. only) NOTE 4: (07931 ~ KF00200 (U.S.A. only) NOTE 4: (07984 - 2000000 (U.S.A. only) NOTE 4 (07GMB-HATOIOA or (07GMB-HA7011A and O7GMB-HATO12A NOTE 4: Poak voltage tester (U.S.A. only) NOTE 3 NOTE 4: (07931 ~ ME4010B and (07931 ~ HB3020A (U.S.A. only) NOTE &: ‘O7HMC ~ MMB011A (U.S.A. only) NOTE &: O7HGB - 0010108 and O7HGB - 0010208 (U.S.A. only) NOTE OTKMK ~ HCSO104 (U.S.A. only) NOTE1 u " " u" 811,13 8,11,13 8 2 2 2 15 16 (98-01), 16 4 n n " ? 8 20 cy 15 ('98-'01), 16 1898-01), 16 15,16 16 18 10,12 8 18 12, n, 2 10 15, 12, 1-17GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS: il fiter cover inside Cylinder bore Cylinder stud bolt threads (at cap nut) Piston pin bore and piston outer surface jon ring surface Connecting rod small end inner surface Centrifugal clutch outer lock nut threads Cam follower surface Cam chain surtaco Rocker arm both ends Clutch friction dise surface Clutch lifter plate outer surface Centrifugal clutch outer sliding surface Clutch drive plate one-way cluten sliding surface Transmission bearing and gear teeth surface ‘Transmission bushing journal surface Main shaft and countershaft journal surface ‘Change cluteh center lock nut threads Shift fork shaft surface Shift drum grooves and surface Roverse stopper shaft journal surface Starter idle gear teeth Recoil pulley bolt threads Starter one-way clutch surface Each ball and needle bearing rolling area Each oll seal lip Crankshaft oil path Engine oll Piston pin outer surface Camshaft lobes Rocker arm shaft (rocker arm sliding surface) Valve stem sliding surface Clutch outer guide sliding surface ‘Starter reduction shaft A surface Starter reduction shaft surface ‘Starter motor pinion end Molybdenum disulfide oll (a mixture of 1/2 ‘engine oil and 1/2 molybdenum disulfide grease) ‘Cam sprocket bolt threads ‘Cam chain tensioner 6 mm flange bolt threads Camshaft bearing fixing plate 8 mm bolt threads Relief valve 14 mm cap threads Goarshift roturn spring pin threads Starter one-way clutch socket bolt threads Neutralreverse switch 6 mm bolt threads Ignition pulse generator 6 mm socket bolt threads Locking agent ‘Change switch grommet Alternator wire grommet Alternator cover gasket 1-18 e@ © ®GENERAL INFORMATION r- ENGINE (cont'd) LOCATION MATERIAL REMARKS Front cover shift reduction gears Unirex N2 (ESO) Apply 3 - 59 of recommended LOCATION (TRX450€S only) Unirex N3 (ESSO} grease. or equivalent | ‘APPLY SPECIFIED GREASE ‘APPLY SPECIFIED GREASE = rp FRAME MATERIAL REMARKS Steering bushing sliding surface Steering shaft oll seal lip Steering shaft dust seal lip, Steering shaft nut threads Steering shaft spline Knuckle dust seal lip and side seal Rear brake cable end. Rear brake cam shaft sliding surface ear brake cam dust seal lip Rear brake panel dust seal lip Roar brake shoe cam contact surface Rear brake shoe anchor pin contact surface Broke pedal shaft sliding surface Brake pedal dust seal lip Brake cover seal lip and side seal Brake lever pivot sliding surface Brake lever parking arm pin sliding surface Rear brake panel O-ring Left axle housing seal lip Loft axie housing bearing Front final drive pinion joint oil seal ip Front drive shaft oll seal lip, Front differential oil cap O-ring Front differential pinion joint O-ring Front final clutch dust seal ip (After ‘01), Front final clutch oil seal lip (After 01) Front final clutch needle bearing (Aftor 07) Front drive pinion spline (After 1) Rear final drive pinion joint oil seal lip Rear final drive ring gear oil seal lip Rear final drive oil cap O-ring Roar final drive pinion joint O-ring Cross joing needle bearing ‘Swingarm bearing and grease holder ‘Swingarm bearing dust seal lip Throttle cable end ‘Multi-purpose grease Apply 2-39 of grease Apply 0.5~ 1.0 g of grease Apply 0.5 ~ 1.0 g of grease Apply 0.5 ~1.0.g of grease Fill up 3.g minimum 1-19GENERAL INFORMATION [- FRAME (Cont'd) LOCATION MATERIAL REMARKS Front brake drum water seal lip and outside lip inside Rear axle shaft spline (lett side) (center) (right side) Rear whee! hub dust seal lip Front differential pinion joint spline Rear final drive pinion joint spline Yoke joints spline Front propeller shaft joint spline (Differential side) (Engine side) Rear propeller shaft seal lip Front propeller shaft seal lip Front drive shaft spline (Whe 5 side) Multi-purpose grease NUGINO.S Fill up 14 ~ 16 g of grease Molybdenum disulfide grease ‘Apply grease to 20 mm width of aroa of 10 mm away from spline right end 0 that spline is filled with grease. Fill up 5-8 g of grease Fill up 5-8 g of grease Fill up 5~8 g of grease Fill up 5~8 g of grease Rear final drive case #80 Front drive shaft boot inside (inboard) 40-609 (Outboard) 30-509 Rear brake inner cable Cable lubricant ‘Throttle inner cable Roverso assist innor cable Choke inner cable | Front differential ease Hypoid gear oll SAE | 200 cv (6.76 02) 100 ce (3.38 07) | Liquid sealant Front differential case mating surfaco Rear final drive case mating surface (Three-bond 1215 or equivalent) Handleber grip rubber inside Handa bond A or Comedine #540 1-20© ve © © GENERAL INFORMATION CABLE & HARNESS ROUTING ‘TAXA60S ('98~01) THROTTLE CABLE CHOKE CABLE REAR BRAKE CABLE BRAKE HOSE REVERSE CONTROL CABLE IGNITION SWITCH WARE HANDLEBAR SWITCH WIRE COMBINATION METER CONNECTOR TRXA50ES ('98~01): THROTTLE CABLE REAR BRAKE CABLE CHOKE KNOB BRAKE HOSE IGNITION SWITCH WIRE Hi Z ul 5 COMBINATION METER = “CONNECTOR 1-21GENERAL INFORMATION ‘TRXASOFM (After 01): ‘CHOKE CABLE REAR BRAKE ‘THROTTLE CABLE CABLE HOSE BRAKE HOS! REVERSE SWITCH 2WD/AWD SWITCH WIRE REVERSE CONTROL IGNITION swiTcH CABLE WIRE THERMO, ‘SENSOR HANDLEBAR SWITCH WIRE METER SPEED SENSOR. SONMEST COMBINATION METER ‘CONNECTOR FINAL CLUTCH SPEED. ‘SENSOR CONNECTOR FINAL CLUTCH 2WD/AWD SWITCH CONTROL UNIT CONNECTOR “TRXASOFE (After ‘01! — RENE REAR BRAKE CABLE THROTTLE CABLE BRAKE HOSE REVERSE SWITCH ‘2WD/4WD SWITCH WIRE REVERSE CONTROL CABLE IGNITION SWITCH > HANDLEBAR SWITCH WIRE WIRE THERMO SENSOR CHOKE CABLE COMBINATION METER CONNECTOR METER SPEED ‘SENSOR CONNECTOR: -2WD/AWD SWITCH FINAL CLUTCH SPEED CONNECTOR ‘SENSOR CONNECTOR Ecu 1-22 e © ©© e © © Le GENERAL INFORMATION ‘TRX450S ('98-'01): IGNITION SWITCH CONNECTOR ACCESSORY SOCKET CONNECTOR RIGHT BRAKE BREATHER HOSE COMBINATION METER RIGHT BRAKE CONNECTOR rere COOLING FAN CONTROL UNIT IGNITION CONTROL MODULE LEFT BRAKE HOSE RIGHT BRAKE HOSE RIGHT BRAKE BREATHER HOSE LEFT BRAKE BREATHER HOSE DIFFERENTIAL CASE BREATHER TUBE HEADLIGHT CONNECTOR vowoaye IGNITION SWITCH TRAGGOEE RESET CONNECTOR ACCESSORY SOCKET CONNECTOR RIGHT BRAKE BREATHER HOSE RIGHT BRAKE: We HOSE ‘COMBINATION METER | CONNECTOR IGNITION CONTROL COOLING FAN MODULE CONTROL UNIT RIGHT BRAKE HOSE "LEFT BRAKE HOSE RAKE BREATHER HOSE RIGHT BRAKE BREATHER HOSE Pere SHIFT CONTROL UNIT DIFFERENTIAL CASE BREATHER HOSE HEADLIGHT CONNECTOR 1-23GENERAL INFORMATION ‘TRXASOFM (After 01): IGNITION SWITCH CONNECTOR lem METER SPEED ACCESSORY SOCKET SENSOR CONNECTOR RIGHT BRAKE conmecron i BREATHER HOSE COMBINATION METER ‘CONNECTOR 2w/aWD ‘SWITCH CONNECTOR i RIGHT BRAKE t HOSE LEFT BRAKE HOUSE RIGHT BRAKE BREATHER HOSE COOLING FAN FINALCLUTCH” — FINAL CLUTCH CONTROLUNIT LEFT BRAKE SPEED SENSOR — CONTROLUNIT DIFFERENTIAL BREATHER HOSE ‘CONNECTOR CASE BREATHER © HEADLIGHT HOSE CONNECTOR TAXASOFE (After 01): ian IGNITION SWITCH CONNECTOR ACCESSORY SOCKET ‘CONNECTOR COMBINATION METER CONNECTOR COOLING FAN CONTROL UNIT RIGHT BRAKE HOSE _2WD/AWD SWITCH ‘CONNECTOR: LEFT BRAKE HOUSE LEFT BRAKE BREATHER LEFT BRAKE HOSE METER SPEED FINALCLUTCH — DIFFERENTIAL = HEADLIGHT. SENSOR SPEED SENSOR CASE BREATHER CONNECTOR BREATHER HOSE CONNECTOR CONNECTOR HOSE 1-24 oe 6 ©GENERAL INFORMATION ‘TAX450S AND TRX4SOES: BRAKE BREATHER TUBE BRAKE HOSE TOP VIEW BRAKE HOSE a i Sj BRAKE BREATHER TUBE REAR VIEW 1-25GENERAL INFORMATION ‘TRX4508 ('98~01 REAR BRAKE CABLE FRONT GEAR CASE BREATHER HOSE REAR GEAR CASE, BREATHER HOSE IGNITION SWITCH CONNECTOR ‘COMBINATION METER CONNECTOR ACCESSORY SockET CONNECTOR HANDLEBAR SWITCH CONNECTOR, ) ‘TRXASOES ('98~'01): es REAR BRAKE CABLE CHOKE KNOB REVERSE SWITCH FRONT GEAR CASE BREATHER HOSE REAR GEAR CASE BREATHER HOSE IGNITION SWITCH. CONNECTOR @ HANDLEBAR SWITCH CONNECTOR COMBINATION ACCESSORY SOCKET fa ia ° S (METER CONNECTOR CONNECTOR 1-26© © © © e © GENERAL INFORMATION TRXASOFM [After 01): 2WD/AWD SWITCH WIRE REAR BRAKE CABLE REVERSE CONTROL FRONT GEAR CASE BREATHER HOSE. REAR GEAR CASE BREATHER HOSE, METER SPEED SENSOR ‘CONNECTOR FINAL CLUTCH CONTROL UNIT IGNITION SwiTcH CONNECTOR ACCESSORY SOCKET CONNECTOR ‘COMBINATION METER 2W/D/AWD SWITCH CONNECTOR ‘CONNECTOR, ‘TAXASOFE (After ‘01): 2WD/aWD SWITCH WIRE REAR BRAKE CABLE CHOKE CABLE. 3 a FRONT GEAR CASE BREATHER HOSE REVERSE CONTROL REAR GEAR CASE 2 ae A CABLE BREATHER HOSE Z ECU. ASSIST HEADLIGHT CONNECTOR HANDLEBAR SWITCH CONNECTOR 2WD/AWD SWITCH ACCESSORY SOCKET CONNECTOR CONNECTOR IGNITION SWITCH CONNECTOR COMBINATION METER CONNECTOR 1-27GENERAL INFORMATION ‘TAX450S ('98~011: CHOKE CABLE REAR BRAKE CABLE ‘THROTTLE CABLE REVERSE CONTROL CABLE COOLING FAN MOTOR BREATHER HOSE FRONT BRAKE BREATHER HOSE REAR BRAKE BREATHER HOSE ‘TRXAB0ES ('98~'01}: CHOKE KNOB REAR BRAKE CABLE THROTTLE CABLE REVERSE CONTROL CABLE ~ COOLING FAN MOTOR BREATHER HOSE FRONT BRAKE BREATHER HOSE REAR BRAKE BREATHER HOSE 1-28© GENERAL INFORMATION ‘TRX450FM (After ‘01): CHOKE CABLE REAR BRAKE CABLE THROTTLE CABLE REVERSE CONTROL CABLE COOLING FAN MOTOR REAR BRAKE FRONT BRAKE BREATHER HOSE BREATHER HOSE BREATHER HOSE TRXA50FE (After ‘O11: {Hncrroe cance REAR BRAKE CABLE REVERSE CONTROL 2wovawo CABLE ‘SWITCH WIRE COOLING FAN MOTOR REAR BRAKE FRONT BRAKE BREATHER HOSE BREATHER HOSE BREATHER HOSE 1-29GENERAL INFORMATION ‘TRX450S/FM AND TRX450ES/FE: FUEL TUBE: CHOKE CABLE CRANKCASE BREATHER TUBE ‘SPEED SENSOR WIRE THROTTLE CABLE CARBURETOR AIR VENT TUBE CHANGE SWITCH WIRE ‘STATORIGNITION PULSE GENERATOR WIRE COOLING FAN MOTOR CONNECTORS COOLING FAN MOTOR BREATHER TUBE IGNITION COIL ‘SPARK PLUG WIRE CHOKE CABLE THROTTLE CABLE 1-30 (MAIN WIRE HARNESS: eGENERAL INFORMATION ‘TRXA50S/FM: Ol COOLER LEFT OIL COOLER HOSE RIGHT OIL COOLER HOSE TRXAS0ES/FE LEFT Olt CQOLER HOSE 1, COOLER ANGLE SENSOR CONNECTOR SHIFT CONTROL MOTOR CONNECTOR 1-31GENERAL INFORMATION TAXA50S (98-01): CARBURETOR HEATER REGULATORIRECTIFIER CONNECTOR GROUND WIRES REAR GEAR CASE, BREATHER HOSE STARTER MOTOR CABLE REAR BRAKE CABLE (HAND BRAKE) REVERSE CONTROL REAR BRAKE CABLE CABLE (FOOT BRAKE) ‘SPEED SENSOR ‘CONNECTOR THERMO STATOR/IGNITION PULSE NEUTRAUREVERSE SENSOR GENERATOR CONNECTOR SWITCH CONNECTOR CONNECTOR THERMO SENSOR WIRE SPEED SENSOR ‘CARBURETOR HEATER CONNECTOR CONNECTOR THERMO SENSOR, STATORAGNITION PULSE NEUTRAL/REVERSE SWITCH CONNECTOR THERMO GENERATOR CONNECTOR ace CONNECTOR 1-32 oe © ©GENERAL INFORMATION ‘TRX450FM (After ‘01): CARBURETOR HEATER < REGULATOR/RECTIFIER CONNECTOR GROUND. WIRES @ sim CASE BREATHER HOSE. REAR BRAKE CABLE ¢ (HAND BRAKE) STARTER MOTOR CABLE REAR BRAKE CABLE ™ (FOOT BRAKE) 3 é REVERSE CONTROL CABLE STATORIGNITION’ —_NEUTRAL/REVERSE PULSE GENERATOR SWITCH Hen ( CONNECTOR CONNECTOR aoe CONNECTOR THERMO SENSOR WIRE CARBURETOR HEATER CONNECTOR ‘THERMO SENSOR. STATORIIGNITION PULSE GENERATOR CONNECTOR SWITCH CONNECTOR THERMO 1-33GENERAL INFORMATION ‘TRXASOES ('98-'01): e REGULATORIRECTIFIER CARBURETOR HEATER CONNECTOR, GROUND WIRES "STARTER MOTOR REAR GEAR CASE é BREATHER HOSE R CABLE REAR BRAKE CABLE. (HAND BRAKE) REVERSE CONTROL CABLE REAR BRAKE CABLE (FOOT BRAKE) CONNECTOR CONNECTOR ‘STATOR/IGNITION PULSE GENERATORCONNECTOR ean rosmow src THenMoSeuscnwine QD) CONNECTOR THERMO ‘SPEED SENSOR SENSOR CONNECTOR CONNECTOR STATOR/IGNITION PULSE GENERATOR CONNECTOR GEAR POSITION SWITCH CONNECTOR 1-34GENERAL INFORMATION rene a GROUND WIRES: scapes REVERSE CONTROL CABLE THERMO SENSOR sess = us Bas ceaneBeren, _srAlomainre oa pepe, Nessun Mee ae nee scare D wrcenorsnits aoa ‘STATOR/JIGNITION PULSE ~ ? ‘ semper nts neni ee 1-35GENERAL INFORMATION ‘TRXA50 ('98~'01): HARNESS CLAMPS STARTER RELAY CONNECTOR MAIN FUSE, BATTERY NEGATIVE (.) CABLE ~~ STARTER RELAY FUSE BOX 4 BATTERY POSITIVE (+) CABLE ‘TRX450ES ('98~'01): ‘STARTER RELAY MAIN FUSE MAIN FUSE HARNESS CLAMPS (CONTROL MOTOR} BATTERY NEGATIVE |-) CABLE. FUSE BOX BATTERY POSITIVE (+) CABLE 1-36GENERAL INFORMATION TRXA5OFM (After 01): BATTERY NEGATIVE (-) CABLE 2 5 2 5 STARTER RELAY SWITCH BATTERY POSITIVE (+) CABLE ‘TRXASOFE (After 01): STARTER MOTOR CABLE g 3 2 q 3 BATTERY Ni BATTERY POSITIVE (+) CABLE 1-37GENERAL INFORMATION EMISSION CONTROL SYSTEMS ‘The California Air Resources Board (CARB) requires manufacturers to certify that their ATVs comply with applicable exhaust ‘emissions standards during their useful life, when operated and maintained according to the instructions provided. SOURCE OF EMISSIONS ‘The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, Under certain conditions, they react to from photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic. Honda Motor Co,, Ltd. utilized 1 carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. Tho exhaust emission control system is separate from the crankcase emission control system. (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 and carburetor. AIR CLEANER DUST COVER DRAIN PLUG. BREATHER 05+03mm (0.02 + 0.01 im) (view FROM AIR CLEANER HOUSING SIDE) FLOAT LEVEL INSPECTION With the float valve seated and the float arm just touching the valve, measure the float level with the special tool as shown. FLOAT LEVEL: 18.5 mm (0.73 in) Too! Carburetor float level gauge 07401-0010000 The float cannot be adjusted. Raplace the float assembly ifthe float level is out of specification. 5-14 SCREWS STARTER JET PILOT SCREW SLOW JET. = NEEDLE eT NEEDLE JET HOLDER —~ SW MAIN JET FLOAT VALVE FLOAT LEVEL GAUGEFUEL SYSTEM Install the baffle plate Install a new O-ring in the float chamber. Install the float chamber, aligning the overflow pipe with the hole in the baffle as shown. 7G OVERFLOW PIPE BAFFLE PLATE = FLOAT CHAMBER SCREWS FLOAT CHAMBER CARBURETOR HEATER! Install the overflow tube. ONE-WAY VALVE NOTE: Note the direction of the one-way valve, (OVERFLOW TUBE Install the four float chamber scrows. Install the carburetor heater and collar. 15FUEL SYSTEM Install the air vent tube and air cut off valve tube. AIR CUT OFF VALVE TUBE AIR VENT TUBE ‘STARTING ENRICHMENT (SE) VALVE Install the spring over the choke cable and connect the cable end to the SE vaive, TRXx450S Move the choke lever all the way to the right and left and make sure that the SE valve operates properly. TRX450ES Move the choke knob all the way to pull and push ‘and make sure that the SE valve operates properly. CARBURETOR INSTALLATION Sa BLOCK NUT jp ADJUSTER Install the throttle eable adjuster to the carburetor body. Connect the throttle cable end to the throttle drum CAUTION: Do not kink or twist the throttle cable. It will not ‘operate smoothly and may stick if it is kinked or twisted. NOTE: Apply grease to the throttle cable end. Install the carburetor cover and tighten the screw. TORQUE: 4 Nem (0.4 kgfom, 3 Ibfft) CARBURETOR COVER 5-16FUEL SYSTEM Apply multi-purpose grease to the SE valve end as | SE VALE "AIR VENT HOSE = « the SE valve and tighten the valve nut. ¥ TORQUE: 3 Nem (0.3 kgfom, 1.8 Ibftt) Conner the air vent hose into the hole on the heat guard © sult carburator by ting ts nak ip boss svn te autor grove Sette ia ofthe iauatr band nthe groove of the neltor ad intl the bon Tighten the insulator band screw. ‘Afor 01: TORQUE: 4 Nem (0.4 kgf-m, 2.9 Ibf-t] Connect the carburetor heater connector. CARBURETOR HEATER CONNECTOR Route the drain hose correctly (page 1-29) ( Adjust the throttle lever free play (page 3-4), Install the removed parts in the reverse order of \ removal Ss 5-17FUEL SYSTEM PILOT SCREW ADJUSTMENT Cm Uf the engine must be running to do some work, ‘make sure the area is well ventilated. Never run the ‘engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust ‘evacuation system in enclosed area. NOTE: SS ——_———__—__—-; PILOT SCREW. + The pilot scrow is factory pre-set. Adjustment is ot nacessary unless the carburetors are over: hauled or new pilot screws are installed. Then engine must be warm for accurate adjust- ment. Ten minutes of stop-and-go riding is sufficient. Use @ tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change. 1. Turn the pilot screw clockwise untiit seats lightly, then back it.out to the specification given, CAUTION: Damage tothe ple screw seat wl ocr the plot ferow le tightened against the sort. ov TooL: Pilot screw wrench (97908-4220201 INITIAL OPENING: 2-5/8 turns out 2. Warm the engine up to operating temperature. 3. Stop the engine and connect a tachometer ac- cording to the tachometer manufacture's instruc: tions, 4, Start the engine and adjust the idle speed with the throttle stop screw. IDLE SPEED: 1,400 = 100 rpm THROTTLE STOP SCREW 5, Turn the pilot screw in or out slowly to obtain the highest engine speed. 6, Readjust the idle speed with the throttle stop, screw. 7. Turn the pilot screw in gradually until the engine @ speed drops 100 rpm. 8, Turn the plot screw counterclockwise the number, ‘of turns to the specification given. FINAL OPENING: 1/2 turns out 5-18FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT MAIN JET SPECIFICATIONS Below Between 5,000 ft 3,000 - 8,000 ft (4,500 m) (7,000 - 2,500 mi Main jot #130 120 The carburetor must be adjusted for high altitude riding (between 3,000 ~ 8,000 f/1,000 - 2,500 m). ‘STANDARD SETTING: Below 5,000 fe (1,500 m) HIGH ALTITUDE SETTING: ‘Between 3,000 ~ 8,000 ft (1,000 - 2,500 m} The high altitude carburetor adjustment is per- formed as follows: Romove the carburetor (page 5-5) and flost chamber. Replace the standard main jet with the high altitude type. HIGH ALTITUDE MAIN JET: #125 Assemble and install the carburetor. Start the engine and adjust the idle speed at high altitude to ensure proper high altitude operation. _ If the engine must be running to do some work, ‘make sure the area is well ventilated. Never run the ‘engine in an enclosed ares. The exhaust contains poisonous carbon monoxide gas that may cause {oss of consciousness and may lead to death. Run the engine in an open area or with an exhaust ‘evacuation system in enclosed area. CAUTION: ‘Sustained operation below 5,000 feet (1,500 m) with the high altitude settings may cause engine overheating and engine dai Install the ‘standard main jet and adjust the idle speed with the throttle stop screw, when riding below 5,000 foot (1,500 m). ‘STANDARD MAIN JET: #130 IDLE SPEED: 1,400 + 100 rpm 5-19FUEL SYSTEM FUEL TANK REMOVAL 12 Nom (1.2 kgfem, 8 Ibi) FUEL TANK 5-20 e® @ ®FUEL SYSTEM Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Turn the fuel valve off Remove the side/fuel tank cover (page 2-4), Remove the fuel tank mounting batts Remove the fuel tank seal rubber. Remove the fuel tank holder bands. FUEL TANK SEAL RUBBER! Slightly pull the fuel tank up, then disconnect the FUEL TANK fuel tube from the fue! valve ‘i Remove the fuel tank. Disconnect the carburetor air vent tube from the fuel tank heat guard. Remove the the guard, retaining clips and fuel tank heat 5-21FUEL SYSTEM FUEL STRAINER SCREEN ‘Turn the fuel valve OFF. Remove the fuel tank Remove the fuel valve mounting bolts and fuel valve, and drain the gasoline into an approved gasoline container. FUEL VALVE CR + Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not ‘smoke or allow flames or sparks in your working area or where gasoline Is stored. [STRAINER SCREEN Romove the O-ring and strainer screen. Wash the strainer soreen in clean non-flammable (high flush point solvent Reinstall the screen Install a new O-ring into the fuel valve body. Reinstall the fuel valve and tighten the bolts to the specified torque. FUEL VALVE TORQUE: 9 Nem (0.9 kgfem, 6.5 Ibfott) Connect the fuel tube. ‘After installing, turn the fuel valve ON and check that there are no fuel leaks. FUEL TANK INSTALLATION AIR VENT TUBE Sot the fuel tank heat guard ante the frame, then install the front section of the heat guard into the frame. Install the retaining clips. Connect the carburetor air vent tube. NoTE: During heat guard installation, route the fuol tube and carburetor air vent tube properly. 5-22FUEL SYSTEM Connect the fue! tube to the fuel valve FUEL TUBE Set the fuel tank onto the frame, install and tighten the mounting bolts. Install the fuel tenk holder bands and fuel tank seal FUEL TANK SEAL RUBBER, rubbar. NOTE: ‘After installation, make sure there are no fuel leaks. 5-23ENGINE REMOVAL/INSTALLATION 32 Nem (3.3 kgfom, 24 Ib) 16 Nem (1.6 kafem, 12 Ibt-f) (after ‘on 20 Nem (2.0 gfe, 14 Ibeft) 32 Nem (3.3 kafem, 24 Ibfft) 6-06. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 61 ENGINE INSTALLATION 66 ENGINE REMOVAL 62 SERVICE INFORMATION GENERAL + The following components require engine removal for service. Crankshaft (Section 11) ~Transmission (Section 11) = Gearshift linkage (Section 9) wo + The Following components can be serviced with the engine instalied in the frame. ~Cylindor headivaives (Section 7) ~ Camshaft (Section 7) Cylindar/piston (Section 7) ~Clutch (Section 8) = Recoil starter/alternator/starter clutch (Section 10) Carburetor (Section 5) =Oill pump (Section 4) Control motor (Section 21) SPECIFICATIONS rem ‘SPECIFICATIONS Engine oll capacity | At draining | 2.0 2 (2.10 USar, 1.76 Imp qt) - ‘At desassembiy 2.7 2 (2.84 USat, 2.38 Imp a) Engine dry weight [50.2 ka (110.7 Ibs) TORQUE VALUES Upper engine hanger bolt 54 Nem (8.5 kafem, 40 Ibfeh) Upper engine hanger plate bolt 82 Nem (3.3 kgfem, 24 Ibft) Lower engine mounting bolt (right) 54 Nem (8.5 kgfem, 40 Ibi) Lower engine mounting bolt (left) 54 Nem (5.5 kaf-m, 40 Ibfft) Lower engine hanger mounting bolt 32 Nem (3.3 kgfem, 24 Ibfeft) Gear shift pedal bolt (98 - 01) 36 Nem (1.8 kafem, 12 IbFft) (After 01) 20 Nem (2.0 kafem, 14 Ibfft) 6-1ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL TAXASOSIFM: ‘98- oF Drain the engine oil (page 3-10) Remove the following ~ Exhaust pipe/Muffler (page 2-15) ~ Front fender (page 26) = Air cleaner housing (page 5-4) ~ Carburetor ipage 5-5) ~ Fuel tank and fuel tank heat guard (nage §-20) Disconnect the spark plug cap. Remove the bolts, collars and right engine side Remove the nut and starter motor cable. Remove the bolt and ground cable terminals. Disconnect the alternator, ignition pulse generator and neutral reverse switch connectors Disconnect the speed sensor connector and connector bracket from the frame stay. EXHAUST PIPE CARBURETOR| "98-01: NEUTRAUREVERSE SPEED SENSOR SWITCH CONNECTOR. CONNECTOR \ i as. ALTERNATOR/PULSE GENERATOR CONNECTOR 6-2© ENGINE REMOVAL/INSTALLATION TRXASOESIFE: 98-01 TRXASOESFE Disconnect the alternator, ignition pulse generator and gear position switch connectors, Disconnect tho speed sensor connector and 1 bracket from the frame stay Disconnect the reverse control cable end from the Disconnect the oil thermo sensor connector from the sonsor. Release the thermo sensor and engine harness wire clamps. Remove the wire clamp from the recall starter cover. Remove the socket bolts, setting plate, oil cooler pipes and O-rings, Disconnect the contra! motor connector (2P white. s8-01 SPEED SENSOR CONNECTOR GEAR POSITION SWITCH CONNECTOR GEAR POSITION SWITCH CONNECTOR REVERSE CONTROL CABLE! TRX4S0ESIFE SHOWN: 2P WHITE CONNECTOR X450ES/FE) OL CQOLER ZS WS » So SETTING PLATE ‘SOCKET BOLTS 6-3ENGINE REMOVAL/INSTALLATION Remove the bolts, collars and left engine side cover. LEFT ENGINE SIDE COVER| TRX«SOS/FM. Remove the gearshift pedal Loosen the swingarm boot band screw. SCREW Boot | Remove the upper engine hanger bolt. Remove the hanger bracket bolts, upper hanger plate and mounting rubbers and bracket. 98-01: Remove the bolt and two retaining clips and propeller shaft cover. PROPELLER SHAFT COVERENGINE REMOVAL/INSTALLATION Remove the let lower engine hanger boltnut, collar HANGER BOLT MOUNTING RUBBERS and engine mounting rubbers. Remove the bolts and left lower engine hanger brackat. Remove the rear mounting bolt. Move the front differential forward, Remove the front propeller shaft PROPELLER SHAFT Remove the right lower engine hanger bolt/nut, MOUNTING RUBBERS: COLLAR collar and engine mounting rubbers. ryENGINE REMOVAL/INSTALLATION Remove the following: UPPER MOUNTING BOLT/NUTI/COLLAR| ~ Front differential mounting bolt and nut ~ Front differential mounting bracket bolts and bracket ~ Upper mounting bolt, nut and collar Be careiui not Move the engine forward, then disconnect the yoke ‘damage the contro!_joint from the final shaft motor upon sane Remove the ongine from the left side of the frame. ENGINE INSTALLATION Apply molybdenum disulfide grease to the yoks joint \ splines, = Install the engine from the left side, Move the engine rearward and connect the final shaft and yoke joint When stating the Install the mounting rubbers and lower left engine | ‘engine loosely hanger bracket. engine anger ard install the lower left engine hanger bolts and nut Then ighten tho (ANGER BOLT, potstoma NOTE: = speeited Yergue 23 install the mounting rubbers with the wide side Show bellow. towards the engine. First tighten the engine hanger bolt to the specified torque. ‘TORQUE: 54 Nem (6.8 kaf, 40 Ibf-ft) Tighten the lower hanger bracket bolts to the specified torque. TORQUE: 32 Nem (3.3 kaf-m, 24 Ibf-t) BRACKET BOLTSENGINE REMOVAL/INSTALLATION ‘mounting rubbers, collar and hanger boltinut tothe =) specified torque. 7; Install and tighten the lower right engine hanger = MOUNTING RUBBERS j COLLAR | TORQUE: 54 Nem (6.5 kgfem, 40 Ibf-ft) HANGER BOLT/NUT Install the upper hanger plale, engine hanger bracket, bracket bolts, mounting rubbers and hanger bolt. MOUNTING RUBBERS. First tighten the hanger bracket bolts to the specified torque, ‘TORQUE: 32 Nem (3.3 kgf+m, 24 tbfett) Tighten the upper engine hanger bolt to the specified torque. ‘TORQUE: 54 Nem (6.5 kat-m, 40 Ibf-tt) Paes yl i} iF a BRACKET BOLTS NT HANGER BOLT Apply molybdenum disulfide grease to the propeller shaft splines, Install the front propeller shaft. ‘Connect the propeller shaft to the engine aver the -ring while pulling back the propeller shaft joint, Rotato the shatt slightly if necessary to align the splines. Tighten the rear mounting bait to the specified torque. TORQUE: 44 Nem (45 kafor, 33 Ibfft) REAR MOUNTING BOLT!ENGINE REMOVAL/INSTALLATION Install the upper mounting bolts with the upper UPPER MOUNTING COLLAR/BOLT/NUT ‘mounting collar and nut in the location as shown. Tighten the upper mounting nut to the specified torque, TORQUE: 44 Nem (455 ki 1m, 33 loft) Install the front mounting bracket and mounting bolt ‘then tighten the bolts and nut to the specified torque. TORQUE: 22 Nem (2.2 kaf+m, 16 lbfett) BRACKET ‘99-01: Install the propeller shaft cover, ‘BOLT pm Install the retaining clips and mounting bolt, then tighten the bolt securely, Set the swingarm boot on the rear crankcase cover properly and tighten the screw. TRX450SM |nstall the gearshift pedal on to the gearshift spindle by aligning the punch marks. ALIGN Tighten the bol to the specified torque. TORQUE: ‘98 - Astor“ 1: 16 Nem (1.6 kgfom, 12 tbfft) 20 Nem (2.0 kgf-m, 14 Ibf-ft)ENGINE REMOVAL/INSTALLATION TAXAGOES FE: TRXASOSIEM. Install the left engine side cover and collars, then, tighten the bolts. LEFT ENGINE SIDE COVER Connect the oil cooler pipes using new O-rings. TARRESESHOWN TS Install the setting plate and tighten the socket bolts. A RN 2P WHITE CONNECTOR (TRX4S0ES/FE) Connect the contro! motor connector (2° White). | OL COOLER PIPES Route the alternator, ignition pulse generator, neutral reverse switeh and oll thermo sensor wire properly (page 1-28) and clamp them securely. Connect the reverse control cable end to the reverse selector lever and hook the cable to the cable guide. Connect the thermo sensor wire connector. Connect the alternator, ignition pulse generator and neutralreverse switch connectors, "98- SPEED SENSOR CONNECTOR NEUTRAU/REVERSE SWITCH CONNECTOR Connect the speed sensor connector and set the connector bracket to the flame stay.ENGINE REMOVAL/INSTALLATION TRXSSOES'FE Connect the alternator, ignition pulse generator and, "960% GEAR POSITION Gear position switch connectors. Se MV EENSIE SATE coNMIGTOR connector bracket to the flame stay, Connect the engine ground cable terminals and tighten the bolts, Connect the starter motor cable and tighten the nuts. Install the right engine side cover and tighten the bolts, 6-10ENGINE REMOVAL/INSTALLATION Install the spark plug cap. SPARK PLUG CAP CARBURETOR] lnstall the carburetor (page 5-16), Install the removed parts in the reverse order of removal Fill the crankcase with recommended engine oil (page 3-10). Fill the front differential with recommended gear oil (page 3-13). Perform the following inspection and adjustment ~ Throttle operation (page 3-4) Reverse selector cable adjustment (page 3-18) 6-11CYLINDER HEAD/CYLINDER/PISTON tirade nan SE Valve seat cutter holder, 5.6 mm 07781-0010101 equivalent commercially available in U.S.A. 7-10 |© Retace ine seat wn a 45-c6gr00 cutter wnenaver a valve guido ie replaced. Use a 45-degree cutter to remove any roughness or imegularities from the seat. Use a 32-degree cutter to remove the top 1/4 of the existing valve seat material Use a 60-degree cutter to remove the bottom 1/4 of the old seat. Romove the cutter and inspect the area you have refaced. Install @ 45-degree finish cutter and cut the seat to the proper width. Make sure that all pitting and irregularities are re- moved. Refinish if necessary, CYLINDER HEAD/CYLINDER/PISTON ROUGHNESS: OLD SEAT WIDTH fay - Qe wort Me ay 7-11CYLINDER HEAD/CYLINDER/PISTON Tha faction ofthe vawe seat in relation 0 9 valve Taco 16 very sreonart for good seaing, Do rot alow lapping compound oenter the guides, Apply a thin coating of Prussian Blue to the valve seat. Press the valve through the valve guide and onto tho seat to make a clear pattern. Ifthe contract area is too high on the valve, the seat ust be lowered using a 32-degree flat cutter. If the contact area is too low on the valve, the seat ‘must be raised using a 60-degree inner cutter. Refinish the seat to specifications, using a 45-degree finish cutter. ‘After cutting the seat, apply lapping compound to ‘the valve face, and lap the valve using light pressure. After lapping, wash all residual compound off the cylinder head and valve. CONTACT TOO HIGH OUD SEAT wioTH 0 CONTACT TOO LOW oun sear ~ Cr HAND-LAPPING TOOL 7-12 eCYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD ASSEMBLY CYLINDER HEAD COTTERS SPRING RETAINER, ‘OUTER SPRING. After ‘01: SPAING — Seat a VALVE: Guibe mI Pom 8 KS exaust VALE INTAKE VALVE Clean the cylinder head assembly with solvent and SPRING SEAT blow through all oll passages with compressed air. Install the valve spring seats. Install the new stom seals. CETER 7 ‘SPRING Lubricate the valve stams with engine oll and insert the valve into the valve guide. To avoid damage to the stom seal, turn the valve a reaneneg Poa jen INNER SPRING ‘SPRING RETAINER g g FACING THE COMBUSTION CHAMBER Install the valve springs with the tightly wound coils facing the combustion chamber. Install the valve spring retainer. 7-13CYLINDER HEAD/CYLINDER/PISTON. Install the valve cotters using the special tool as VALVE SPRING COMPRESSOR shown, TooL: Valve spring compressor (07757-0010000 CAUTION: To prevent loss of tension, do not compress the valve spring more than necessary. Tap the valve stems gently with two plastic hammers as shown to seat the cotters firmly. CAUTION: ‘Support the cylinder head above the work bench surface to prevent possible vaive damage. CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket {as shown. Install the cylinder head. NOTE: Do not install the gasket upside down. Install it a5 shown. ROCKER ARM HOLDER ASSEMBLY Lubricate the rocker arm and rocker arm shaft with molybdenum disulfide oil. Place the rocker arm into the rocker arm holder, then insert the rocker arm shat. NOTE: If reusing, install the rocker arms in their of locations as marked. Turn the rocker arm shaft using @ screwdriver to align the hole between the racker arm holder and. shaft. Apply oil to the thread and flange surface of the rocker arm holder bolt. Install and tighten the bolt to the specified torque, TORQUE: 7 Nem (0.7 kgfom, 5.1 bfft) MOCKER ARM SHAFT Bill ROCKER ARMS 7-14ROCKER ARM HOLDER INSTALLATION Properly install the push rods into the center groove of the cam follower. NOTE: tf reusing, install the push rods in their original loca- tions as marked. Install the two dowel pins. Turn the crankshaft clockwise using the recoil starter knob, and align the *T* mark on the flywheel with the indox mark on the rear crankcase cover. ‘Make sure the piston is at TOC on the compression stroke. Ifnot, rotate the crankshaft 360° (1 full turn) and align the "T* mark with the index mark. Install the rocker arm holder onto the cylinder head, Install the new washers and cap nuts, Tighten the cap nut in a crisscross pattorn in 2-3 steps. TORQUE: 39 N-m (4.0 kgfom, 29 Ibf-tt) Install and tighten the cylinder head mounting 6 mm bolts. Install the upper engine hanger bracket, and tighten bracket bolts and the hanger bolt ‘TORQUE: Bracket bolt: 32 Nem (3.3 kgfom, 24 lb-ft) Hanger bolt: 54 Nem (6.5 kafom, 40 Ibf-ft) Check the O-ring Is in good condition, install the carburetor insulator. Tighten the insulator bolts. Install the fuel tank bracket and tighten the bolts. CYLINDER HEAD/CYLINDER/PISTON PUSH RODS, WASHERS (SMALL! ©.D,/CAP NUTS INSULATOR [FUEL TANK BRACKET BOLTS 7-15CYLINDER HEAD/CYLINDER/PISTON Install the following: ~ Spark plug cap = Carburetor (page 5-16) ~ Exhaust pipe (page 2-16) EXHAUST PIPE mm SPARK PLUG CAP, Install a new cylinder head cover gasket. Install a new O-ting into the groove of th arm holder. Install the cylinder head cover and tighten the bolts Install the fuel tank heat insulator and fuel tank (page 521) CYLINDER/PISTON REMOVAL CYLIDER REMOVAL Remove the cylinder head (page 7-4). Remove the cylinder bolts and cylinder. CYLINDER 7-16CYLINDER HEAD/CYLINDER/PISTON Remove the cylinder gasket and dowel pins. PISTON REMOVAL Do nctiet he piston Remove the piston pin clip with pliers. en cips fal ito the crankcase. Press the piston pin out of the piston and remove the piston. CYLINDER/PISTON INSPECTION CYLINDER Inspect the cylinder bore for wear or damage. Measure the cylinder I.D. in X and ¥ axis at three levels. Take the maximum reading to determine the cylin: der wear, ‘SERVICE LIMIT: 90.10 mm (3.547 in) Calculate the piston-to-cylinder clearance. Take a maximum reading to determine the clear- ance. Rofer to page 7-19 for measurement of the piston OD. ‘SERVICE LIMIT: 0.10 mm (0.004 in} Calculate the taper and out of round at three levels, in X and ¥ axis. Take the maximum reading to determine them. SERVICE LIMITS: Taper: {0.10 mm (0.004 in) Out of round: 0.10 mm (0.004 in} ‘The cylinder must be rebored and an overs fitted ifthe service limits are exceeded. piston The following oversize pistons aro available: 0.25 mm (0.010 in) (0.50 mm (0.020 in) 0.75 mm (0.030 in) 1.00 mm (0.039 in) ‘The piston to cylinder clearance for the oversize pis- ‘ton must be: 0.036-0.058 mm (0.0014-0.0022 in) 7-17CYLINDER HEAD/CYLINDER/PISTON Inspect the top of the evlinder for warpag ‘SERVICE LIMIT: 0.10 mm (0.004 in) PISTON Do not damage tte Remove the piston rings. ston rings dung removal Remove any carbon deposits from the piston ring ‘grooves, using an old piston ring as shown. position with the mark facing up. Measure the piston ring-to-ring groove cl with the rings pushed into the grooves, ‘SERVICE LIMIT: Top: 0.09 mm (0.004 in) Second: 0.09 mm (0.004 in) 7-18CYLINDER HEAD/CYLINDER/PISTON Inspect the piston for wear or damage. Measure the diameter of the piston at 10 mm (0.4 in) from the bottom and 90 degrees to the piston, pin hole. 10 mm ‘SERVICE LIMIT: 89.90 mm (3.639 in) Measure the piston pin bore, SERVICE LIMIT: 19.08 mm (0.751 in) Ld Measure the 0.0. of the piston pin. SERVICE LIMIT: 18.96 mm (0.746 in) Calculate the piston-to-piston pin clearance. ‘SERVICE LIMIT: 0.12 mm (0.039 in) Measute the connecting rod small end 1.D. ‘SERVICE LIMIT: 19.07 mm (0.7508 in)CYLINDER HEAD/CYLINDER/PISTON Push ne rings rio Insart tho piston ring squarely into the bottom of tho onder win 12 the eylinder and measure the ring end gap. topot tte pistono desu ieyare SERVICE LIMITS: squarely inte Top: 0.5 mm (0.02 in} "M22" Second: 0.6 mm (0.02 in} PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings. NOTE: + Apply oil to the piston rings. + Avoid piston and piston ring damage during installation. + Install the piston rings with their markings facing up. + Do not mix the top and second rings: the top ring is narrower thaa the second ring in width, ‘Space the piston ring end gaps 120 degrees apart. Do not align the gaps in the oil rings (side rails). ‘After installation, the rings should rotate freely in the ring grooves. CYLINDER/PISTON INSTALLATION PISTON INSTALLATION IN" MARK | ‘Apply oll to the piston pin outer surtace. Install the piston with its “IN" mark facing the intake side. Install the piston pin and secure it with new piston pin clips. NOTE: + Do not align the piston pin clips end gap with the piston cut-out. + Do not let the piston pin clips fall into the crank- case. 7-20CYLINDER HEAD/CYLINDER/PISTON CYLINDER INSTALLATION Clean off any gasket materials from the crankcase surface. Apply liquid sealant to the crankcase mating surface. Install the dowel pins and new gasket. ‘Avoid piston ring Coat the cylinder bore and piston with engine oil ‘damage during and install the cylinder. instaliaon. Install and tighten the eylinder mounting bolts. Install the cylinder head and push rods (page 7-14)CYLINDER HEAD/CYLINDER/PISTON CAMSHAFT/CAM CHAIN TENSIONER ‘CAM FOLLOWERS CAMSHAFT REMOVAL oO Remove the following: ~ Cylinder head (page 7-4) = Cylinder (page 7-16) Of = Centrifugal clutch and change clutch (section 8) Remove the cam followers. Mark the cam followers so they can be reinstalled in their original positions. Ay book FL S—— 7mm 9.5mm Remove the cam chain tensioner lifter mounting bolts and tensioner. Remove the cam sprocket bolts, sprocket from the camshaft flange. If itis necessary hold the end of the crankshaft to remove the cam sprocket bolts, use the special too) TOOL: Main shaft Holder (07JMB-MIN50200 Remove the cam sprocket and cam chain. Remove the camshaft bearing 1 tainer. 7-22‘Align the punch mark on the cam spracket with the index mark on the crankcase, then remove the cam- shaft CAM CHAIN TENSIONER REMOVAL Romove the mainshaft bearing retainer bolts and bearing retainericam chain tensioner assembly. Remove the oil pump (page 4-8) and cam chain slipper. INSPECTION Camshaft Using a micrometer, measure the height of each cam lobe and inspect it for wear or damage. ‘SERVICE LIMITS: IN: 36.25 mm (1.427 in) EX: 36.10 mm (1.421 in) Turn the camshaft bearing outer race with your finger. The bearing should be turn smoothly and quietly ‘Also check that the bearing inner race fits tightly on the camshaft. Replace the camshaft as an assembly, if the races do not turn smoothly, quietly, or if they fit loosely ‘on the camshaft, Check the decompressor cam operation. Look at the base of the exhaust lobe. Press on the decompressor cam as shown. ‘As you press on one side, the decompressor cam should lock above the exhaust base. As you press (on the other side, the decompressor lobe should be CYLINDER HEAD/CYLINDER/PISTON INDEX MARK BEARING DECOMPRESSOR CAM DEPRESS 7-23CYLINDER HEAD/CYLINDER/PISTON: Push rod (Check that the push rads are not bent. CAUTION: Do not disassemble the push rods, f you do, replace the push rods necessary. ‘Cam follower Cheek the cam follower for damage. Measure the cam follower 0.0. SERVICE LIMIT: 22.46 mm (0.884 in} Measure the crankcase |.D. at the cam follower sliding surface. ‘SERVICE LIMIT: 22.54 mm (0.887 In} Calculate the clearance. SERVICE LIMIT: 0 ‘mm (0.003 in) Cam chain tensioner Check the slipper surface of the cam chain tensioner arm for wear or damage. PUSH ROD) 9 SLIPPER SURFACE 7-24CYLINDER HEAD/CYLINDER/PISTON (CAM CHAIN TENSIONER ‘SLIPPER| TENSIONER, INSTALLATION 4 Apply a locking agent tothe threads of the mainshatt bearing retainer bolts. Install the mainshatt bearing retainer/cam chain tensioner, tighten the bolts. Install the cam chain slipper and oil pump (page 4- 1). CAMSHAFT INSTALLATION Align the “T" mark on the fiyhwheel with the index ‘mark on the rear crankcase by turning the recoil starter, Apply molybdenum disulfide oil to the camshatt Iobes and apply cil to the camshaft journal. Install the camshaft and camchain into the crankcase with its cam lobes facing down. Install the camshaft bearing retainer aligning the _- {grove of the retainer with the crankcase boss. Apaly a locking agent to the retainer bolt threads. Install and tighten the bos. 7-25CYLINDER HEAD/CYLINDER/PISTON aft flange with ‘Align the punch mark on the cam sprocket with the index mark on the crankcase, then install the cam. chain and cam sprocket onto the camshaft flange. NOTE: Do not turn the crankshaft while installing the cam. sprocket. Apply a locking agent to the threads of the cam sprocket bolts. Install the cam sprocket bolts. Tighten the punch mark side boit frst then the other, bolt. NOTE: Confirm that the “T" mark on the fiywhee! with the index mark on the rear crankcase cover, while the punch mark on the camshaft is aligned ‘with the index mark on the front erankcas ‘TORQUE: 20 Nem (2.0 kgfem, 14 Ibi) Apply clean engine oil tothe outer and inner surface, of the cam followers, Install the cam follower into the crankcase, INDEX MARK a a Y 7-26INSTALLATION ‘Turn the tensioner shaft clockwise with the stopper tool to retract the tensioner, then insert the stopper fully to hold the tensioner in the filly retracted position, Install a new gasket on the cam chain tensioner lifter. Install the cam chain tensioner lifter and tighten the bolts. Remove the holder tool from the tensioner lifter. Check the O-ring is in good condition, install the sealing screw. TORQUE: 4 Nem (0.4 kgfem, 3 Ibftt) Install the following: = Change clutch and centrifugal clutch (section 8) = Cylinder (page 7-20) ~ Cylinder head (page 7-14) CYLINDER HEAD/CYLINDER/PISTON QI Vie) C&S renboken Wiel rome oe BOLTS 7-27CLUTCH 118 Nem (12.0 kafem, 87 Ibfeft) 108 Nem (11.0 kghm, 80 tbftt)” “A \ 8-0 ©8. CLUTCH SERVICE INFORMATION 81 CENTRIFUGAL CLUTCH a4 TROUBLESHOOTING 82 CHANGE CLUTCH 8-12 FRONT CRANKCASE COVER FRONT CRANKCASE COVER REMOVAL 8-3 INSTALLATION 8-18 SERVICE INFORMATION GENERAL + This section covers removal and installation of tho contrifugal clutch, change clutch. + These parts can be serviced with the engine installed in the frame. + TAX 450 ES must have the electric shift control motor and reduction gears removed before servicing (section 21). SPECIFICATIONS unison EE Tem STANDARDS | service unit Change clutch | Spring tree length [wea a26) win (12a) Dise thickness 2.62 276 0.103 - 0.109) 2.3 (0.09) Plate warpoge [00 10.008) Clutch outer guide 00, 27.969 ~ 27.980 (1.1007 7.1016) | 27.92 (7.088) | 1D 72,000 22.021 10.8661 0.8670) | 22.05 (0860) Mainshalt 01D. at outer guide 71972 21.959 0.9650-0.9659) | 27.89 10.863) Centitugel Drum 1.9 [taoo-w02 (551-552) 140.4 6.59) ee Weight lining thickness [30 (0.12) 2.0 (0.08) Clutch spring height 3.10.12) 2.95 (0.116) Cluten weight spring fee length 21.6 (0.85) 725 009) Primary drive bo, 27,000 ~ 27,021 (1.0630 - 1.0638) | 27.05 (1.065) oe Crankshaft 0.0. at drive gear 726.959 — 26.980 1.0614 - 1.0622) | 26.83 (1.060) TORQUE VALUES Centrifugal clutch outer lock nut 118 Nem (12.0 kgf+m, 87 Ibf-ft) Apply oil to the threads {luton spring bot 12Nem (1.2 kgf, 9 br) Change clutch center lock nut 102 Nim [1.0 gk, BOB) Apply oto the threads Angie sensor Bem [08 kgm, 4 otCLUTCH TOOLS Remover handle 07936-3710100 Bearing remover, 17 mm 07836-3710300 Remover weight 0781-0010201__0r 07936-371020A or 07936-3710200 Clutch holder (O7GMB-HA70101_or 07GMB-HA7010A or 07GMB-HA7011A ond O7GMB-HA7012A, Clutch center holder (O7JMB-MN50300 or 07HGB-0010108 and 07HGB-0010208 (U.S.A. only) Clutch puller (07833-HA80000 or 07933-HB3000A (U.S.A. only) Driver 0749-0010000 Attachment, 42 X 47 mm (07746-0010300, Pilot, 17 mm 07746-0080400, Driver, 22mm LD, (0746-0020100 Attachment, 20 mm 1D. 0746.0020400 TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch. Clutch operating feels rough (Clutch slips when accelerating + Outer drum siots rough + Feulty clutch lifter + Incorrect idle speed adjustment + Discs/piates worn + Weak springs Hard to shitt + Incorrect clutch adjustment (Clutch will not disengage + Faulty clutch lifter mechanism + Faulty clutch lifter mechanism + Shift drum cam plate damaged + Plates warped ‘The vehicle creeps with clutch disengaged + Faulty centrifugal clutch + Plate warpedCLUTCH FRONT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-11). Remove the oil cooler pipes (page 4-2), Remove the right engine side cover. TAX450ES only Remove the front propeller shaft (page 6-4) and control motor (page 21-28) Remove the bolts and front crankcase cover. Romove the gasket, O-ring and three dowel pins. Remove the clutch adjusting bolt lock nut, then re- ‘move the clutch adjusting plate, BEARING REPLACEMENT Turn the crankshaft end bearing inner race with your finger. ‘The bearing should turn smoothly and quietly. ‘Also check that the bearing outer race fits tightly in the crankcase cover. Replace it if necessary. BOLTS 8-3CLUTCH Remove the crankshaft end bearing from the front crankcase cover using the special tools as shown, Toots: Remover handler 07936-3710100 Bearing remover, 17mm 07936-71030 Remover weight (07741-0010201 or (07936-3710200 or (07936-3710208 BEARING REMOVER Drive @ new crankshaft end bearing into the cover, DRIVER with its sealed side facing the cover, using the ‘special tools as shown. Toots: Driver (0748-0010000 ‘Attachment, 42 X47 mm 07746-0010300 Pilot, 17 mm. (0746-0040400 CENTRIFUGAL CLUTCH REMOVAL Unstake the lock nut, Hold the centrifugal clutch weight assembly with 2 clutch holder and remove the lock nut. TooL: Clutch holder (07GMB-HA70101 or (O7GMB-HA7O10A (U.S.A. only) or Clutch holder plate O7GMB-HA7011A, Clutch holder pins O7GMB-HA7012A Discard the lock nut. CLUTCH HOLDER 8-4Remove the washer. using the special tool as shown. Too: Clutch puller (07GMC-HB30100 or (07933-HB3000A (USA. only) Remove the change clutch assembly (page 8-12) Remove the primary drive gear and washer. INSPECTION ‘One-way eluteh & Hold the clutch drum and rotate the clutch weight assembly. ‘You should only be able to turn it counterclockwise Remove the clutch weight assembly. 8-5CLUTCH Remove the one-way clutch from the clutch drum. Inspect the one-way clutch for smooth operation and ccheck the rollers for excessive wear. }ONE-WAY CLUTCH. raya cavenarcce OD rl Weight lining ‘Measure the weight lining thickness as shown. UNING SERVICE LIMIT: 2.0 mm (0.08 in) For replacement, see page 8-7. Clutch drum Check the inside of the centrifugal clutch drum for scratches or excessive wear. Roplace if necessary. Measure the ID. of the clutch drum. SERVICE LIMIT: 140.4 mm (5.53 in)Primary drive gear Inspect the primary drive gear for damage or ox. Measure the primary drive gear |.0. ‘SERVICE LIMIT: 27.05 mm (1.065 in) Weight spring/clutch spring Remove the E-clips using screw driver. CAUTION: Wien compressing the clutch spring, be careful not to damage the clutch weight assembh Remove the following: ut side washer = Clutch spring = Inside washer Remove the weight springs and clutch weights from the drive plate, ‘Measure the height of the clutch spring. SERVICE LIMIT: 2.95 mm (0.116 in} Replace the spring if itis shorter than the servico limit WASHER WEIGHTS CLUTCH SPRINGSCLUTCH Check the weight springs for wear or damage, and Measure the length of the weight spring. ‘SERVICE LIMIT; 22.5 mm (0.89 in) Replace the spring if they are longer than the service limit. Crankshaft at the primary drive gear Measure the crankshaft 0.D, at two locations as shown. ‘SERVICE LIMIT: 26.93 mm (1.060 in) ASSEMBLY PRIMARY DRIVE GEAR ONE-WAY CLUTCH CLUTCH WEIGHT INSIDE WASHER. OUTSIDE WASHER ae | Lock NUT 118 Nem (12.0 kgfem, 87 IbfeA) i y \ DRIVER PLATE WASHER CUP 8-8Install the clutch weights and springs onto the drive WEIGHTS plate. NOTE: + Install the weights as shown. + Install the springs with the open ends down. Install the inside washer and cluteh spring. INSIDE WASHER NOTE: Install the spring with the dished face down towards the inside as shown. Install the outside washer with the locating pins facing out. CLUTCH SPRING. Install the €-clips with their gaps aligned with the locating pins Install the one-way clutch in the eluteh drum with its “OUT-SIDE" mark facing out. CLUTCH ‘SPRINGS ‘QUT SIDE WASHER OUT-SIDE MARK jONE-WAY CLUTCH 8-9CLUTCH Install the centrifugal clutch weight assembly in the clutch drum, rotating the weight assembly counter- clockwise. INSTALLATION Install the washer onto the crankshatt. Install the primary drive gear. Install the change clutch (page 8-16). Install the centrifugal clutch weight assembly and clutch drum to the crankshaft. Nort How to install: First align the splines of the drive plate and crankshaft; and then rotating the clutch ‘outer, align the splines of the primary drive gear ‘and elutch outer, ‘Tap the clutch drum lightly using the special tools. TOOLS: Driver, 22 mm LD. (07746-0020100 Attachment, 20 mm, (07746-02040 8-10CLUTCH Install the washer. Apply oll to the new lock nut threads. Install the new lock nut, Hold the centrifugal clutch weight assembly with the ‘special tool and tighten the lock nut to the specified torque. TORQUE: 118 Nem (12.0 kgfom, 87 Ibf-ft) TooL: Clutch holder 07GMB-HA70101 or O7GMB-HA7010A, (U.S.A. only) oF Clutch holder plate O7GME-HA7011A Clutch holder pins O7GMB-HA7012A, Stake the lock aut Install the front crankcase cover (page 8-18). 8-11CLUTCH CHANGE CLUTCH BALL RETAINER/LIFTER CAM REMOVAL Remove the following: ~ Front crankcase cover (page 8-3) = Centrifugal clutch (page 8-3) = Clutch lever and washer ~ Ball retainer and spring = Lifter cam move the lifter bearing and bearing holder. Remove the clutch bolts, loosening them in a criss- 9) ross pattern in 2 or 3 steps. Remove the lifter plate and clutch springs. Unstake the clutch center lock nut. 8-12Install the special tool using four 6 X 5 mm bolts {as shown, and remove the clutch lock nut. Toots: Clutch center holder (07JMB-MIN50300 or Holder plate (O7HGB-0010108 (S.A. only) of ‘O7HGB.001010A (U.S.A. only) Holder collar ‘O7HGB-0010208 (U.S.A. only) oF (07HGB-001020A (U.S.A. only! Discard the lock nut. Remove the washer, clutch cer pressure plate as an assembly. Remove the thrust washer and clutch outer. Remove the clutch outer guide from the mai‘CLUTCH 8-14 INSPECTION Clutch lifter bearing Turn the lifter boaring with your finger. ‘The bearing should turn smoothly and freely without excessive play. necessary replace the bearing. ‘Clutch spring Measure the clutch spring free length, ‘SERVICE LIMIT: 31.0 mm (1.22 in) Clutch center Check the grooves of the clutch center for damage or wear caused by the clutch plates. Replace if necessary. Clutch dise Replace the clutch discs if they show signs of scoring or discoloration. Measure the thickness of each disc. ‘SERVICE LIMIT: 2.3 mm (0.09 in) BEARING HOLDER eCLUTCH Clutch plate Check each clutch plate for warpage on a surface plate using @ feeler gauge. SERVICE LIMIT: 0.20 mm (0.008 in] Clutch outer Chock the slots of the clutch outer for damage or wear caused by the clutch discs. Replace if necessary. Measure the 0.0. and |.0. of the clutch outer guide. ‘SERVICE LIMIT: 0.D.: 27.92 mm (1.099 in) LD. 22.05 mm (0-868 in) Mainshaft at the clutch outer guide Measure the 0.D. of the mainshatt. ‘SERVICE LIMIT: 21.93 mm (0.863 in}CLUTCH INSTALLATION OUTER GUIDE WASHER PRESSURE PLATE x @ CLUTCH OUTER | ! iQ LUFTER CAM ae CLUTCH CENTER BALL RETAINER o SPRING SPRING iS WASHER Tierer pvare Leven DP ADoocx wr Visa tase eras eo) Apply molybdenum disulfide oil to the inner and : HM OUTER cuive, ‘outer surfaces of the clutch outer guide. washen __ Instllthe cluteh outer guide on the mainshaft. Install the cluteh outer an thrust washer. Nort Confirm that the camshaft, primary drive gear, washer and the chain tensioner arm are installed. 8-16Assemble the clutch pressure plate, discs, plates and clutch center, and install them in the clutch outer. Goat new clutch discs with clean engine oil Stack the discs and plates alternately. NOTE: ‘Bo sure the clutch contor and pressure plate grooves ‘are properly aligned, or the clutch will not operate properly. Install the washer on the mainshatt Apply oil to the new lock nut threads. Install a now lock nut. Hold the clutch center using the special tool and four 6X 55 mm bolts. Tighten the lock nut to the specified torque. Toots: Clutch center holder (07JMB-MIN50300 Holder plate O7HGB-001010B (U.S.A. only! or O7HGB-001010A (U.S.A. only) Holder collar O7HGB-0010208 (USA. onlyl or ‘O7HGB-001020A (U.S.A. only! TORQUE: 108 Nem (11.0 kgfem, 80 Ibf-ft) ‘Stake the clutch center lock nut. CLUTCH PLATE, bisc PRESSURE PLATECLUTCH Install the clutch springs, lifter plate assembly and bolts. Loosely tighten the clutch bolts. Then tighten the index groove side bolts first; to center the clutch lifter plate ‘TORQUE: 12 Nem (1.2 kgf-m, 9 Ibf-ft Install the following: ~ Lifter bearing holder ~ Lifter bearing = Litter cam, = Clutch lever aligning it between the wide splines and centering in the lifter cam = Centrifugal clutch (page 8-10) = Front crankcase cover FRONT CRANKCASE COVER INSTALLATION Install the O-ring and clutch adjusting plate by align- ing its cutout with the crankcase cover stopper pin Install the washer and adjuster lock nut. 8-18TANESOES CLUTCH Apply grease to the clutch lifter cap. SPRING Install te ball retainer and spring to the clutch lifter UFTER CAP BALL RETAINER Apply oil to the clutch lever, Install the clutch lifter cam and ball retainer to the clutch lifter plate as shown, NOTE: ‘Make sure the clutch lover points toward the centor, of clutch as shown. Install the O-ring and dowel pin onto the oll pump. Install the dowel pins and new gaskot. O-RING Install the front crankcase cover and tighten the BOLTS thirteen bolts in 2 or 3 steps in a crisscross pattern, Install the right engine side cover. Install the oll cooler pipe (page 4-3) Install the front propeller shaft (page 6-4) and control ‘motor (page 21-28) Pour recommended engine oil (page 3-10) Make sure there are no oil leaks. Adjust the clutch (page 3-19).GEARSHIFT LINKAGE 22Nem (2.2 kgferm, 16 Ibfeft) TAXASOESIFE 12.Nem (1.2 kofem, 9 lb-ft) 16 Nem (1.6 kgfem, 12 tht) 9-0e 9. GEARSHIFT LINKAG SERVICE INFORMATION 9-1 GEARSHIFT LINKAGE INSPECTION 9-4 TROUBLESHOOTING 9-1 GEARSHIFT LINKAGE INSTALLATION 9-4 GEARSHIFT LINKAGE REMOVAL 9-2 REVERSE STOPPER SHAFT 9-7 SERVICE INFORMATION GENERAL + This section covers removal and installation of the gearshift linkage. + The engine must be removed from the frame before servicing the gearshift linkage except for gearshift plate mounting 9 bolt adjustment. TORQUE VALUE Drum shifter and guide piste bolt (98-01) 12 Nem (1.2 kgm, 9 Ibf-ft) Apply locking to the threads. (After ‘01) 16 Nem (1.8 kafom, 12 Ibfett) Gearshift drum stopper arm bolt 12.Nem (1.2 kafem, 9 IbFf Gearshift return spring pin 22 Nem (2.2 kgfom, 16 ft) Gearshift A arm bolt 25 Nem (2.6 kafer, 18 lb) Gearshift pedal bolt ('98 ‘01 46 Nem (1.6 kgfem, 12 lb-ft) (After ‘01) 20 Nem (2.0 kafom, 14 bff) TROUBLESHOOTING Transmission jumps put of gear * Shift drum stopper arm broken Gearshift pedal will not return + Weak or broken shift return spring + Shift spindle binding with case 9-1GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL TRxASOSEM Remove the following ~ Centrifugal clutch (page 8-8) = Ghange cluteh (page 8-12) Remove the gearshift pedal. Remove the alternator cover (page 10-6). Bond down the tab of the lock washer of gearshift A Remove the bolt and lock washer. Remove the sub-gearshitt arm. Unhook the shift arm spring from the gearshitt plate. Remove the gearshift master arm assembly. GEARSHIFT PEDAL; 9-2Remove the drum shifter and guide plate bolt, Remove the shift quide plate and gearshift plate. Remove the drum shifter while holding the stopper arm using a serewriver Remove the dowel pin. Remove the bolt, stopper arm, washer and return IRN SPRINGIWASHER spring. ae Remove the sub-gearshift spindle thrust washer. Remove the sub-gearshift spindle and thrust washer from the rear crankcase. 'SUB-GEARSHIFT SPINDLEGEARSHIFT LINKAGE GEARSHIFT LINKAGE INSPECTION Sue eats tee CALNE Inspect the sub-gearshift spindle for bends or other damage. bearings for wear or damage, DUST SEAL GEARSHIFT LINKAGE INSTALLATION SUB-GEARSHIFT SPINOLE STOPPER ARM RETURN SPRING STOPPER ARM GEARSHIFT PLATE DRUM SHIFTER GUIDE PLATE J 22. Nem (2.2 kotor, or 16 lot) GEAR SHIFT SPINDLE “ MASTERARM GEARSHIFT A ARM GEARSHIFT RETURN SPRING 25 Nem (2.5kg¢m, 12.Nem (1.2kghm, SUB-GEARSHIFT SPINDLE ARM 18 IbF) S IDF) 9-4 e {GEARSHIFT LINKAGE Install the sub-gearshift spindle and thrust washer WASHER, to the rear crankcase. ss If reverse stopper arm was removed, it must be i stalled before sub-gearshift spindle (page 9-8). Install the thrust washer onto the sub-gearshift spindle. Install the return spring, washer and stopper arm. into the crankease so that arm lies below bearing edge. Install and tighten the stopper arm bolt. TORQUE: 12 Nem (1.2 kgfem, 9 Ibeft) ifthe return spring pin was removed, apply a locking agent tothe threads and install it. ‘TORQUE: 22 Nem (2.2 kgfom, 16 Ibfeft) Install the dowel pin on the gearshift drum. Instalt the drum shifter while holding the stopper ‘arm using a screwdriver. NOTE: ‘The transmission is in neutral when the dowel pin is aligned with the index mark (boss) on the crank- case. DRUM SHIFTER Install the gearshift plate. GEARSHIFT PLATE Install the shift guide plate aligning the boss with the gearsGEARSHIFT LINKAGE Apply locking agent to the drum shifter and guide plate bolt threads. Install and tighten the bolt to the specified torque ToRQU "98—'01: 12 Nem (1.2 kgtom, 9 Ibfett) After ‘01: 16 Nem (1.6 kofem, 12 lb-ft) Align the hole in the plate with the index mark on the crankcase to place the transmission in neutral Install the gearshift master arm and return spring conte the sub-gearshift spindle. Now Install the master arm by aligning the return spring ‘ends with the crankcase stopper pin. Hook the shift arm spring between the master arm and gearshift arm. Install the sub-gearshift spindle arm onto the spindle. Nort Align the wide splines between the arm boss and sub-gearshift spindle, Install the clutch level ipage 8-18). ‘SUB-GEARSHIFT SPINDLE ARM. Install the gearshift A arm into the alternator cover groove, then install the gearshift spindle. (GEARSHIFT SPINDLE | NOTE: Align the wide splines between the gearshift erm A and spindle. GEARSHIFT A ARM 9-6TRXAs0S/FU GEARSHIFT LINKAGE Install the new lock washer and bolt, then tighten, BOLT the bolt to the specified torque. ‘TORQUE: 25 N-m (2.5 kgf-m, 8 Itt) Bend the tab of the lock washer against the bolt. Install the following e Rear erankcase cover (page 10-12) Flywheel / starter clutch (page 10-13) ~ Alternator cover (page 10-14) Docc wasven TORQUE: '98 -'01: 16 Nem (1.6 kgfom, 12 Ibftt) After'01: 20 Nem (2.0 kgfem, 14 Ibf-tt) Install the romoved parts in the reverse order of removal ALIGN REVERSE STOPPER SHAFT REVERSE (STOPPER ARM REMOVAL Remove the bolt and reverse stopper arm. Remove the rear crankcase cover (page 10-8). Remove the washer from the reverse stopper shaft, WASHERGEARSHIFT LINKAGE Pull out the reverse stopper shaft while holding the reverse arm using a screwdriver. Install the reverse stopper arm shaft in the reverse Install tho thrust washer onto the reverse stopper shaft. Install the rear crankcase cover (page 10-12), Install the reverse stopper arm with its “OUT” mark facing out. Install and tighten the reverse stopper arm bolt se- Install the alternator cover (page 10-14),MEMOALTERNATOR/STARTER CLUTCH 10-010. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION 10-1 ALTERNATOR REMOVAL 10-6 TROUBLESHOOTING 10-1 FLYWHEEL/STARTER CLUTCH —10-9 RECOIL STARTER 10-2 ALTERNATOR INSTALLATION 10-14 SERVICE INFORMATION GENERAL + This section covers removal and installation of the starter reduction gear, alternator, ignition pulse generator, flywheel and starter clutch, + Refer to section 17 for alternator inspection, and to section 18 for ignition pulse generator inspection, ‘+ These parts can be serviced with the engine in tho frame. TORQUE VALUES Recoil pulley flange bolt Starter one-way clutch socket bolt Stator socket bolt Ignition pulse generator socket bolt TOOLS Recoil pulley holder Rotor puller Flywmneel holder Driver Attachment, 24 X 26 mm, Attachment, 52 X 55 mm ‘Attachmont, 68 mm Pilot, 10 mm TROUBLESHOOTING Engine does not turn + Faulty one-way starter cluteh + Starter reduction gear broken 110 Nem (11.0 kgfem, 80 IbF ft} Apply oll to the thread and flange surface. 30 Nem (8.1 kgfem, 22 loft) Apply locking agent to the threads. 40 Nem (1.0 kgf, 7 Inf 6 Nem (06 kgfm, 43 Ibf-t) Apply locking agent tothe threads o7SMB-HNA70100 (07733-0020001 or 07833-3950000 (U.S.A. only) (0725-0040000 or equivalent commercially available in U.S.A. 07748.0010000 0746-0010700 07746-0010400 OTJAD-PHBO101 07746-0040100 10-1ALTERNATOR/STARTER CLUTCH RECOIL STARTER RECOIL STARTER ASSEMBLY REMOVAL Remove the breather tube clamps from the recoil starter cover. Remove the bolts and recoil starter assembly. DISASSEMBLY Remove the nut and the ratchet cover. Remove the ratchet and spring, RATCHET, ‘Check each part for wear or damage. SPRING. Untie the starter rope and remove the starter grip. STARTER GRIP ROPE Ruleee the star te slow Remove the starter drive pulley. DRIVE PULLEY eamow Wen ye protection and uae ere when removing the chive ply and starter spring. Th pring can ‘Pop out of the housing it care is not used. 10-2ALTERNATOR/STARTER CLUTCH Remove the starter rope from the drive pulley. DRIVE PULLEY ROPE ‘Check the starter rope for wear or damage. Check the recoil starter spring. Romove the spring and replace it if itis broken, ASSEMBLY RATCHET RATCHET SPRING FRICTION SPRING A y O RATCHET COVER Sf ROPE ‘SPRING 10-3ALTERNATOR/STARTER CLUTCH 10-4 Install the starter rope and tie a square knot as) DRIVE PULLEY shown, ‘Wrap the rope around the starter pulley in a counter clockwise direction as viewed from the ratchet side as shown, Install the spring by hooking the end on the starter ws SPRING housing hook. fo CAUTION Wear eye protection and use care when installing the starter spring. The spring can pop out of the ‘housing if care is not used. Grease the drive pulley shaft and install the pulley bby hooking the end of the spring on the pulley shaft. ‘SPRING Reload the starter spring by turning the pulley 2-1/2 DRIVE PULLEY turns clockwise. e @ ©ALTERNATOR/STARTER CLUTCH Route the rope end through the starter housing hole STARTER GRIP ROPE ‘and install the grip. Tie the rope end in a square knot. stall it with the spring. Install the clip to the ratchet cover. Install the ratchet cover and tighten the nut. Check the starter operation by pulling the starter, rip. 10-5ALTERNATOR/STARTER CLUTCH INSTALLATION RECOIL STARTER ASSEMBLY Install the recoil starter assembly and tighten the bolts, Route the wires and secure them with the clamps. ALTERNATOR REMOVAL ALTERNATOR COVER REMOVAL Remove the recoil starter (page 10-2), Disconnect the thermosensor connector from the Disconnect the reverse control cable end from the lever. Tax«scs/em Disconnect the newtral/reverse switch and [egroq, alternator/puise generator connectors. TRX4SOESIFE: Disconnect the gear position switeh and alternator pulse generator connectors, . Nf 4508; NEUTRALREVERS SWITCH CONNECTOR EANPOSITION SUMTCH CONNECTOR | QD) my GEAR POSITION swiTcH CONNECTOR ¥ ALTERNATOR/PULSE GENERATOR CONNECTOR 10-6Hold the starter driven pulley using th then remove the bolt and O-ting. pocial tool, TooL: Recoil pulley holder (07SMB-HM70100 Remove the eleven bolts and alternator cover. NOTE: The starter reduction gears may fall out as the cover is removed. Remove the O-ring and dowel pins. ALTERNATOR COVER DISASSEMBLY Disconnect the ignition pulse generator connector. Remove the wire grommet from the alternator cover ‘groove. Remove the ignition pulse generator and stator ‘mounting bolts. Remove the stator/ignition pulse generator bly. Remove the bolt and neutral/reverse (gear position) switeh ALTERNATOR/STARTER CLUTCH DRIVEN PULLEY en ALTERNATOR COVER! SSE IGNITION, (GEAR POSITION) (= PULSE GENERATOR: SWITCH 10-7ALTERNATOR/STARTER CLUTCH Turn the starter bearing Inner race with your fingor. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the alternator cover. lf you need to replace the bearing, heat the alternator cover and remove the bearing by tapping the cover. on ‘Always wear gloves when handling the case after it has been heated to prevent burning your hands. STARTER BEARING CAUTION. Do not use a torch to heat the case, it may cause warping. e Drive the new bearing into the alternator cover. TooLs: Driver 07749-00100 Attachment, 24 X26 mm (07748-0010700 Pilot, 10 mm 07748-0040100 ATTACHMENT/PILOT ) Inspect the alternator cover oil seal for wear or . OIL SEAL damage. Hf replacement is required, remove the oil seat from the alternator cover. Install the oll seal using the special tools as shown. DRIVER © TooLs: Driver 07749-0010000 > Attachment, 52 X55 mm 07746.0010400, | ATTACHMENT 10-8© ALTERNATOR/STARTER CLUTCH FLYWHEEL/STARTER CLUTCH FLYWHEEL/STARTER CLUTCH REMOVAL Remove the starter reduction gear A and shaft. Romove the washer and reduction gear C. Fomove the starter motor (page 19-3) the special tool, Toot: Rotor puller (07733-0020001 or (07933-3950000 (USA. only) Remove the starter reduction shaft. key. Remove the speed sensor (page 20-12), Remove the bolt and reverse control lever. Remove the bolts, cable guide and rear crankcase CABLE GUIDE 10-9ALTERNATOR/STARTER CLUTCH STARTER CLUTCH INSPECTION/ DISASSEMBLY Check the operation of the one-way clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counter: clockwise. Inspect the starter driven gear teeth for damage or DRIVEN GEAR NEEDLE BEARING abnormal wear. Check the needle bearing for damage. Remove the six socket bolts and remove the one: ‘way clutch from the flywheel, SOCKET BOLTS TooL: Flywheel holder 107725-0040000 or ‘equivalent commercially available in U.S.A. Check the one-way clutch rollers for wear or DRIVEN GEAR BOSS damage. Check the starter driven gear boss for wear or damage. 10-10e e@ @ © DRIVEN GEAR ALTERNATOR/STARTER CLUTCH STARTER CLUTCH ASSEMBLY NEEDLE BEARING CLUTCH OUTER FLYWHEEL (ONE-WAY CLUTCH 3.0 Nem (3.1 kgfom, 22 Ibfft) Apply oil to one-way cluteh rollers. Install the one-way clutch in the clutch outer. Install the lips of the alut the groove of the clutch outer as shawn. NOTE: Make sure the flange side of the o' faces toward the flywheel.ALTERNATOR/STARTER CLUTCH Use the back side ofthe oll sea iver. ‘Apply a locking agent to the threads of the socket, bolt threads Hold the fiywhee! using the special tool and install {and tighten the six socket bolts. TORQUE: 30 Nem (3.1 kgfom, 22 Ibf-t) To01: Fvwhee! holder ———_07726-0040000 or seein covey o dvallabie in U.S.A. “HI socker sour seams saaeananitacte mera S by turing It clockwise —, DRIVE SHAFT OIL SEAL REPLACEMENT Olt SEAL Romove the clip and oil seal. rive new ol saal into the rear crankcase cover using the special tools. TooLs: Driver 07749-00100 Attachment, 58 mm 07JAD-PHA0101 Install the oil seat clip. cm REAR CRANKCASE COVER x Ces) INSTALLATION Install the dowel pins, washer and new gasket. ‘WASHER 10-12ALTERNATOR/STARTER CLUTCH Install the rear crankcase cover, reversecontrolcable REAR CRANKCASE COVER BOLTS guide and bolts. Tighten the bolts in a crisscross pattern in two or three steps. Install the speed sensor (page 20-12), NOTE: + Align the gearshift A-arm with the sub-gearshift spindle as you install the cover. + Make sure the washer is installed on the reverse spindle Install the reverse stopper arm with its "OUT* mark facing out, then tighten the reverse stopper shaft bolts. [REVERSE CONTROL LEVER FLYWHEEL/STARTER CLUTCH SS _ INSTALLATION . wee Clean any oil from the crankshaft taper. Install the washer. Install the needle bearing onto the crankshaft Install the woodruft key. Make sure the starter reduction gear shaft is. igie=-mmes STARTER REDUCTION GEAR SHAFT instal, Be iE Install the flywheeVstarter reduction gear aligning DRIVEN PULLEY] aa the key way in the flywheel with the key on the crankshaft For installation of the alternator cover, temporarily Install the driven pulley and tighten the driven pulley bolt to seat the flywheelALTERNATOR/STARTER CLUTCH Install the starter reduction gear C and thrust washer. Install the starter reduction shaft and redu A WASHER} — 4 Install the alternator cover (see below). ALTERNATOR INSTALLATION STATOR _;/GNITION PULSE GENERATOR o ALTERNATOR ASSEMBLY Apply sealant to the grommets of the alternator/ ignition pulse generator and neutral/reverse (gear position) switch wire grommets. Install the nevtralreverse (gear pos aiternatorfignition pulse generato \ the alternator cover. a Route the wites properly as shown and install the | NEUTRAL/REVERSE: grommets into the groove of tha alternator cover. | (GEAR POSITION) Switch Apply a locking agent to the neutral/reverse (gear position) switch mounting bolt threads. Install the neutralreverse (gear position) switch and, tighten the bolt. ‘TORQUE: 12 Nem (1.2 kafim, 9 Ibfft) Install and tighten the stator mounting bolts. TORQUE: 10 Nem (1.0 kgfim, 7 tbf-ft) Install and tighten the ignition pulse generator ‘mounting bolts. Connect the ignition pulse generator connector. ALTERNATOR COVER INSTALLATION. Install the new O-ring into the groove of the rear ‘crankcase cover. Install the dowel pins. Apply sealant to the indicated area of the alternator cover as shown, 10-14ALTERNATOR/STARTER CLUTCH Shift the transmission into neutral, by aligning the yy INDEX MARK slit of the shift drum with the index mark on the crank jj case as shown Align the long end of the neutral/reverse (gear position) switch pin with the “N” mark on the switch as shown, bolts securely. The alternator cover (stator) is magnetically attracted to the flywheel, be careful not to pinch your finger. Nom Ifthe cover doesn't install easily, remove it and check the alignment of the reverse/ncutral (gear position) switch with the shift drum. Be careful not to damage the pin on the switch, Install the starter motor (page 19-7). Install the starter driven pulley aligning the boss with the groove on the flywheel.ALTERNATOR/STARTER CLUTCH TAxasosrMe TAXASOESIFE 10-16 Apply oil to the driven pulley bolt threads and O- fing, Install the driven pulley bolt with a O-ring. Hold the starter driven pulley using the special tool, then tighten the bolt to the specified torque. TOOL: Recoil pulley holder 07SMB-HM70100 TORQUE: 108 Nem (11.0 kgfom, 80 tht) Install the recoil starter (nage 10-6) Connect the neutral/reverse switch and alternator! pulse generator connector. Connect the gear position switch and alternator/ pulse genorator eonnsctor. 01 }450S: NEUTRALIREVERS SWITCH CONNECTOR 6088: GEAR POSITION SWITCH CONNECTOR 2e Sy ALTERNATOR/PULS ENERATOR ~ a ALTERNATORIPULSE GENERATOR CONNECTORALTERNATOR/STARTER CLUTCH Connect the thermosensor connector to the sensor, THERMOSENSOR WIRE Connect the reverse control cable end to the lover. Adjust the reverse selector lever free play (page 3 18), REVERSE CONTROL CABLE! 10-17CRANKSHAFT/BALANCER/TRANSMISSION 11-011. CRANKSHAFT/BALANCER/TRANSMISSION SERVICE INFORMATION 11-1 TRANSMISSION 11-4 TROUBLESHOOTING 11-3 CRANKSHAFT/BALANCER 11-16 CRANKCASE SEPARATION 11-4 CRANKCASE ASSEMBLY 11-19 SERVICE INFORMATION GENERAL + For crankshaft and transmission repair, the crankcat + The following components must be removed before separating the crankeas ~ Centrifugal clutch, change clutch (Section 8) = Cylinder head, cylinder, piston (Section 7) = Alternator, starter clutch (Section 10) ~ Gearshift linkage (Section 9) = Oil pump (Section 4) must be separated and engine must be removed from the frame. SPECIFICATIONS unener ae) Tem ‘STANDARDS ‘SERVICE LIMIT Crankshaft, Side clearance 0.05 — 0.65 (0.002 - 0.026) 0.80 (0.031) 11 connecting rod Ragial clearance 0.006 — 0.078 (0.0002 - 0.0007) 0.05 (0.002) Runout —o (0.05 (0.002) Transmission | Gearl.D. | M4 25.000 ~ 26.021 (0.9643 - 0.9851) 25.05 (0.986) M5 20,000 - 20.021 (0.7874 — 0.7882) 25,05 (0.986) €1,62,63 28.020 ~ 28.041 (1.1031 - 1.1040) 28.07 (1.105) [er 28,021 ~ 28.042 (1.1082 — 1.1040) 28.07 (1.108) [Reverse idle | 18.000 18021 (0.7087 ~ 0.7095) 18.08(0.710)_| Sha. | Me 27.959 - 21.980 (0.8685 - 0.8654) 21.95 (0.883) Ms | 16.963 - 16.994 (0.6686 0.6651) 16.95 (0.687) [ Reverse idio | 12.966 - 13.984 0.5498 - 0.6608), 13.93 (0.548) Gear bushing | C10. 27.964 - 26.006 (1.1017 - 1.1026) 27.98 (1.100) 200. 27.979 28.000 (1.1015 - 7.1024) 27.98 (1.100) cROD, 27.879 ~ 28,000 (1.1016 - 7.1024) 27.98 (1.100) Ma [LD. | 22.000-22.021 (0.8661 - 0.86701 22.05 (0.868) ©.D. | 24.959 24.980 (0.9826 - 0.96351 24,93 (0.981) MB | 1D. _| 17.076 17.034 (0.6699 - 0.6706) 17.08 (0.672) ©.D. _ | 19.966~ 19.984 (0.7861 - 0.7868) 19.93 (0.785) [ro | 14.000 - 14.026 0.5612 — 0.6522) 14.08 (0.563) ©. _| 17.966~ 17.986 (0.7073 - 0.7080) 17.98 (0.708) 11-1CRANKSHAFT/BALANCER/TRANSMISSION Uri: tnd trem STANDARDS SERVICE LIMIT Transmission | Gearto- | MA 0.020 - 0.062 0.0008 - 0.0024) 0.10 (0.004) a, [es 0.016 ~ 0.055 (0.0008 - 0.0022) 0.10 (0.004 a 0.015 ~ 0.057 (0.0008 - 0.0022) 0.10 (0.004 CI 0.020 ~ 0.062 (0.0008 - 0.0028) 0.10 (0.004) cR 0.020 ~ 0.062 (0.0008 - 0.0024) 0.10 (0.004) 3 0.015 - 0.057 0.0006 -0.0022) 0.10 (0.004) [ Reverse idie | 0.016 ~0.055 (0.0006 - 0.0022) 0.10 (0.0041 Bushingto- | Ma 0.020 — 0.062 (0.0008 - 0.0028) 0.10 (0.004) shaft clearance) yg 0.022 - 0.051 (0.0003 - 0.0020) 0.10 (0.004) Reverse idle | 0.016 - 0.069 (0.0008 - 0.0023) 0.10 (0.004) Shift fork shaft | Fork 1D. 13.000 ~ 13.021 (0.5118 0.5126) 13.08 (0513) Claw thickness | 4936.00 (0.194 0.197) 450 0.17), Fork shaft 0.0, 12.986 ~ 12.984 (0.5105 - 0.5112) 12.96 (0.510) TOOLS Bearing remover sot =Remover handle ~ Bearing remover, 20 mm = Remover weight Remover handle Bearing remove Remover weight Assembly collar ‘Assembly shaft Threaded adaptor Driver Attachment, 24 X 26 Attachment, 37 X 40 ‘Attachment, 42 X 47 ‘Attachment, 52 X 55. ‘Attachment, 72 X 75, Pilot, 22mm Pilot, 17 mm lot, 20 mm lot, 26 mm Pilot, 35 mm. Pilot, 40 mm. Pilot, 32 mm ” 11-2 mm (07936-3710001 Not available in U.S.A. (07936-3710100 (07936-3710600 (07741-0010201 or 07936-371020A or 07936-3710200 07936-3710100 (07936-3710300 (07741-0010201 or 07836-371020A or 07836-3710200 (07965-VIM00100 (07965-VM00200 or 07931-ME40108 and 07931-HE30204, (07965-00300 or 07831-KF00200 (U.S.A. only) 07749-0010000 07746-0010700 07746-0010200 (07746-0010300 (07746-0010400 07746-0010600 (0746-004 1000 07746-0040400 07746-0040500 07746-0040600 07746-0040800 07746-0080900 ‘O7MAD-PR9O200u CRANKSHAFT/BALANCER/TRANSMISSION TROUBLESHOOTING Crankshaft noisy + Worn connecting rod big end bearing + Bent connecting rod + Worn erankshaft bearing fansmission jumps out of gear + Shift fork bent or damaged * Shift fork shaft bent + Shift fork claw bent + Gear engagement dogs or slots worn Hard to shift * Incorrect clutch adjustment + Shift fork bent or damaged + Shift fork shaft be 11-3CRANKSHAFT/BALANCER/TRANSMISSION CRANKCASE SEPARATION NoTe: Refer to page 11-1 for the parts which must be removed before separating the crankcase. Remove the engine hanger bushing dust seals and dive out the hanger bushings, Remove the three front crankcase bolts. Remove the final drive shaft O-ring Loosen the twelve rear crankcase bolts in a REAR CRANKCASE BOLTS | crisscross pattern in 20r3 steps to prevent crankcase distortion. Remove the rear crankcase bolts. Remove the O-ring from the mainshaft. DOWEL PINS Place the crankcase with the rear crankcase down “ ‘and remove the front crankcase. Remove the gasket and dowel pins. Install @ new O-ring onto the mainshatt. TRANSMISSION REMOVAL/DISASSEMBLY Remove the following: ~ Copper washer =C1 gear =€1 gear bushing 11-4CRANKSHAFT/BALANCER/TRANSMISSION Romove the following: eM WASHER = Thrust washer a ~ Reverse idle gear assembly ~ Shift fork shaft =Front shift fork = Center shift fork = Rear shift fork you de not ~ Shift drum remove the reverso ‘Stopper ar itis necessary 1 hold ‘down the reverse am to rerave the ‘shit rum, SHIFT DRUM HHIFT FORKS= Remove the final drive shaft and final drive gear. FINAL DRIVE SHAFT Remove the mainshaft and countershaft as an assembly. Remove the mainshaft thrust washer. 11-5CRANKSHAFT/BALANCER/TRANSMISSION Disassomble the mainshatt and countershaft. COUNTERSHAFT NOTE: + 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 + Do not expand the snap ring more than necessary for removal. To remove a snap ring, expand the ‘snap ring and pull it off using the gear behind it MAINSHAFT INSPECTION Check the gear dogs, dog holes and teeth for p ~ ‘abnormal wear or lack of lubrication. ‘Measure the 1.0. of each gear. a SERVICE LIMITS: C1, C2,C3,CR: 28.07 mm (1.105 in) Ms, 5 25.05 mm (0.986 in) Measure the I.D. and 0.0. of each gear bushing ‘SERVICE LIMITS: C1, C2, CRO.D.: 27.93 mm (1.100 in) M4: 0.0.: 24.93 mm (0.981 in) 1. 22.05 mm (0.868 in) Ms: 0. 19.93 mm (0.785 in) 1D. 17.06 mm (0.672 in) Caleutete the gear-to-gear bushing clearance. ‘SERVICE LIMIT: 0.10 mm (0.004 in) Check the shift fork groove of the shifter gear for ‘excessive wear or damage. Measure the O.D. of the mainshatt ‘SERVICE LIMITS: M4: 21.83 mm (0.863 in) Ms: 16.95 mm (0.867 in) Calculate the gear bushing to-shaft clearance. ‘SERVICE LIMIT: 0.10 mm (0.004 in}CRANKSHAFT/BALANCER/TRANSMISSION Disossemble the reverse idle gear assembly. Measure the 0.0. of the reverse idle gear shaft. SERVICE LIMIT: 13.93 mm (0.548 in) Calculate the bushing-to-shatt clearance. SERVICE LIMIT: 0.10 mrn (0.004 in} Check the shift fork and fork shaft for wear or damage. Measure the LD. of the si fork. SERVICE LIMIT: 13.04 mm (0.513 in) ‘Measure the shift fork claw thickness. ‘SERVICE LIMIT: 4.50 mm (0.177 in) ‘Measure the 0.0. of the shift fork shaft SERVICE LIMIT: 12.96 mm (0.510 in) Inspect the shift drum grooves for wear or damage. / oe € ®e, 11-7(CRANKSHAFT/BALANCER/TRANSMISSION BEARING REPLACEMENT NOTE: For crankshaft bearing replacement, see page 17 16. ‘Turn the inner race of each bearing with your finger. ‘The boarings should turn smoothly and quietly. ‘Also check that the outer race of each bearing fits tightly in the crankcase. FRONT CRANKCASE Remove the final shaft oil se If the bearings need replacement, drive out the mainshaft and shift drum bearing. Remove the countershaft bearing using the special tools. Toots: Bearing remover set 07936-3710001 (Not available in S.A) or = Remover handle 07936-3710100 ~ Bearing remover, 20 mm 07936-3710600 ~ Remover weight 077410010201 or 2 07836-3710200 or COUNTERSHAFT BEARING: \ 07936-3710200 (S.A. only) Drive new bearings into the front crankcase using the special tools. TooLs: Driver 07749-00100 ‘Mainshaft bearing: ‘Attachment, 52 55mm 07746-0010400 Pilot, 22 mm 0746-0081000 ‘Countershaft bearing: ‘Attachment, 42 X 47 mm_07746-0010300 Pilot, 20 mm (07746-0040500 Final shaft bearing: ‘Attachment, 42 47 mm 07746-01030 Pilot, 22 mm 0746-0081000 Shift drum bearing: ‘Attachment, 42 X 47 mm_ 07746-01030 Pilot, 35 mm (07746-0040800 Install the new final shaft oil seal 11-8CRANKSHAFT/BALANCER/TRANSMISSION © | } Make sure bearing puri inside case ip before removing shaun neese bearng © REAR CRANKCASE CAMSHAFT MAINSHAFT — COUNTERSHAFT BEARING BEARING _ SEARING Drive out the final shaft bearing from the rear crankcase. Remove the rear crankcase bearings using the special tools. TooLs: Mainshatt, camshaft and shiftdrum bearings: Remover handle 07936-37 10100 Bearing remover, 17 mm _07936-3710300 Remover weight 07741-0010201 or (07936-3710200 or 07936-3710208 FINAL SHAFT BEARING (U.S.A. only) Countershaft bearing: 07936-3710001 Teese REAR CRANKCASE usa) = Remover handle 07936-2710100 = Bearing remover, 20 mm 07936-3710600 = = Remover weight 07747-0010201 or (07936-371020A or = 07936-3710200 (U.S.A. oniy) BEARING SHiET ORUM REMOVER NEEDLE BEARING Drive new bearings into the rear crankcase. CAMSHAFT MAINSHAFT COUNTERSHAFT BEARING BEARING —_« BEARING Toots: me . Driver 07749-0010000 x Countershatt bearing: ‘Attachment, 42 X47 mm 07746-0010300 Pilot, 20 mm 07746-0040500 Mainshaft/carshaft bearing: ‘Attachment, 37 X 40 mm _07746-0010200 a Pilot, 17 mm’ (07746-04040 =a oad, - Final shaft bearing: ‘Attachment, 52 X 55mm 077460010400 Pilot, 25 mm, (07746-0040600 4 = FINAL SHAFT BEARING Press the shiftdrum needle bearing using the sspecaial tools and hydralic press TooLs: Driver (07748-0010000 Attachment, 24 X 26mm 07746-01070(CRANKSHAFT/BALANCER/TRANSMISSION CRANKCASE BEARING LOCATIONS FRONT craneense Cc REAR CRANKCASE camstare | WxX76X175 ERS ( 7 6203 } ~ CRANKSHAFT 7 = FRONT CRANKCASE REAR CRANKCASE 32X76 X 17.5 (Special) TL 62030 MAINSHAFT EF } Rl) i countersHarT || s20s_ A 6204U) eat) fot FINALSHAFT FO} 25 52X15 a a a y NL "SHIFTDRUM 11-10CRANKSHAFT/BALANCER/TRANSMISSION ASSEMBLY/INSTALLATION NOTE: + Apply oll to the shitter gear grooves. + Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load. After installing the snap ring, slightly open the ring and rotate groove to be sure itis fully seated. Do not used worn ‘snap ring which could easily spinning in the groove. They may be too loose to properly seat in the groove. Align the gap in the snap ring with the groove of spline, Align the oil holes on the shafts and bushings. The countershatt must be installed with the inside oll feed hole to the back, and the outside oil holes to the front as shown. ‘TAXAS0S/FM MAIN SHAFT: M5 GEAR (337) M3 GEAR (237) Ma GEAR (287) M2 GEAR (187) BUSHING THRUST WASHER Mt GEAR (127) pune SNAPRING WASHER BUSHING M4GEAR M3GEAR M5 GEAR MAINSHAFT SPLINE SNAP RING weit WASHER WASHERS: 11-11CRANKSHAFT/BALANCER/TRANSMISSION (COUNTERSHAFT: REVERSE ttaein tie SO o® o> 4 GEAR (377) (C4 GEAR (337) THRUST WASHERS C2.GEAR (43T) CR GEAR (277) C1-REVERSE COUNTER cue - Ss [ 4 COUNTERSHAFT Qo ax LD eases , wn C1-REVERSE COUNTER SHIFTER C5 GEAR (287) COPPER WASHER cigar \cRGeAR — c2GEAR Install the countershaft with the inside CAGEAR Dil food hole facing the rear crankcase. C3.GEAR Hes, 8 FINAL DRIVE ca | GEAR COPPER WASHER THRUST WASHER 11-12CRANKSHAFT/BALANCER/TRANSMISSION ‘TAXAS50ES/FE (MAINSHAFT: Ms GEAR (337) Ma GEAR (237) MA4GEAR (287) M2 GEAR (187) M1 GEAR (127) THRUST BUSHING WASHER SNAP RING SPLINE WASHER BUSHING MAIN SHAFT M4GEAR M3 GEAR MB GEAR SPLINE SNAPRING = THRUST WASHER WASHERS, 11-13CRANKSHAFT/BALANCER/TRANSMISSION CCOUNTERSHAFT: oO REVERSE DLE GEAR 5 Ganen SF ©) 3 GEAR (377) << ~ ie C2 GEAR (437) THRUST WASHERS SHIFTER &» cr ean ser SPLINE ®D COLLAR E C1-REVERSE COUNTER COPPER SHETES C5GEAR (28T) WASHER CI GEAR FINAL DRIVE GEAR (207) CRGEAR c2GEAR Install the countershatft with the inside il feed hole facing the rear crankcase. FINAL DRIVE GEAR COPPER WASHER THRUST WASHER: 11-14CRANKSHAFT/BALANCER/TRANSMISSION Install the mainshaft end washer into the crankcase. MAINSHAFT/COUNTERSHFT ASSEMBLY Install the mainshaft and countershaft as an assembly. Verify that the top end of the countershaft does not have an oil feed hole. Assemble the final drive gear and shaft, then install FINAL DRIVE SHAFT the drive shaft assembly into the rear crankcase. J FINAL ORIVE GEAR Install the shift drum, Install the rear shift fork into the M2 shifter gear ‘groove with its "RR" mark facing up. Install the center shift fork into the C3 shifter gear ‘groove with its “C” mark facing up. Install the front shift fork into the counter shifter groove with its “FR” mark facing up. ‘Make sure all of the shift fork pins are aligned with the grooves in the shift drum. Install the shift fork shaft SHIFT FORKS, Assemble the reverse idle gear, bushings, washer and shatt. WASHER BUSHINGS IDLE GEAR 11-15(CRANKSHAFT/BALANCER/TRANSMISSION Install the reverse idle gear aligning the pin on the shaft with the crankcase groove. Install the washer. Install the C1 gear bushing making sure oll passages are aligned, C1 gear and copper washer. CRANKSHAFT/BALANCER 11-16 REMOVAL Remove the transmission (page 11-4). Romove the crankshaft and balancer from the rear crankcase using a hydraulic press. If the rear crankshaft bearing remains on the crankshaft, remove it with @ commercially available ‘bearing separator (4 1/2 in) as shown. Ifthe bearing remains in the rear crankcase, drive it out from the outside. Discard the rear crankshaft b NOTE: ‘Always replace the rear bearing with a new one Whenever the crankshaft is removed from the crankcase. REVERSE IDLE GEAR, ASSEMBLY C1 GEAR BUSHING BEARING SEPARATORCRANKSHAFT/BALANCER/TRANSMISSION INSPECTION Set the crankshaft in a stand or V-blocks and read ‘the runout using dial indicators at the A and B points as shown, ‘SERVICE LIMIT: 0.05 mm (0.002 in} Measure the side clearance between the connecting rod big end and the crankshaft weight with a fecler gauge. SERVICE LIMIT: 0.80 mm (0.031 in) Measure the radial clearance at the connecting rod r big end, at two points in the directions indicated by the arrows. / ‘SERVICE LIMIT: 0.05 mm (0.002 in) (Check the balancer gear teeth for abnormal wear or damage. 11-17CRANKSHAFT/BALANCER/TRANSMISSION BEARING REPLACEMENT Turn the inner race of each bearing with your finger, The bearings should turn smoothly and quietly. Aliso check the outer race of each bearing fits tightly in the crankcase. Drive out the crankshaft bearing, Pull the balancer bearings out of the cranksase using the special tools as shown, TooLs: Remover handle (07936-3710100 17mm —07936-3710300 Romover weight (07741-0010201 or (07939-3710200 or (07936-3710208, (S.A. only) Drive new bearings in using the following tools. ‘Toots: Crankshaft bearing: Driver 0749-0010000 Attachment, 72 X 75 mm 07746-01060 Pilot, 40 mm (07746-0040300 Balancer bearing: Driver 07749-0010000 Attachment, 37 X 40 mm 07746-01020 Pilot, 17 mm 0746-0080400 INSTALLATION ‘Temporarily install the balancer and crankshaft in the front crankcase and align their timing marks. BEARING REMOVER 11-18CRANKSHAFT/BALANCER/TRANSMISSION Install the rear crankcase on the front crankcase. THREADED ADAPTER Install the threaded adapter on the crankshatt \ TOOL: Threaded adapter (07965-VNM00300 or (07931-KF00200 (U.S.A. only) Draw the crankshaft into the rear crankcase using the special tools. TooLs: Assembly collar 07965-VMi00100 Assembly shaft 7965-VM00200 or 07931-ME40108 and (U.S.A. only) Special nut 07931-HB30200 ‘ASSEMBLY COLLAR SPECIAL NUT Remove the front crankcase and make sure tho indox: marks on the balancer and crankshaft are aligned, Install the transmission jpage 11-11), CRANKCASE ASSEMBLY Install the dowel pins and new gasket.CRANKSHAFT/BALANCER/TRANSMISSION Install the front crankcase onto the rear crankcase. REAR CRANKCASE NOTE: + Mako sure that the gasket stays in place. + Make sure the bearing holdericam chain tensioner ‘arm is on the correct side of the mainshaft. Refer to page 7-23 for proper positioning. + Make sure that the oil pump shatt is correctly aligned. Install and tighten all the rear crankcase bolts in 2 or 3 steps in a crisscross pattern. Tighten the front crankcase bolts. Install the new O-ring onto the fi FRONT CRANKCASE Install the engine hanger bushings and dust seals. DUST SEALS Nor! ‘When installing the engine hanger bushing dust, seals, install the dust seal lips to the outside as shown. Roinstall the removed parts in the reverse order of removal ausanes e 11-20MEMOFRONT WHEEL/SUSPENSION/STEERING 39 Nem (4.0 kgfern, 28 Ibfeft) 44 Nem (4.5 katem, 33 Ibf-tt) 108 Nem (11.0 kafem, 80 Itt) "98 -'01: 29 Nem (3.0 kgfern, 22 Ib ‘After “Or: 32. Nem (3.3 kgfem, 24 1b) 12 Nem (1.2 kgf, Steen) “Ss 15 Nem (1.5 kgfem, 17 bth) 29 Nem (3.0 kgfem, 22 Ibfett) 78 Nem (8.0 kgfer, 58 loft) 64 Nem (6.5 kgfem, 47 Ibfeft) 12-012. FRONT WHEEL/SUSPENSION/STEERING ‘SERVICE INFORMATION 12-1 TIRES 12-8 | TROUBLESHOOTING 122 TIE-ROD/KNUCKLE 12-12 HANDLEBAR 12:3 UPPER/LOWER ARMS 12:20 THROTTLE HOUSING 12-6 STEERING SHAFT 12:23 FRONT WHEEL 12-8 FRONT SHOCK ABSORBER 12-29 SERVICE INFORMATION GENERAL Fe A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated ‘drum with a high quality brake degreasing agent. + Ajjack or other support is requred to support the vehicle, + Adjust toe whenever the tie-rod, knuckle or steering shaft are replaced or removed (pege 3-22) + Do not twist or bend the brake hoses and pipes when removing them from the knuckle or upper arm SPECIFICATIONS. Unit: mm {ind rem. ‘STANDARDS | SERVICE LIMIT Minimum tire tread depth — 410.2) Cold tire pressure Stantard 28 kPa (0.25 kgticm’, 2.8 psi) —- Minimum 22 kPa (0.22 katicm’, 3.2 psi) Maximum 28 kPa (0.28 kgticm, 4.0 psi) h cargo. 25 kPa (0.25 kgticm, 3.6 psi) Tie-rod distance between the ball joints 369 + 1(14.5 + 0.04) — Too Toe-out: 35 = 15 mm (1-3/8 + 9/6 in) TORQUE VALUES Handlebar lower holder nut 38 Nem (4.0 kafm, 29 Ibfft) Do not reuse; replace with a new one. Steering shaft U-nut 108 Nem (17.0 kgfem, 80 Ibfeft) Urnut Tie-rod ball joint self lock nut 54 Nem (5.5 kaf+m, 40 Ife) Do not reuse; replace with 3 new one, Tie-rod lock nut 54 Nem (5.5 kgm, 40 Ibt+ft) Steering shaft holder flange bott 32 Nem (3.3 kafem, 24 Ibfef) Upper/iawer arm pivot seif lock nut 44 Nem (4.5 kgfem, 33 Ibfeft) Do not reuse: replace with @ new one. Knuckle ball joint castle nut ('98 -'01) 29 Nem (3.0 kgfem, 22 Ibfeft) Castle nut (After ‘01) 32.Nem (3.3 kafem, 24 Ibff) — Castio nut Shock absorber upper mounting self lock nut 44 Nem (4.5 kgf+m, 33 Ibfet) Do not reuse: replace with a naw one, Shock absorber lower mounting self lock nut 44 Nem (4.6 kgf*m, 33 Ibft) Do not reuse; replace with a new one, Front whee! hub castle nut 78 Nem (8.0 kgf+m, 58 Ibfft) Castle nut Front wheel nut 64 Nem (6.5 kgfem, 47 Ibtet) ‘Throttle case cover 4.Nem (0.4 kafem, 2.9 Ib) Brake hose 2 way jaint nut 15 Nem (1.5 kgfern, 11 Ibff0 Brake hose clamp bolt 12 Nem (1.2 kgfem, 9 Ibfett) Brake panel bolt 28 Nem (3.0 kgfem. 22 Ibf+ti Do not reuse; replace with a new one. 12-1