TYPE CODE

• Throughout this manual, the following abbreviations are used to identify individual type.

CODE AREA TYPE

U Australia

BR Brazil
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and
the reliability of the vehicle. Any error or oversight while servicing a vehicle Improper service or repairs can create an
can result in faulty operation, damage to the vehicle, or injury to others. unsafe condition that can cause your customer
or others to be seriously hurt or killed.
For Your Safety Follow the procedures and precautions in this
Because this manual is intended for the professional service technician, we manual and other service materials carefully.
do not provide warnings about many basic shop safety practices (e.g., Hot
parts–wear gloves). If you have not received shop safety training or do not
feel confident about your knowledge of safe servicing practice, we
recommended that you do not attempt to perform the procedures described Failure to properly follow instructions and
in this manual. precautions can cause you to be seriously hurt
or killed.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions in this
arise in performing service and repair procedures. Only you can decide manual carefully.
whether or not you should perform a given task.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:

• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.

• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.

• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.

• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.

• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never drain or store gasoline in an open container.

• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
HOW TO USE THIS MANUAL CONTENTS
This service manual describes the service procedures for the CRF230F.
GENERAL INFORMATION 1
Follow the Maintenance Schedule (Section 3) recommendations to
ensure that the vehicle is in peak operating condition.
FRAME/BODY PANELS/EXHAUST 2
Performing the first scheduled maintenance is very important. It SYSTEM
compensates for the initial wear that occurs during the break-in period.
MAINTENANCE 3
Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates
procedures for removal/installation of components that may be required
to perform service described in the following sections. LUBRICATION SYSTEM 4
Section 4 through 18 describe parts of the motorcycle, grouped
according to location.
FUEL SYSTEM 5
Find the section you want on this page, then turn to the table of contents
on the first page of the section.
ENGINE REMOVAL/INSTALLATION 6
Most sections start with an assembly or system illustration, service

ENGINE
information and troubleshooting for the section. The subsequent pages
give detailed procedure.
CYLINDER HEAD/VALVES 7
If you don't know the source of the trouble, go to section 20
Troubleshooting.
CYLINDER/PISTON 8
CLUTCH/GEARSHIFT LINKAGE 9
ALTERNATOR/STARTER CLUTCH 10
Your safety, and the safety of others, is very important. To help you
make informed decisions we have provided safety messages and
other information throughout this manual. Of course, it is not CRANKCASE/TRANSMISSION/CRANKSHAFT 11
practical or possible to warn you about all the hazards associated
with servicing this vehicle.
You must use your own good judgement. FRONT WHEEL/SUSPENSION/STEERING 12
CHASSIS

You will find important safety information in a variety of forms

including:
• Safety Labels – on the vehicle
REAR WHEEL/BRAKE/SUSPENSION 13
• Safety Messages – preceded by a safety alert symbol and
one of three signal words, DANGER, WARNING, or CAUTION. HYDRAULIC BRAKE 14
These signal words mean:
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions. BATTERY/CHARGING SYSTEM 15
ELECTRICAL

You CAN be KILLED or SERIOUSLY HURT

if you don’t follow instructions. IGNITION SYSTEM 16
You CAN be HURT if you don’t follow
instructions. ELECTRIC STARTER 17
• Instructions – how to service this vehicle correctly and safely.
LIGHT/SWITCHES 18
As you read this manual, you will find information that is preceded by a WIRING DIAGRAM 19
symbol. The purpose of this message is to help prevent
damage to your vehicle, other property, or the environment. TROUBLESHOOTING 20

ALL INFORMATION, ILLUSTRATIONS, DIREC-

INDEX 21
TIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LAT-
EST 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 OBLI-
GATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITH-
OUT WRITTEN PERMISSION. THIS MANUAL IS
WRITTEN FOR PERSONS WHO HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTE-
NANCE ON Honda MOTORCYCLES, MOTOR
SCOOTERS OR ATVS.

Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE

Date of Issue: July, 2006

© Honda Motor Co., Ltd.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.

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

Use the 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% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease.

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use fork or suspension fluid.

 1. GENERAL INFORMATION

SERVICE RULES ········································· 1-2 REAR WHEEL/BRAKE/

SUSPENSION SPECIFICATIONS··············· 1-9
MODEL IDENTIFICATION··························· 1-2
HYDRAULIC BRAKE
GENERAL SPECIFICATIONS······················ 1-5 SPECIFICATIONS ····································· 1-10

LUBRICATION SYSTEM BATTERY/CHARGING SYSTEM

SPECIFICATIONS········································ 1-7 SPECIFICATIONS ····································· 1-10

FUEL SYSTEM SPECIFICATIONS IGNITION SYSTEM SPECIFICATIONS ···· 1-10

(U TYPE) ······················································ 1-7
ELECTRIC STARTER
FUEL SYSTEM SPECIFICATIONS SPECIFICATIONS ····································· 1-10
(BR TYPE) ··················································· 1-7
LIGHT/SWITCHES SPECIFICATIONS ····· 1-10
CYLINDER HEAD/
VALVES SPECIFICATIONS ························ 1-8 STANDARD TORQUE VALUES ··············· 1-11

CYLINDER/PISTON SPECIFICATIONS ······ 1-8 ENGINE & FRAME TORQUE VALUES ···· 1-11

CLUTCH/GEARSHIFT LINKAGE LUBRICATION & SEAL POINTS ·············· 1-15

SPECIFICATIONS········································ 1-8
CABLE & HARNESS ROUTING ··············· 1-17
ALTERNATOR/STARTER CLUTCH
SPECIFICATIONS········································ 1-8 EMISSION CONTROL SYSTEMS
(U type) ····················································· 1-24
CRANKCASE/TRANSMISSION/
CRANKSHAFT SPECIFICATIONS ·············· 1-9 EMISSION CONTROL SYSTEMS
(BR TYPE)·················································· 1-25
FRONT WHEEL/SUSPENSION/
STEERING SPECIFICATIONS····················· 1-9

1-1
GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's
design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
English fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-17).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
ICM Ignition Control Module

MODEL IDENTIFICATION
’07 model:

After ’07:

1-2
 GENERAL INFORMATION
SERIAL NUMBER
The Vehicle Identification Number (VIN) is stamped on the right side of
the steering head.

VEHICLE IDENTIFICATION NUMBER

The engine serial number is stamped on the lower left side of the
crankcase.
ENGINE SERIAL NUMBER

The carburetor identification number is stamped on the right side of

the carburetor body.

CARBURETOR IDENTIFICATION NUMBER

LABELS
The name plate is attached on the frame down tube.

NAME PLATE

1-3
GENERAL INFORMATION
The color label is attached on the left rear frame behind the left side
cover (U type only). When ordering color-coded parts, always specify U type:
the designated color code.

COLOR LABEL

1-4
 GENERAL INFORMATION
GENERAL SPECIFICATIONS
’07 model:
ITEM SPECIFICATION
DIMENSIONS Overall length 2,059 mm (81.1 in)
Overall width 812 mm (32.0 in)
Overall height 1,190 mm (46.9 in)
Wheelbase 1,372 mm (54.0 in)
Seat height 872 mm (34.3 in)
Footpeg height 365 mm (14.4 in)
Ground clearance 305 mm (12.0 in)
Curb weight U type: 113.8 kg (250.9 lbs)
BR type: 114 kg (251 lbs)
FRAME Frame type Semi-double cradle
Front suspension Telescopic fork
Front wheel travel 216 mm (8.5 in)
Rear suspension Swingarm
Rear wheel travel 230 mm (9.1 in)
Rear damper Nitrogen gas filled damper
Front tire size 80/100-21 NHS
Rear tire size 100/100-18 NHS
Front tire brand MT320 H (Pirelli)
Rear tire brand MT320 H (Pirelli)
Front brake Hydraulic single disc
Rear brake Mechanical drum (leading-trailing)
Caster angle 26°45’
Trail length 111 mm (4.4 in)
Fuel tank capacity 8.2 liter (2.17 US gal, 1.80 lmp gal)
Fuel tank reserve capacity 1.5 liter (0.40 US gal, 0.33 lmp gal)
ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical
Bore and stroke 65.5 x 66.2 mm (2.58 x 2.61 in)
Displacement 223 cm3 (13.6 cu-in)
Compression ratio 9.0 : 1
Valve train Chain driven OHC with rocker arm
Intake valve opens at 1 mm (0.04 in) lift 10° BTDC
closes at 1 mm (0.04 in) lift 40° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 35° BBDC
closes at 1 mm (0.04 in) lift 10° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Oiled polyurethane foam
Engine dry weight 31.2 kg (68.8 lbs)
CARBURETOR Carburetor type Piston valve
Throttle bore 28 mm (1.1 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 6 speeds
Primary reduction 3.090 (68/22)
Final reduction 3.846 (50/13)
Gear ratio 1st 2.769 (36/13)
2nd 1.941 (33/17)
3rd 1.450 (29/20)
4th 1.148 (31/27)
5th 0.960 (24/25)
6th 0.812 (26/32)
Gearshift pattern Left foot operated return system
1-N-2-3-4-5-6
ELECTRICAL Ignition system CDI
Starting system Electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR shorted, single phase half-wave rec-
tification

1-5
GENERAL INFORMATION
After ’07:
ITEM SPECIFICATION
DIMENSIONS Overall length 2,059 mm (81.1 in)
Overall width 801 mm (31.5 in)
Overall height 1,190 mm (46.9 in)
Wheelbase 1,372 mm (54.0 in)
Seat height 878 mm (34.6 in)
Footpeg height 365 mm (14.4 in)
Ground clearance 305 mm (12.0 in)
Curb weight U type: 112.9 kg (248.9 lbs)
BR type: 112.7 kg (248.5 lbs)
FRAME Frame type Semi-double cradle
Front suspension Telescopic fork
Front wheel travel 216 mm (8.5 in)
Rear suspension Swingarm
Rear wheel travel 230 mm (9.1 in)
Rear damper Nitrogen gas filled damper
Front tire size 80/100-21 NHS
Rear tire size 100/100-18 NHS
Front tire brand MT320 H (Pirelli)
Rear tire brand MT320 H (Pirelli)
Front brake Hydraulic single disc
Rear brake Mechanical drum (leading-trailing)
Caster angle 26°45’
Trail length 111 mm (4.4 in)
Fuel tank capacity 7.0 liter (1.85 US gal, 1.54 lmp gal)
Fuel tank reserve capacity 1.3 liter (0.34 US gal, 0.29 lmp gal)
ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical
Bore and stroke 65.5 x 66.2 mm (2.58 x 2.61 in)
Displacement 223 cm3 (13.6 cu-in)
Compression ratio 9.0 : 1
Valve train Chain driven OHC with rocker arm
Intake valve opens at 1 mm (0.04 in) lift 10° BTDC
closes at 1 mm (0.04 in) lift 40° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 35° BBDC
closes at 1 mm (0.04 in) lift 10° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Oiled polyurethane foam
Engine dry weight 31.2 kg (68.8 lbs)
CARBURETOR Carburetor type Piston valve
Throttle bore 28 mm (1.1 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 6 speeds
Primary reduction 3.090 (68/22)
Final reduction 3.846 (50/13)
Gear ratio 1st 2.769 (36/13)
2nd 1.941 (33/17)
3rd 1.450 (29/20)
4th 1.148 (31/27)
5th 0.960 (24/25)
6th 0.812 (26/32)
Gearshift pattern Left foot operated return system
1-N-2-3-4-5-6
ELECTRICAL Ignition system CDI
Starting system Electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR shorted, single phase half-wave rec-
tification

1-6
 GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil After draining 1.0 liter (1.1 US qt,0.9 lmp qt) –
capacity After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) –
Engine oil U type: Suggested oil: –
Honda "4-stroke motorcycle oil" or an
equivalent
Oil recommendation:
API classification: SG or higher
(except oils labeled as energy con-
serving on the circular API service
label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA
BR type: API service classification: SG or higher –
(except oils labeled as energy conserv-
ing on the circular API service label)
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Suggested oil: Oil which Honda recom-
mends
Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)
rotor Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.03 – 0.12 (0.001 – 0.005) 0.15 (0.006)

FUEL SYSTEM SPECIFICATIONS (U TYPE)

ITEM SPECIFICATIONS
Carburetor identification number ’07 model PD9CA
After ’07 PD9CJ
Main jet #102
Slow jet #42
Jet needle clip position 3rd groove
Pilot screw See page 5-18
Float level 12.5 mm (0.49 in)
Idle speed 1,400 ± 100 min-1 (rpm)
Throttle grip free play 2 – 6 mm (1/12 – 1/4 in)

FUEL SYSTEM SPECIFICATIONS (BR TYPE)

ITEM SPECIFICATIONS
Carburetor identification number ’07 model PD9CE
After ’07 PD9CH
Main jet #140
Slow jet #42
Jet needle clip position 3rd groove
Pilot screw See page 5-18
Float level 12.5 mm (0.49 in)
Idle speed 1,500 ± 100 min-1 (rpm)
Throttle grip free play 2 – 6 mm (1/12 – 1/4 in)

1-7
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 450 min-1 (rpm) 1,294 kPa (13.2 kgf/cm2, 188 psi) –
Valve clearance IN/EX 0.1 (0.004) –
Valve, Valve stem O.D. IN 5.450 – 5.465 (0.2146 – 0.2152) 5.42 (0.213)
valve guide EX 5.430 – 5.445 (0.2138 – 0.2144) 5.40 (0.213)
Valve guide I.D. IN/EX 5.475 – 5.485 (0.2156 – 0.2159) 5.50 (0.217)
Stem-to-guide clear- IN 0.010 – 0.035 (0.0004 – 0.0014) 0.08 (0.003)
ance EX 0.030 – 0.055 (0.0012 – 0.0022) 0.10 (0.004)
Valve seat width IN/EX 1.1 – 1.3 (0.04 – 0.05) 1.5 (0.06)
Valve spring Free length Inner 39.2 (1.54) 38.0 (1.50)
Outer 44.9 (1.77) 43.5 (1.71)
Rocker arm Arm I.D. IN/EX 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)
Shaft O.D. IN/EX 11.966 – 11.984 (0.4711 – 0.4718) 11.93 (0.470)
Arm-to-shaft clear- IN/EX 0.016 – 0.052 (0.0006 – 0.0020) 0.08 (0.003)
ance
Camshaft Cam lobe height IN 31.610 – 31.690 (1.2445 – 1.2476) 31.3 (1.23)
EX 31.452 – 31.532 (1.2383 – 1.2414) 31.2 (1.23)
Cylinder head warpage – 0.10 (0.004)

CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 65.500 – 65.510 (2.5787 – 2.5791) 65.60 (2.583)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Piston, Piston O.D. at 10 (0.4) from bottom 65.470 – 65.490 (2.5776 – 2.5783) 65.40 (2.575)
piston pin, Piston pin hole I.D. 15.002 – 15.008 (0.5906 – 0.5909) 15.04 (0.592)
piston ring Piston pin O.D. 14.994 – 15.000 (0.5903 – 0.5906) 14.96 (0.589)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring end gap Top 0.20 – 0.35 (0.008 – 0.014) 0.5 (0.02)
Second 0.35 – 0.50 (0.014 – 0.020) 0.65 (0.026)
Oil (side rail) 0.20 – 0.70 (0.08 – 0.028) 0.9 (0.04)
Piston ring-to-ring Top 0.025 – 0.060 (0.0010 – 0.0024) 0.09 (0.004)
groove clearance Second 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.20 (0.008)
Connecting rod small end I.D. 15.010 – 15.028 (0.5909 – 0.5917) 15.06 (0.593)
Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.10 (0.004)

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Clutch lever free play 10 – 20 (3/8 – 3/4) –
Clutch Spring free length 39.2 (1.54) 36.1 (1.42)
Disc thickness A 3.62 – 3.70 (0.143 – 0.146) 3.3 (0.13)
B 2.90 – 3.00 (0.114 – 0.118) 2.6 (0.10)
C 2.90 – 3.00 (0.114 – 0.118) 2.6 (0.10)
Plate warpage – 0.20 (0.008)
Clutch outer guide I.D. 19.983 – 19.996 (0.7867 – 0.7872) 20.02 (0.788)
Mainshaft O.D. at clutch outer guide 19.959 – 19.980 (0.7858 – 0.7866) 19.92 (0.784)

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.56 (1.794)

1-8
 GENERAL INFORMATION
CRANKCASE/TRANSMISSION/CRANKSHAFT SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Runout – 0.03 (0.001)
Connecting rod big end radial clear- 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
ance
Connecting rod big end side clear- 0.05 – 0.30 (0.002 – 0.012) 0.80 (0.031)
ance
Transmission Gear I.D. M5, M6, C2 23.020 – 23.041 (0.9063 – 0.9071) 23.08 (0.909)
C1 19.520 – 19.541 (0.7685 – 0.7693) 19.57 (0.770)
C3, C4 22.020 – 22.041 (0.9063 – 0.9071) 22.08 (0.869)
Gear busing C1 O.D. 19.479 – 19.500 (0.7669 – 0.7677) 19.43 (0.765)
I.D. 16.516 – 16.534 (0.6502 – 0.6509) 16.60 (0.654)
M5, M6, O.D. 22.979 – 23.000 (0.9047 – 0.9055) 22.93 (0.903)
C2 I.D. 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
Mainshaft at M5 19.959 – 19.980 (0.7858 – 0.7866) 19.90 (0.783)
O.D.
Counter- at C1 16.466 – 16.484 (0.7864 – 0.7869) 16.41 (0.646)
shaft O.D. at C2 19.974 – 19.987 (0.8645 – 0.8654) 19.94 (0.785)
Shift fork, Shift fork shaft O.D. 11.976 – 11.994 (0.4715 – 0.4722) 11.96 (0.471)
shift fork shaft Shift fork I.D. 12.000 – 12.021 (0.4724 – 0.4733) 12.05 (0.474)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire pressure 100 kPa (1.00 kgf/cm2, 15 psi) –
Axle runout – 0.20 (0.008)
Wheel rim Radial – 2.0 (0.08)
runout Axial – 2.0 (0.08)
Wheel hub-to-rim distance 20.3 ± 1 (0.80 ± 0.04) –
Fork Spring free length 597.6 (23.53) 586 (23.1)
Tube runout – 0.20 (0.008)
Recommended fluid Honda Ultra Cushion Oil 10W or equiv- –
alent
Fluid level ’07 model 144 (5.7) –
After ’07 142 (5.6) –
Fluid capacity ’07 model 380 ± 2.5 cm3 (12.9 ± 0.08 US oz, 13.4 ± –
0.09 lmp oz)
After ’07 382 ± 2.5 cm3 (12.9 ± 0.08 US oz, 13.4 ± –
0.09 lmp oz)

REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire pressure 100 kPa (1.00 kgf/cm2, 15 psi) –
Axle runout – 0.2 (0.01)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance 22.3 ± 1.0 (0.88 ± 0.04) –
Drive chain Size/link DID DID520V6/110 –
RK RK520SMOZ2/110 –
Slack 20 – 30 (3/4 – 1-1/4) –
Brake Pedal free play 20 – 30 (3/4 – 1-1/4) –
Drum I.D. 110.0 – 110.2 (4.33 – 4.34) 111 (4.4)
Lining thickness 4.2 (0.17) 2.0 (0.08)

1-9
GENERAL INFORMATION
HYDRAULIC BRAKE SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Specified brake fluid DOT 4 –
Brake disc thickness 3.0 ± 0.2 (0.12 ± 0.01) 2.5 (0.10)
Brake disc runout – 0.10 (0.004)
Master cylinder I.D. 12.700 (0.5000) –
Master piston O.D. 12.684 (0.4994) –
Caliper cylinder I.D. 27.000 (1.0630) –
Caliper piston O.D. 26.968 (1.0617) –

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Battery Capacity 12 V – 4 Ah or 5 Ah
Current leakage 0.1 mA max.
Voltage Fully charged 13.0 – 13.2 V
(20°C/68°F) Needs Below 12.3 V
charging
Charging current Normal 0.5 A/5 – 10 h
Quick 5.0 A/0.5 h
Alternator Capacity 60 W/5,000 min-1 (rpm)
Charging coil resistance (20°C/68°F) 0.5 – 1.2 Ω
Lighting coil resistance (20°C/68°F) 0.1 – 1.0 Ω

IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATION
Spark plug Standard DPR8EA-9 (NGK) X24EPR-U9 (DENSO)
For cold climate (below 5°C/41°F) DPR7EA-9 (NGK) X22EPR-U9 (DENSO)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil primary peak voltage 70 V minimum
Alternator exciter coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 12° BTDC at idle

ELECTRIC STARTER SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Starter motor brush length ’07 model 12.5 (0.49) 9.0 (0.35)
After ’07 12.0 (0.47) 6.5 (0.26)

LIGHT/SWITCHES SPECIFICATIONS
ITEM SPECIFICATION
Headlight bulb 12 V - 35 W
Main fuse 7.5 A

1-10
 GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head; small 9 (0.9, 6.5)
head)
10 mm bolt and nut 34 (3.5, 25) 6 mm flange bolt (8 mm head; large 12 (1.2, 9)
flange) and nut
12 mm bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and 12 (1.2, 9)
nut
8 mm flange bolt and nut 26 (2.7, 20)
10 mm flange bolt and nut 39 (4.0, 29)

ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
ENGINE
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Spark plug 1 12 18 (1.8, 13)
Oil strainer cap 1 36 15 (1.5, 11)
Timing hole cap 1 14 6 (0.6, 4.4)
Crankshaft hole cap 1 30 8 (0.8, 5.9)
Valve adjusting hole cap 2 36 15 (1.5, 11)
Valve adjusting lock nut 2 6 14 (1.4, 10) Apply engine oil to the
threads and seating surface
Oil filter rotor cover screw 3 5 5 (0.5, 3.7)

LUBRICATION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Oil pump rotor cover screw 2 4 3 (0.3, 2.2)

CYLINDER HEAD/VALVES
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head cover cap nut 4 8 27 (2.8, 20) Apply engine oil to the
threads and seating surface
Cylinder head cover bolt 4 6 12 (1.2, 9)
Cylinder head socket bolt 1 6 10 (1.0, 7)
Cam sprocket bolt 2 6 12 (1.2, 9) Apply engine oil to the
threads and seating surface
Cam chain tensioner lifter mount- 2 6 12 (1.2, 9)
ing bolt
Cam chain tensioner lifter sealing 1 6 4 (0.4, 3.0)
plug
Cam chain tensioner pivot bolt 1 8 10 (1.0, 7)

1-11
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Clutch spring bolt 4 6 12 (1.2, 9)
Clutch center lock nut 1 16 93 (9.5, 69) Apply engine oil to the
threads and seating surface/
Stake
Oil filter rotor lock nut 1 16 83 (8.5, 61) Apply engine oil to the
threads and seating surface
Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9)
Gearshift pedal pinch bolt 1 6 12 (1.2, 9)

ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Starter clutch bolt 6 6 16 (1.6, 12) Apply locking agent to the
threads
Flywheel bolt 1 10 74 (7.5, 55) Apply engine oil to the
threads and seating surface
Ignition pulse generator mount- 2 5 5 (0.5, 3.7) Apply locking agent to the
ing bolt threads
CRANKCASE/TRANSMISSION/CRANKSHAFT
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Mainshaft bearing set plate bolt 1 8 23 (2.3, 17) Apply locking agent to the
threads

1-12
 GENERAL INFORMATION
FRAME
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Exhaust pipe joint nut 2 7 20 (2.0, 15)
Exhaust pipe protector bolt 2 6 14 (1.4, 10)
Muffler mounting bolt 2 8 26 (2.7, 19)
Muffler band bolt 1 8 20 (2.0, 15)
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Brake lever adjusting bolt lock nut 1 5 5.9 (0.6, 4.4)
Side stand pivot bolt 1 10 10 (1.0, 7)
Side stand pivot lock nut 1 10 39 (4.0, 29) U-nut
Spark arrester mounting bolt 3 6 14 (1.4, 10)

FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Fuel valve mounting bolt 2 6 9 (0.9, 6.6)
Mudguard mounting screw 2 5 0.8 (0.1, 0.6)

ENGINE MOUNTING
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Upper engine hanger nut 3 8 35 (3.6, 26)
Front engine hanger nut 3 8 35 (3.6, 26)
Front lower engine hanger nut 1 8 35 (3.6, 26)
Rear upper engine hanger nut 1 10 60 (6.1, 44)
Rear lower engine hanger nut 1 10 60 (6.1, 44)
Footpeg mounting bolt 4 10 59 (6.0, 44) ALOC bolt; replace with a new
one.

FRONT WHEEL/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Handlebar upper holder bolt 4 8 26 (2.7, 19)
Steering stem nut 1 24 108 (11.0, 80)
Steering bearing adjustment nut 1 26 – page 12-24
Fork top bridge pinch bolt 4 8 27 (2.8, 20)
Fork bottom bridge pinch bolt 4 8 31.5 (3.2, 23)
Fork cap 2 – 23 (2.3, 17)
Fork socket bolt 2 8 20 (2.0, 15) Apply locking agent to the
threads
Front axle 1 14 73.5 (7.5, 54)
Front axle holder nut 4 6 12 (1.2, 9) U-nut
Front brake disc bolt 4 6 20 (2.0, 15) ALOC bolt; replace with a new
one.
Wheel hub cover screw 4 4 0.74 (0.1, 0.5)
Spoke nipple 36 BC3.2 3.7 (0.4, 2.7)
Rim lock nut 1 8 12.2 (1.2, 9)
Clutch lever pivot bolt 1 6 1 (0.1, 0.7)
Clutch lever pivot nut 1 6 5.9 (0.6, 4.4)

1-13
GENERAL INFORMATION
REAR WHEEL/BRAKE/SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear axle nut 1 16 108 (11.0, 80) U-nut
Driven sprocket nut 6 8 32 (3.3, 24) U-nut
Swingarm pivot nut 1 14 88 (9.0, 65) U-nut
Shock absorber upper mounting 1 10 44 (4.5, 32)
bolt
Shock absorber lower mounting 1 10 44 (4.5, 32) U-nut
nut
Shock arm-to-swingarm nut 1 12 78 (8.0, 58) U-nut
Shock arm-to-shock link nut 1 10 44 (4.5, 32) U-nut
Shock link-to-frame nut 1 10 44 (4.5, 32) U-nut
Drive chain slider screw 2 5 4.2 (0.4, 3.1) ALOC screw, replace with a
new one.
Spoke nipple 36 BC3.2 3.7 (0.4, 2.7)
Rim lock nut 1 8 12.2 (1.2, 9)
Rear brake arm nut 1 6 9.8 (1.0, 7.2)

HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Master cylinder reservoir cap 2 4 1.5 (0.2, 1.1)
screw
Master cylinder holder bolt 2 6 9.8 (1.0, 7.2)
Brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Brake lever pivot nut 1 6 5.9 (0.6, 4.4)
Pad pin 1 10 17.2 (1.8, 13)
Pad pin plug 1 10 2.5 (0.3, 1.8)
Caliper bleeder valve 1 8 5.4 (0.6, 4.0)
Caliper pin bolt A 1 8 22 (2.2, 16) Apply locking agent to the
threads.
Brake caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt, replace with a new
one.
Brake hose oil bolt 2 10 34 (3.5, 25)
Brake hose clamp bolt 2 6 9.8 (1.0, 7.2)

1-14
 GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Engine oil Oil pump rotors
Oil through sliding area
Cylinder head cover 8 mm cap nut threads and seating
surface
Piston outer surface and piston rings
Cam sprocket bolt threads and seating surface
Cam chain entire surface
Valve adjusting lock nut threads
Oil filter rotor lock nut threads and seating surface
Clutch disc entire surface
Clutch center lock nut threads and seating surface
Stator mounting bolt threads and seating surface
Starter reduction gear shaft entire surface
Starter idle gear shaft entire surface
Stater sprag clutch contacting surfaces
Crankshaft connecting rod big end bearing
Each oil seal lip
Each bearing rotating area
Each O-ring
Molybdenum oil solution Valve stem sliding surface
(a mixture of engine oil Camshaft bearings and cam lobes
and molybdenum Rocker arm shaft entire surface
disulfide grease in a ratio Piston pin entire surface
of 1:1) Clutch outer guide entire surface
Transmission gear rotating surface
Locking agent Starter clutch bolt threads Coating width: 6.5 ± 1.0
mm
Ignition pulse generator mounting bolt threads Coating width: 6.5 ± 1.0
mm
Mainshaft bearing set plate bolt threads Coating width: 6.5 ± 1.0
mm
Liquid sealant Cylinder head cover mating surface (cover side) Coating area: page 7-21
Crankcase mating areas (cylinder gasket mating sur- Coating area: page 8-8
faces)
Alternator wire grommet seating surface

1-15
GENERAL INFORMATION
FRAME
MATERIAL LOCATION REMARKS
Urea based multi-purpose Steering head bearings Apply 3 – 5 g for each bear-
grease with extreme pres- ing
sure agent (Example: Steering head bearing dust seal lips
Excelite EP2 manufac-
tured by Kyodo Yushi,
Japan)
Multi-purpose grease Rear brake cam (rotating surface and shoe contacting Apply 0.5 – 1 g
area)
Rear brake panel anchor pin Apply 0.5 – 1 g
Brake cam dust seal
Wheel dust seal lips
Shock linkage needle bearings
Shock linkage pivot dust seal lips
Swingarm pivot needle bearings
Swingarm pivot dust seal cap lips
Side stand pivot
Rear brake pedal pivot
Throttle grip pipe flange sliding surface and cable roll-
ing area
Throttle cable slider sliding area
Clutch lever pivot
Silicone grease Brake lever pivot
Front brake lever-to-master piston contacting area
Brake caliper pin boots inside
DOT4 brake fluid Brake master piston and cups
Brake caliper pistons and piston seals
Locking agent Brake caliper pin bolt threads
Footpeg mounting bolt threads
Honda Ultra Cushion Oil Fork cap O-ring
10W or equivalent Fork oil seal lips and dust seal lips
Honda Bond A Left handlebar grip inner surface

1-16
 GENERAL INFORMATION
CABLE & HARNESS ROUTING
CLUTCH CABLE
THROTTLE CABLES

CLUTCH SWITCH/ENGINE
STARTER SWITCH WIRE STOP SWITCH WIRE

IGNITION SWITCH WIRE

HEADLIGHT WIRE

IGNITION CONTROL MODULE (ICM)

FRONT BRAKE HOSE

FRONT BRAKE HOSE

10 mm

HOSE CLAMP

1-17
GENERAL INFORMATION

THROTTLE CABLES
BRAKE HOSE

IGNITION SWITCH

CLUTCH CABLE

ENGINE STOP SWITCH

STARTER SWITCH

BAND:

Front
HEADLIGHT WIRE
(4 places)

CABLE GUIDE

THROTTLE CABLES

STARTER SWITCH WIRE

CLUTCH SWITCH/ENGINE
STOP SWITCH WIRE

CLUTCH CABLE

1-18
 GENERAL INFORMATION

HEADLIGHT WIRE

HEADLIGHT WIRE
ENGINE STOP/
CLUTCH SWITCH
WIRE

IGNITION
SWITCH WIRE

THROTTLE
CABLES

THROTTLE CABLES

CONNECTORS:
· Ignition switch connectors
· Engine stop switch connector
· Starter switch 2P (white) connector
· Clutch switch 2P (black) connector
· Headlight connectors

1-19
GENERAL INFORMATION

IGNITION COIL

5° max

5° max REGULATOR/RECTIFIER
IGNITION COIL
GROUND TERMINAL

SPARK PLUG WIRE

STARTER SWITCH WIRE

CLUTCH CABLE

CLUTCH CABLE

MAIN WIRE HARNESS

CARBURETOR DRAIN HOSE

1-20
 GENERAL INFORMATION

’07 model:

CARBURETOR AIR VENT HOSE

CONNECTORS:
· Alternator/ignition pulse generator/
neutral switch 4P connector
· Exciter coil connector

CRANKCASE BREATHER HOSE

ALTERNATOR/IGNITION PULSE
GENERATOR/NEUTRAL
BATTERY (–) CABLE SWITCH WIRE

STARTER MOTOR CABLE

1-21
GENERAL INFORMATION

After ’07:

FUEL HOSE

CARBURETOR AIR VENT HOSE

BATTERY (–) CABLE

FUEL VALVE
STARTER MOTOR:

0 – 3 mm

STARTER MOTOR CABLE

CONNECTORS:
STARTER MOTOR · Alternator/ignition pulse
CABLE CRANKCASE generator/neutral switch
BREATHER HOSE 4P connector
· Exciter coil connector

CRANKCASE
BREATHER HOSE

ALTERNATOR/IGNITION
PULSE GENERATOR/
NEUTRAL SWITCH WIRE
ALTERNATOR/IGNITION
BATTERY (–) CABLE PULSE GENERATOR/
NEUTRAL SWITCH WIRE

1-22
 GENERAL INFORMATION

STARTER MOTOR CABLE

MAIN WIRE HARNESS

(2 places)
STARTER MOTOR CABLE

BATTERY
STARTER RELAY SWITCH

BATTERY (+) CABLE

1-23
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS (U type)
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of hydrocarbons and
oxides nitrogen is very important because, under certain conditions, they react to form photochemical smog when sub-
jected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of
nitrogen and hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of an appropriate carburetor settings and no adjustment should be
made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the
crankcase emission control system.
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.

CRANKCASE BREATHER SEPARATOR

CARBURETOR

AIR CLEANER

CRANKCASE BREATHER HOSE

Fresh Air
Blow-by Gas

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person, other than for the purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in use; (2) the use of any vehicle after such device or element of
design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those speci-
fied by the manufacturer.

1-24
 GENERAL INFORMATION
EMISSION CONTROL SYSTEMS (BR TYPE)
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.

CRANKCASE BREATHER SEPARATOR

CARBURETOR

AIR CLEANER

CRANKCASE BREATHER HOSE

Fresh Air
Blow-by Gas

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person, other than for the purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in use; (2) the use of any vehicle after such device or element of
design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those speci-
fied by the manufacturer.

1-25
MEMO
2. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION ··························· 2-2 REAR FENDER ············································ 2-4

TROUBLESHOOTING ································· 2-2 FUEL TANK ················································· 2-5

SEAT···························································· 2-3 SKID PLATE ················································ 2-5

SIDE COVERS ············································· 2-3 EXHAUST PIPE/MUFFLER ························ 2-6

FRONT FENDER·········································· 2-4

2-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM

GENERAL
• This section covers removal and installation of the body panels, fuel tank and exhaust system.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
• Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all fasteners, tighten the exhaust pipe joint nuts first, tighten the
muffler band bolt, then tighten the muffler mounting bolts.
• Always inspect the exhaust system for leaks after installation.
• Refer to page 18-4 for headlight removal/installation.

TORQUE VALUES
Exhaust pipe joint nut 20 N·m (2.0 kgf·m, 15 lbf·ft)
Exhaust pipe protector mounting bolt 14 N·m (1.4 kgf·m, 10 lbf·ft)
Muffler mounting bolt 26 N·m (2.7 kgf·m, 19 lbf·ft)
Muffler band bolt 20 N·m (2.0 kgf·m, 15 lbf·ft)

TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

2-2
 FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL
Remove the nuts, collars and bolts.
Slide the seat backward and remove it. SEAT

INSTALLATION
Install the seat by aligning the groove and prongs
with the boss and hooks.
Install the bolts, collars and nuts, then tighten the
nuts securely.

NUT COLLAR BOLT

SIDE COVERS
LEFT SIDE:
Remove the screw and two bolts.
GROMMETS BOSSES
Remove the left side cover by releasing the three
bosses from the grommets. BOLT
Installation is in the reverse order of removal.

COLLAR
BOLT SCREW

RIGHT SIDE:
Remove the screw.
Remove the right side cover by releasing the two GROMMETS
bosses from the grommets.
Installation is in the reverse order of removal.

BOSSES

SCREW

2-3
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT FENDER
The two front bolts Remove the following:
are longer than the
– two cap nuts
two rear bolts.
– headlight stay CAP NUTS
– four bolts and washers
– front fender
Installation is in the reverse order of removal.

STAY

BOLTS, WASHERS

REAR FENDER
Remove the following:
BOLTS, WASHERS
– seat (page 2-3)
– both side covers (page 2-3)
– two bolts and washers
– rear fender
Installation is in the reverse order of removal.

2-4
 FRAME/BODY PANELS/EXHAUST SYSTEM
FUEL TANK
Remove the seat (page 2-3).
Disconnect the breather hose from the steering
stem nut.
Turn the fuel valve OFF, and disconnect the fuel
hose from the fuel valve.
Unhook the mounting strap.
Remove the two mounting bolts, washers, collars
and the fuel tank from the frame.
Installation is in the reverse order of removal.
(’07 model shown)
BREATHER HOSE

FUEL TANK

STRAP

BOLT, WASHER

FUEL VALVE
BOLT, WASHER
COLLAR
COLLAR After ’07:
CLAMP FUEL HOSE
FUEL HOSE

0 – 3 mm
FUEL VALVE

SKID PLATE
Remove the 8 mm bolt, two 6 mm bolts and the skid
SKID PLATE
plate.
Installation is in the reverse order of removal.

8 mm BOLT
6 mm BOLTS

2-5
FRAME/BODY PANELS/EXHAUST SYSTEM
EXHAUST PIPE/MUFFLER
REMOVAL
MUFFLER
Remove the right side cover (page 2-3).
MUFFLER BAND BOLT
Loosen the muffler band bolt.

Remove the muffler mounting bolts, nut, washer

and the muffler. BOLT, NUT

Remove the muffler gasket.

BOLT, WASHER
EXHAUST PIPE
Loosen the muffler band bolt.
MUFFLER BAND BOLT

Remove the exhaust pipe joint nuts and exhaust

pipe. JOINT NUTS

Remove the exhaust pipe gasket and muffler gasket.

EXHAUST PIPE

2-6
 FRAME/BODY PANELS/EXHAUST SYSTEM
INSTALLATION

MUFFLER

EXHAUST PIPE GASKET

MOUNTING BOLTS

MUFFLER GASKET
BAND BOLT
JOINT NUTS
PROTECTOR EXHAUST PIPE

If the exhaust pipe stud bolts are loose, tighten

them. Be sure to verify the distance from the top of
the stud to the cylinder head as shown.

25 mm (1.0 in)

EXHAUST PIPE
Install a new exhaust pipe gasket into the cylinder
head.
Install a new muffler gasket onto the exhaust pipe.

GASKET

2-7
FRAME/BODY PANELS/EXHAUST SYSTEM
Install the exhaust pipe and joint nuts.
Tighten the joint nuts to the specified torque. JOINT NUTS

TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

EXHAUST PIPE

Tighten the muffler band bolt to the specified

MUFFLER BAND BOLT
torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

MUFFLER
Install a new muffler gasket onto the exhaust pipe.
BOLT, NUT
Install the muffler, washer, mounting bolts and nut,
and loosely tighten the mounting bolts.

BOLT, WASHER
Tighten the muffler band bolt to the specified
MUFFLER BAND BOLT
torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)
Tighten the muffler mounting bolts to the specified
torque.
TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft)
Install the right side cover (page 2-3).

2-8
 3. MAINTENANCE

SERVICE INFORMATION ··························· 3-2 DRIVE CHAIN············································ 3-14

MAINTENANCE SCHEDULE ······················ 3-4 DRIVE CHAIN SLIDER ······························ 3-17

FUEL LINE ··················································· 3-5 BRAKE FLUID ··········································· 3-18

THROTTLE OPERATION····························· 3-5 BRAKE SHOE/PAD WEAR ······················· 3-19

AIR CLEANER·············································· 3-6 BRAKE SYSTEM ······································· 3-19

CRANKCASE BREATHER ··························· 3-7 CLUTCH SYSTEM ···································· 3-21

SPARK PLUG ·············································· 3-7 SIDE STAND ············································· 3-21

VALVE CLEARANCE··································· 3-8 SUSPENSION ··········································· 3-22

ENGINE OIL··············································· 3-11 SPARK ARRESTER ··································· 3-22

ENGINE OIL STRAINER SCREEN ············ 3-12 NUTS, BOLTS, FASTENERS···················· 3-23

ENGINE OIL CENTRIFUGAL FILTER········ 3-13 WHEELS/TIRES ········································ 3-23

ENGINE IDLE SPEED ································ 3-13 STEERING HEAD BEARINGS ·················· 3-24

3-1
MAINTENANCE
SERVICE INFORMATION
MAINTENANCE

GENERAL
• Place the motorcycle on a level surface before starting any work.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle grip free play 2 – 6 mm (1/12 – 1/4 in)
Spark plug NGK DENSO
Standard DPR8EA-9 X24EPR-U9
For cold climate (below 5°C/41°F) DPR7EA-9 X22EPR-U9
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Valve clearance Intake 0.1 mm (0.004 in)
Exhaust 0.1 mm (0.004 in)
Engine oil capacity After draining 1.0 liter (1.1 US qt,0.9 lmp qt)
After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt)
Engine oil U type Suggested oil:
Honda "4-stroke motorcycle oil" or an equivalent
Oil recommendation:
API classification: SG or higher
(except oils labeled as energy conserving on the cir-
cular API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA
BR type API service classification: SG or higher (except oils
labeled as energy conserving on the circular API ser-
vice label)
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Suggested oil: Oil which Honda recommends
Engine idle speed U type 1,400 ± 100 min-1 (rpm)
BR type 1,500 ± 100 min-1 (rpm)
Drive chain slack 20 – 30 mm (3/4 – 1-1/4 in)
Drive chain size/link DID DID520V6/110
RK RK520SMOZ2/110
Recommended brake fluid DOT 4
Brake pedal free play 20 – 30 mm (3/4 – 1-1/4 in)
Clutch lever free play 10 – 20 mm (3/8 – 3/4 in)
Tire size Front 80/100-21 NHS
Rear 100/100-18 NHS
Cold tire pressure Front 100 kPa (1.00 kgf/cm2, 15 psi)
Rear 100 kPa (1.00 kgf/cm2, 15 psi)

TORQUE VALUES
Spark plug 18 N·m (1.8 kgf·m, 13 lbf·ft)
Oil strainer cap 15 N·m (1.5 kgf·m, 11 lbf·ft)
Valve adjusting hole cap 15 N·m (1.5 kgf·m, 11 lbf·ft)
Valve adjusting lock nut 14 N·m (1.4 kgf·m, 10 lbf·ft) Apply engine oil to the threads and seating
surface.
Timing hole cap 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
Crankshaft hole cap 8 N·m (0.8 kgf·m, 5.9 lbf·ft)
Upper engine hanger nut 35 N·m (3.6 kgf·m, 26 lbf·ft)
Oil filter rotor cover screw 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
Master cylinder reservoir cap screw 1.5 N·m (0.2 kgf·m, 1.4 lbf·ft)
Brake lever adjusting bolt lock nut 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)
Rear axle nut 108 N·m (11.0 kgf·m, 80 lbf·ft) U-nut
Side stand pivot bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Side stand pivot lock nut 39 N·m (4.0 kgf·m, 29 lbf·ft) U-nut
Spark arrester mounting bolt 14 N·m (1.4 kgf·m, 10 lbf·ft)
Spoke nipple 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Rim lock nut 12.2 N·m (1.2 kgf·m, 9 lbf·ft)

3-2
 MAINTENANCE
TOOLS
Spoke wrench, 5.8 x 6.1 mm Wrench, 10 x 12 mm Valve adjusting wrench B
07701-0020300 07708-0030200 07708-0030400

Drive chain tool set

07HMH-MR10103

3-3
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
FREQUENCY INITIAL
WHICHEVER COMES REGULAR MAINTENANCE
MAINTE-
FIRST INTERVAL
NANCE REFER TO
mi 100 600 1,200 1,800 2,400 PAGE
km 150 1,000 2,000 3,000 4,000
ITEMS NOTE MONTH 1 6 12 18 24
* FUEL LINE I I 3-5
* THROTTLE OPERATION I I 3-5
AIR CLEANER NOTE 1 C C C C 3-6
CRANKCASE BREATHER I I I I 3-7
SPARK PLUG I I I I 3-7
* VALVE CLEARANCE I I I I I 3-8
ENGINE OIL R R R R R 3-11
** ENGINE OIL STRAINER SCREEN C C 3-12
** ENGINE OIL CENTRIFUGAL FILTER C C 3-13
** ENGINE IDLE SPEED I I I I I 3-13
DRIVE CHAIN I, L I, L: Every 300 mi (500 km) 3-14
NOTE 1
or 3 month
DRIVE CHAIN SLIDER I I I I 3-17
BRAKE FLUID NOTE 2 I I I I 3-18
BRAKE SHOE/PAD WEAR I I I I 3-19
BRAKE SYSTEM I I I I I 3-19
* HEADLIGHT AIM I I 3-19
CLUTCH SYSTEM I I I I I 3-21
SIDE STAND I I 3-21
* SUSPENSION I I 3-22
* SPARK ARRESTER C: Every 1,000 mi (1,600 km) or every 3-22
100 operating hours
* NUTS, BOLTS, FASTENERS I I I 3-23
** WHEELS/TIRES I I I I I 3-23
** STEERING HEAD BEARINGS I I I 3-24

* Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
** In the interest of safety, we recommended these items be serviced only by your Honda dealer.
NOTES:
1. Service more frequently when ridden in wet or dusty conditions.
2. Replace every 2 years. Replacement requires mechanical skill.

3-4
 MAINTENANCE
FUEL LINE
Check the fuel line for deterioration, damage or
leakage. FUEL LINE
Replace the fuel line if necessary.
For fuel strainer cleaning, refer to page 5-19.

THROTTLE OPERATION
Check for any deterioration or damage to the throt-
tle cables. Check the throttle grip for smooth opera- 2 – 6 mm (1/12 – 1/4 in)
tion. Check that the throttle opens and automatically
closes in all steering positions.
If the throttle grip does not return properly, lubricate
the throttle cables and overhaul and lubricate the
throttle housing.
For cable lubrication: Disconnect the throttle cables
at their upper ends. Thoroughly lubricate the cables
and their pivot points with a commercially available
cable lubricant or a light weight oil.
If the throttle grip still does not return properly,
replace the throttle cables.
With the engine idling, turn the handlebar all the
way to the right and left to ensure that the idle
speed does not change. If idle speed increase, check
the throttle grip free play and the throttle cable con-
nection.
Measure the free play at the throttle grip flange.
FREE PLAY: 2 – 6 mm (1/12 – 1/4 in)
Throttle grip free play can be adjusted at either end
of the throttle cable. Minor adjustments are made
with the upper adjuster.
Slide the dust cover off the throttle housing.
Loosen the lock nut, turn the adjuster as required ADJUSTER
and tighten the lock nut.

DUST COVER

LOCK NUT

3-5
MAINTENANCE
Minor adjustments are made with the lower
adjuster.
Loosen the lock nut, turn the adjuster as required
and tighten the lock nut.
Recheck the throttle operation.
Install the dust cove over the throttle housing.

ADJUSTER
LOCK NUT

AIR CLEANER
• If the motorcycle is used in wet or dusty condi-
tions, more frequent service is required.
Remove the right side cover (page 2-3).
Remove the five screws and air cleaner housing
cover.

COVER

Release the element retainer rod and remove the air ELEMENT
cleaner.

RETAINER ROD

Remove the element from the holder.

ELEMENT
Never use gasoline Thoroughly wash the element in non-flammable or
or low flash point high flash point solvent. Then wash the element in PINS
solvents for clean- hot, soapy water and allow it to dry thoroughly.
ing the element. A
Soak the element in Pro Honda Foam Filter Oil or an
fire or explosion
equivalent.
could result.
Apply filter oil to the entire surface of the element
and rub it with both hands to saturate the element
with oil. Gently squeeze out excess oil. (To keep
your hands dry, place the element in a clean plastic
bag before rubbing the oil into the element.)
Assemble the element and holder by aligning the HOLDER
locating pins with the holes.

3-6
 MAINTENANCE
Install the air cleaner by aligning the pins with the ELEMENT
hole in the housing. PINS

Make sure the mat- Align the retainer rod with the holder groove and
ing surface evenly secure it with the retainer hook.
touch, that there is
Install the removed parts in the reverse order of
no clearance GROOVE
removal.
between the ele-
ment and housing.

ROD

HOOK

CRANKCASE BREATHER
Check the crankcase breather hose for deterioration,
damage or loose connection.
Make sure the breather hose is not kinked, pinched
or cracked. CRANKCASE BREATHER HOSE

Squeeze the drain tube open to empty any deposits.

DRAIN TUBE

SPARK PLUG
Disconnect the spark plug cap.

Clean around the Remove the spark plug.

spark plug base
with compressed
PLUG CAP
air before removing
the plug, and be
sure that no debris
is allowed to enter
into the combustion
chamber.

SPARK PLUG

3-7
MAINTENANCE
Check the insulator for cracks or damage, and the
electrodes for wear, fouling or discoloration.
Replace the plug if necessary. CENTER ELECTRODE
RECOMMENDED SPARK PLUG:
Standard:
DPR8EA-9 (NGK), X24EPR-U9 (DENSO)
For cold climate (below 5°C/41°F)
DPR7EA-9 (NGK), X22EPR-U9 (DENSO)

INSULATOR
SIDE ELECTRODE

Clean the spark plug electrodes with a wire brush or

special plug cleaner.
Check the gap between the center electrodes with a
wire-type feeler gauge. 0.8 – 0.9 mm
(0.03 – 0.04 in)
If necessary, adjust the gap by bending the side
electrode carefully.
SPARK PLUG GAP: 0.8 – 0.9 mm (0.03 – 0.04 in)
Thread the spark plug into the cylinder head in by
hand to prevent cross-threading and tighten it with
a spark plug wrench.
TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
Connect the spark plug cap.

VALVE CLEARANCE
• Inspect and adjust the valve clearance while the
engine is cold (below 35°C/95°F).
Remove the fuel tank (page 2-5). RUBBER CAPS
Remove the following: ADJUSTING
– rubber caps HOLE CAPS
– three nuts and bolts
– engine hanger plates
– valve adjusting hole caps

HANGER PLATES

NUTS AND BOLTS

3-8
 MAINTENANCE
– timing hole cap
– crankshaft hole cap TIMING HOLE CAP

CRANKSHAFT
HOLE CAP

Rotate the crankshaft counterclockwise and align

the “T” mark on the flywheel with the index notch in
the crankcase cover. INDEX NOTCH
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
This position can be obtained by confirming that
there is slack in the rocker arm. If there is no slack, it
is because the piston is moving through the exhaust
stroke to TDC. Rotate the crankshaft one full turn
and match up the “T” mark again.

“T” MARK

When checking the Check the clearances of the intake and exhaust
clearance, slide the valves by inserting the feeler gauge between the
feeler gauge from adjusting screw and valve stem. ADJUSTING SCREW
the center toward
the outside. VALVE CLEARANCE: IN/EX: 0.1 mm (0.004 in)

LOCK NUT

FEELER GAUGE

Adjust by loosening the lock nut and turning the

adjusting screw until there is a slight drag on the
feeler gauge.
TOOLS: WRENCH B
Wrench, 10 x 12 mm 07708-0030200
Valve adjusting wrench B 07708-0030400
Hold the adjusting screw and tighten the lock nut.
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)
After tightening the valve adjuster lock nut, recheck
the valve clearance.

WRENCH, 10 X 12 mm

3-9
MAINTENANCE
Coat new O-rings with engine oil and install them
into the adjusting hole cap grooves.
Install the adjusting hole caps and tighten them. O-RING
TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft)

Coat new O-rings with engine oil and install them

into the hole cap grooves.
Install the crankshaft hole cap and timing hole cap
and tighten them.
TORQUE:
Timing hole cap: 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
Crankshaft hole cap: 8 N·m (0.8 kgf·m, 5.9 lbf·ft)

O–RINGS

Install the following:

– engine hanger plates RUBBER CAPS
– three nuts and bolts
TORQUE: 35 N·m (3.6 kgf·m, 26 lbf·ft)
– rubber caps
Install the fuel tank (page 2-5).

HANGER PLATES

NUTS AND BOLTS

3-10
 MAINTENANCE
ENGINE OIL
For engine oil LEVEL CHECK
change, see page Clean around the oil filler cap/dipstick and nearby
3-12 “Engine Oil surface.
Strainer Screen”.
Start the engine and let it idle for 3 – 5 minutes.
Stop the engine and wait 2 – 3 minutes. UPPER
Support the motorcycle upright on a level surface.
Remove the filler cap/dipstick and wipe the oil with LOWER
a clean cloth.
Insert the dipstick without screwing it in, remove it
and check the oil level
FILLER CAP/DIPSTICK
If the oil level is below or near the lower level line
on the dipstick, add the recommended oil to the
upper level line through the oil filler hole.

SUGGESTED OIL (U TYPE)

U TYPE: OIL VISCOSITIES
Honda "4-stroke motorcycle oil" or an equivalent
OIL RECOMMENDATION:
API classification: SG or higher
(except oils labeled as energy conserving on the
circular API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA

RECOMMENDED ENGINE OIL (BR TYPE)

BR TYPE: OIL VISCOSITIES
API service classification: SG or higher (except oils
labeled as energy conserving on the circular API
service label)
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Suggested oil: Oil which Honda recommends

• Other viscosities shown in the chart may be used

when the average temperature in your riding
area is within the indicated range.
Reinstall the filler cap/dipstick.

3-11
MAINTENANCE
ENGINE OIL STRAINER SCREEN
OIL CHANGE/STRAINER CLEANING

• Change the oil with the engine warm and the

motorcycle on its side stand to assure complete
and rapid draining.
Start the engine, warm it up and stop it.
Remove the oil filler cap/dipstick.
Remove the oil strainer cap, spring and strainer, and
drain the oil.

OIL STRAINER CAP

Wash the strainer screen thoroughly in non-flam-
mable or high flash point solvent until all accumu-
lated dirt has been removed.
Blow dry it with compressed air to clean completely
SPRING
Before installing the strainer, it should be examined
closely for damage and make sure the sealing rub-
ber is good condition.

STRAINER

Coat a new O-ring with engine oil and install it into

strainer cap groove.
Install the oil strainer and spring with the strainer
sealing rubber toward the crankcase.
Install the strainer cap and tighten it.
TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft) O-RING
Fill the crankcase with the recommended engine oil
(page 3-11). CAP

OIL CAPACITY:
1.0 liter (1.1 US qt,0.9 lmp qt) at draining
1.2 liter (1.3 US qt, 1.1 lmp qt) at disassembly
STRAINER SPRING
Check the engine oil level (page 3-11).
Make sure there are no oil leaks.

3-12
 MAINTENANCE
ENGINE OIL CENTRIFUGAL FILTER
Remove the right crankcase cover (page 9-5).
COVER
Remove the following:
– three screws
– filter rotor cover
– gasket

Do not allow dust Clean the inside of the oil centrifugal filter rotor and
and dirt to enter the cover.
oil passage in the
crankshaft. Never
use compressed air
for cleaning.

Check that the oil through operates freely, without

binding.
Install the filter rotor cover with a new gasket and ROTOR COVER
tighten the three screws.
TORQUE: 5 N·m (0.5 kgf·m, 3.7 lbf·ft)
Install the right crankcase cover (page 9-14).

GASKET
OIL THROUGH

ENGINE IDLE SPEED

• Inspect and adjust the idle speed after all other
engine maintenance items have been performed
and are within specifications.
• Engine must be warm for accurate adjustment.
Ten minutes of stop-and-go riding is sufficient.
Warm the engine, shift the transmission into neutral
and support the motorcycle upright on a level sur-
face.
Connect a tachometer and check the idle speed.
IDLE SPEED:
U type: 1,400 ± 100 min-1 (rpm)
BR type: 1,500 ± 100 min-1 (rpm) THROTTLE STOP SCREW
If the adjustment is necessary, turn the throttle stop
screw as required.

3-13
MAINTENANCE
DRIVE CHAIN
CHAIN SLACK INSPECTION
Turn the ignition switch OFF, place the motorcycle
on its side stand and shift the transmission into neu-
tral.
Check the slack in the lower drive chain run midway
between the sprockets.
CHAIN SLACK: 20 – 30 mm (3/4 – 1-1/4 in)

Excessive chain slack, 60 mm (2-3/8 in) or more,

may damage the frame.

25mm (1 in)

ADJUSTMENT
Loosen the rear axle nut.
Turn both chain adjusters equally until the slack is STOPPER PINS
correct, then temporarily tighten the axle nut.
A scale is included on the adjusters. Be sure the AXLE NUT
same adjuster grooves align with the stopper pins
on both sides of the swingarm.
Chain slack should remain constant as the wheel
rotates.
If the chain is slack only in certain sections, inspect
it.
Tighten the rear axle nut. ADJUSTERS
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)
Recheck the chain slack and free wheel rotation.

CLEANING AND INSPECTION

Clean the chain with a soft brush using a non-flam-
mable or high flash point solvent and wipe it dry. SOFT BRUSH
Be sure the chain has dried completely before lubri- SOLVENT
cating.
Inspect the drive chain for possible damage or wear.
CLEANING
Replace any chain that has damaged rollers, loose
fitting links, or otherwise appears unserviceable.
Installing a new chain on badly worn sprockets will
cause the new chain to wear quickly. Inspect and WIPE AND DRY
replace sprocket as necessary.

LUBRICATE

3-14
 MAINTENANCE
LUBRICATION
Lubricate the drive chain with Pro Honda Chain
Lube or equivalent chain lubricant designed specifi-
cally for use on O-ring chains.
Some commercially available chain lubricants may
contain solvents which could damage the O-rings.
Wipe off the excess chain lube.

CHAIN LUBRICANTS

SPROCKET INSPECTION
Inspect the drive and driven sprocket teeth for wear
or damage. Replace if necessary.
WEAR
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condi-
tion, or the new replacement parts will wear rapidly.
Check the attaching bolts and nuts on the drive and
driven sprockets. If any are loose, torque them.
DAMAGE NORMAL

REPLACEMENT
This motorcycle uses a drive chain with a staked
master link. DRIVE CHAIN TOOL SET:
Loosen the drive chain (page 3-14).
Assemble the special tool as shown.
TOOL:
Drive chain tool set 07HMH–MR10103

• When using the special tool, follow the manufac-

turer's instruction.

3-15
MAINTENANCE
Locate the crimped pin ends of the master link from
the outside of the chain and remove the link with
the drive chain tool set. MASTER LINK
Remove the drive chain.

DRIVE CHAIN TOOL SET

Remove the excess drive chain links from the new

drive chain with the drive chain tool set.

1 LINK
• Include the master link when you count the drive MASTER LINK
chain links.
SPECIFIED LINKS: 110 links

REPLACEMENT CHAIN: DID: DID520V6

RK: RK520SMOZ2

110 LINKS

Never reuse the old drive chain, master link, master

link plate and O-rings. O-RINGS
PLATE
Install the new drive chain over the sprockets.
Assemble the new master link, O-rings and plate
with the drive chain tool set.

• Insert the master link from the inside of the drive

chain, and install the plate with the identification
mark facing the outside.

MASTER LINK

Assemble the part with the drive chain tool set.

DRIVE CHAIN TOOL SET
TOOL:
Drive chain tool set 07HMH–MR10103

3-16
 MAINTENANCE
Make sure the master link pins are installed prop-
erly.
Measure the master link pin length projected from MASTER LINK PINS
the plate.
STANDARD LENGTH::
DID: 1.15 – 1.55 mm (0.045 – 0.061 in)
RK: 1.2 – 1.4 mm (0.47 – 0.55 in)
Stake the master link pins with the drive chain tool
set.

Make sure the pins are staked properly by measur-

ing the diameter of the staked area. VERNIER CALIPERS
DIAMETER OF THE STAKED AREA:
DID: 5.4 – 5.6 mm (0.21 – 0.22 in)
RK: 5.40 – 5.65 mm (0.213 – 0.222 in)

After staking, check the staked area of the master

link for cracks.
A drive chain with a If there is any cracking, replace the master link, O- GOOD NO GOOD
clip-type master link rings and plate.
must not be used.

CRACKS

DRIVE CHAIN SLIDER

DRIVE CHAIN SLIDERS
Check the drive chain sliders and roller for wear or
CHAIN ROLLER
damage.
If the slider is worn to the bottom of the wear limit
groove, replace it.
If the roller O.D. is smaller than 18 mm (0.7 in),
replace chain roller.

LIMIT GROOVES CHAIN SLIDERS

3-17
MAINTENANCE
CHAIN GUIDE SLIDER
Check the chain guide and guide slider for align-
ment, wear or damage.
If the chain is visible through the wear inspection
window, replace the guide slider.
CHAIN GUIDE

GUIDE SLIDER

INSPECTION WINDOW

BRAKE FLUID

Spilling fluid can damage painted, plastic or rubber

parts. Place a rag over these parts whenever the
system is serviced.

• Do not mix different types of fluid, as they are

not compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• When the fluid level is low, check the brake pads
for wear. A low fluid level may be due to worn
brake pads. If the brake pads are worn, the cali-
per pistons are pushed out, and this causes a low
reservoir level. If the brake pads are not worn
and the fluid level is low, check entire system for
leaks (page 3-19).
Turn the handlebar so the reservoir is level and
RESERVOIR CAP
check the front brake fluid reservoir level through
the sight glass.

SIGHT GLASS

LOWER LEVEL LINE

If the level is near the lower (LWR) level line,

remove the reservoir cap and diaphragm, and fill
the reservoir with DOT 4 brake fluid from a sealed CASTING LEDGE
container to the casting ledge.
Install the diaphragm, reservoir cap, and tighten the
cap screws.
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

3-18
 MAINTENANCE
BRAKE SHOE/PAD WEAR
FRONT BRAKE PAD
Check the brake pad for wear.
Replace the brake pads if wear limit groove of either
pad is worn out.
Refer to procedure for brake pad replacement (page
14-6).

LIMIT GROOVES
REAR BRAKE SHOE
Check the wear indicator position when the brake
pedal is applied. " " MARK

If the indicator aligns with the " " mark, inspect the
brake drum.
Replace the brake shoes if the drum I.D. is within the
service limit (page 13-11).

ARROW MARK

BRAKE SYSTEM
HYDRAULIC BRAKE
Firmly apply the brake lever and check that no air
has entered the system. If the lever feels soft or BRAKE HOSE
spongy when operated, bleed air from the system.
Refer to procedures for air bleeding (page 14-5).
Inspect the brake hose and fittings for deterioration,
cracks, damage and signs of leakage. Tighten any
loose fittings.
Replace hose and fittings as required.

3-19
MAINTENANCE
BRAKE LEVER POSITION
Remove the dust cover.
The brake lever position can be adjusted by loosen-
ing the lock nut and turning the adjuster bolt.
Turning adjuster bolt clockwise moves the brake
lever farther away from the grip; turning adjuster
bolt counterclockwise moves the brake lever closer
to the grip. DUST COVER
Hold the adjusting bolt and tighten the lock nut.
TORQUE: 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft) LOCK NUT

Apply silicone After tightening the lock nut, make sure there is
grease to the con- slight clearance between the adjuster bolt tip and
tact faces of the master piston end when moving the lever forward ADJUSTER BOLT
adjuster bolt and (the adjuster bolt is not pushing the piston at the
piston. lever free).
Install the dust cover over the brake lever.
BRAKE PEDAL HEIGHT
Adjust the brake pedal to the desired height.
Loosen the lock nut and turn the adjusting bolt to
obtain the pedal height. After adjustment tighten
the lock nut.
Adjust the pedal free play.
ADJUSTING BOLT

LOCK NUT

BRAKE PEDAL FREE PLAY

Perform the free Check the brake pedal free play.
play adjustment
after adjusting FREE PLAY: 20 – 30 mm (3/4 – 1-1/4 in)
pedal height.

20 – 30 mm
(3/4 – 1-1/4 in)

Adjust the free play by turning the adjusting nut.

Make sure the cutout of the adjusting nut is seated ADJUSTING NUT
on the joint pin.

JOINT PIN

3-20
 MAINTENANCE
CLUTCH SYSTEM
Inspect the clutch cable for kinks or damage, and
lubricate the cable if necessary.
Measure the clutch lever free play at the end of the
lever.
FREE PLAY: 10 – 20 mm (3/8 – 3/4 in)
10 – 20 mm (3/8 – 3/4 in)

Minor adjustment are made with the upper adjuster

at the clutch lever.

The adjuster may Slide the dust cover off, loosen the lock nut and turn ADJUSTER
be damaged if it is the adjuster to obtain the free play. LOCK NUT
positioned too far Tighten the lock nut and install the dust cover.
out, leaving minimal
If the adjuster is threaded out near the limit and the
thread
correct free play cannot be obtained, turn the
engagement.
adjuster all the way in and back out one turn.
Tighten the lock nut and make major adjustments as
described below.

DUST COVER

Major adjustments are made with the lower adjust-

ing nut at the engine.
Loosen the lock nut and turn the adjusting nut. LOCK NUT
After adjustment is complete, tighten the lock nut
while holding the adjusting nut.
Check the clutch operation.
If the free play cannot be obtained, or the clutch
slips during the test ride, disassemble and inspect
the clutch (page 9-6).

ADJUSTING NUT

SIDE STAND
Check the side stand spring for damage or loss of
tension.
Check the side stand operation for freedom of
movement and lubricate the side stand pivot if nec-
essary.
Check that the side stand pivot bolt and lock nut are
tightened. Torque any loose bolt and nut.
Tighten the pivot bolt.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Tighten the pivot lock nut while holding the pivot SIDE STAND
bolt.
TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft)

3-21
MAINTENANCE
SUSPENSION
FRONT
Check the action of the forks by applying the front
brake and compressing it several times.
Check the entire assembly for leaks, damage or
loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer to service for fork (page 12-13).

REAR
Check the action of the shock absorber by com-
pressing it several times.
Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer to service for rear suspension (page 13-16).

Raise the rear wheel off the ground and support the
motorcycle securely.
Check for worn swingarm and linkage bearings by
grabbing the swingarm and attempting to move the
wheel side to side.
Replace the bearings if any looseness is noted (page
13-2).

SPARK ARRESTER
Remove the three bolts and spark arrester with the
gasket. ARRESTER

BOLTS

3-22
 MAINTENANCE
Use a soft brush to remove carbon deposits from
the screen mesh, being careful not to damage the
screen mesh.
The screen mesh must be free of breaks and holes.
Replace the spark arrester if necessary.

SCREEN MESH

Install the spark arrester with a new gasket and

tighten the bolts securely.
ARRESTER
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) GASKET

NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-11).
Check that all cotter pins, safety clips, hose clamps
and cable stays are in place and properly secured.

WHEELS/TIRES
Tire pressure Check the cold tire pressure.
should be checked
when the tires are TIRE PRESSURE:
cold. FRONT: 100 kPa (1.0 kgf/cm2, 15 psi)
REAR: 100 kPa (1.0 kgf/cm2, 15 psi)
Check the tires for cuts, embedded nails, or other
damage.
Check the front and rear wheels for trueness.
– front wheel (page 12-10)
– rear wheel (page 13-7)

3-23
MAINTENANCE
Inspect the wheel rims and spokes for damage.
Tighten any loose spokes and rim locks.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701 – 0020300

TORQUE:
Spoke nipple: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Rim lock nut: 12.2 N·m (1.2 kgf·m, 9 lbf·ft)
RIM LOCK NUT

SPOKE WRENCH

STEERING HEAD BEARINGS

Raise the front wheel off the ground by placing a
work stand or a box under the engine.
Check that the handlebar moves freely from side to
side. Make sure the control cables do not interfere
with the handlebar rotation.
If the handlebar moves unevenly, binds, or has ver-
tical movement, inspect the steering head bearings
(page 12-21).

3-24
 4. LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM ·········· 4-2 TROUBLESHOOTING································· 4-3

SERVICE INFORMATION ··························· 4-3 OIL PUMP ··················································· 4-4

4-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM

CAMSHAFT

CRANKSHAFT

OIL FILTER ROTOR

MAINSHAFT

OIL THROUGH

OIL PUMP
COUNTERSHAFT

OIL STRAINER SCREEN

4-2
 LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.

• The oil pump can be serviced with the engine installed in the frame.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• Refer to the following:
– engine oil level check and oil change (page 3-11)
– engine oil strainer cleaning (page 3-12)
– engine oil centrifugal filter cleaning (page 3-13)

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil After draining 1.0 liter (1.1 US qt,0.9 lmp qt) –
capacity After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) –
Engine oil U type Suggested oil: –
Honda "4-stroke motorcycle oil" or an
equivalent
Oil recommendation:
API classification: SG or higher
(except oils labeled as energy con-
serving on the circular API service
label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA
BR type API service classification: SG or higher –
(except oils labeled as energy conserv-
ing on the circular API service label)
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Suggested oil: Oil which Honda recom-
mends
Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)
rotor Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.03 – 0.12 (0.001 – 0.005) 0.15 (0.006)

TORQUE VALUE
Oil pump rotor cover screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)

TROUBLESHOOTING
Engine oil level too low, high oil consumption
• External oil leaks
• Worn valve guide or seal
• Worn piston rings or incorrect piston ring installation
• Worn cylinder
Engine oil contamination
• Oil not changed often enough
• Faulty cylinder head gasket
• Worn piston rings

4-3
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
Drain the engine oil (page 3-12).
OIL PUMP
Remove the right crankcase cover (page 9-5).
Turn the crankshaft clockwise and align the holes in
the oil pump drive gear with oil pump mounting
screws.
Remove the two mounting screws and oil pump.

MOUNTING SCREWS
Remove the O-rings from the crankcase grooves.

O-RINGS
INSPECTION
If any portion of the Remove the two screws and rotor cover.
ROTOR COVER
oil pump is worn
beyond the service
limit, replace the oil
pump as an assem-
bly.

SCREWS
Measure the tip clearance between the inner and
outer rotors.

SERVICE LIMIT: 0.20 mm (0.008 in)

4-4
 LUBRICATION SYSTEM
Measure the body clearance between the outer
rotor and pump body.

SERVICE LIMIT: 0.35 mm (0.014 in)

Measure the side clearance using a straight edge

and feeler gauge.
SERVICE LIMIT: 0.15 mm (0.016 in)

DISASSEMBLY
Remove the following:
INNER ROTOR
– rotor cover (page 4-4)
– inner and outer rotors

OUTER ROTOR
– two bolts
– gear cover BOLTS

GEAR COVER

4-5
LUBRICATION SYSTEM
– rotor shaft
– pump gear ROTOR SHAFT

Check the pump gear and rotor shaft for wear or

damage.

PUMP GEAR
ASSEMBLY

ROTOR COVER

OUTER ROTOR

PUMP BODY

PUMP GEAR

ROTOR SHAFT

INNER ROTOR

GEAR COVER

Install the pump gear and rotor shaft in the pump

body by aligning the flats of the gear and shaft. ROTOR SHAFT

PUMP GEAR

4-6
 LUBRICATION SYSTEM
Install the gear cover and tighten the bolts.
BOLTS

GEAR COVER
Apply oil to the inner and outer rotors and install
them into the oil pump body. INNER ROTOR

OUTER ROTOR

Install the rotor cover by aligning its boss with the

ROTOR COVER
dent in the pump body.
Install the rotor cover screws and tighten them.
TORQUE: 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Check that the oil pump rotates smoothly.

SCREWS Align
INSTALLATION
Coat new O-rings with oil and install them into the
crankcase grooves.

O-RINGS

4-7
LUBRICATION SYSTEM
Align the holes in the oil pump drive gear with oil
OIL PUMP
pump mounting screw holes.
Install the oil pump onto the crankcase and tighten
the mounting screws.
Install the right crankcase cover (page 9-14).

MOUNTING SCREWS

4-8
 5. FUEL SYSTEM

SYSTEM COMPONENTS ··························· 5-2 CARBURETOR DISASSEMBLY ················· 5-7

SERVICE INFORMATION ··························· 5-3 CARBURETOR ASSEMBLY ····················· 5-11

TROUBLESHOOTING ································· 5-5 CARBURETOR INSTALLATION ··············· 5-17

AIR CLEANER HOUSING ··························· 5-6 PILOT SCREW ADJUSTMENT ··············· 5-18

CARBURETOR REMOVAL·························· 5-6 FUEL STRAINER ······································· 5-19

5-1
FUEL SYSTEM
SYSTEM COMPONENTS
FUEL SYSTEM

0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)

5-2
 FUEL SYSTEM
SERVICE INFORMATION
GENERAL
• Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting
in loss of vehicle control.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
• Be sure to remove the air cut-off valve diaphragm before cleaning air and fuel passages with compressed air, or the dia-
phragm might be damaged.
• When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassem-
bly.
• Before removing the carburetor, place an approved gasoline container under the carburetor drain hose, loosen the
drain screw and drain the carburetor.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to
prevent any foreign material from dropping into the engine.
• If the vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause
clogged jets, resulting in hard starting or poor driveability.
• Refer to the fuel tank removal and installation (page 2-5).

SPECIFICATIONS
U type:
ITEM SPECIFICATIONS
Carburetor identification number ’07 model PD9CA
After ’07 PD9CJ
Main jet #102
Slow jet #42
Jet needle clip position 3rd groove
Pilot screw See page 5-18
Float level 12.5 mm (0.49 in)
Idle speed 1,400 ± 100 min-1 (rpm)
Throttle grip free play 2 – 6 mm (1/12 – 1/4 in)
BR type:
ITEM SPECIFICATIONS
Carburetor identification number ’07 model PD9CE
After ’07 PD9CH
Main jet #140
Slow jet #42
Jet needle clip position 3rd groove
Pilot screw See page 5-18
Float level 12.5 mm (0.49 in)
Idle speed 1,500 ± 100 min-1 (rpm)
Throttle grip free play 2 – 6 mm (1/12 – 1/4 in)

TORQUE VALUES
Mudguard mounting screw 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)
Fuel valve mounting bolt 9 N·m (0.9 kgf·m, 6.6 lbf·ft)

5-3
FUEL SYSTEM
TOOL
Carburetor float level gauge
07401-0010000

5-4
 FUEL SYSTEM
TROUBLESHOOTING
Engine cranks but won’t start
• No fuel in tank
• No fuel to carburetor
– Clogged fuel strainer
– Clogged fuel line
– Clogged fuel tank breather hose
• Too much fuel getting to the engine
– Clogged air cleaner
– Flooded carburetor
• Intake air leak
• Contaminated/deteriorated fuel
– Clogged jets
• Improper choke operation
• Improper throttle operation
• No spark at plug (faulty ignition system – page 16-4)
Lean mixture
• Clogged fuel jets
• Faulty float valve
• Float level too low
• Restricted fuel line
• Clogged carburetor air vent hose
• Restricted fuel tank breather hose
• Intake air leak
• Faulty throttle valve
Rich mixture
• Choke valve closed
• Clogged air jets
• Faulty float valve
• Float level too high
• Dirty air cleaner
• Worn jet needle or needle jet
Engine stalls, hard to start, rough idling
• Restricted fuel line
• Fuel mixture too lean/rich
• Contaminated/deteriorated fuel
– Clogged jets
• Intake air leak
• Misadjusted idle speed
• Restricted fuel tank breather hose
• Dirty air cleaner
• Misadjusted pilot screw
• Faulty ignition system (page 16-4)
Afterburn when engine braking is used
• Lean mixture in slow circuit
• Faulty ignition system (page 16-4)
Backfiring or misfiring during acceleration
• Lean mixture
• Faulty ignition system (page 16-4)
Poor performance (driveability) and poor fuel economy
• Clogged fuel system
• Faulty ignition system (page 16-4)

5-5
FUEL SYSTEM
AIR CLEANER HOUSING
REMOVAL/INSTALLATION
Remove the following:
SCREWS MUDGUARD
– seat (page 2-3)
– left and right side cover (page 2-3)
– rear fender (page 2-4)
– two screws and mudguard
– rear mounting bolt

REAR MOUNTING BOLT

Disconnect the crankcase breather hose from the air
cleaner housing. BOOT
Release the connector boot from the boot guide of
the battery box.
Release the starter motor cable and wire harness
from the clamps.
Remove the two upper mounting bolts, collars and
clamps.

BOLTS, COLLARS
AND CLAMPS

BREATHER HOSE

Loosen the connecting hose band screw.

AIR CLEANER HOUSING
Remove the air cleaner housing from the frame.
Installation is in the reverse order of removal.

BAND SCREW

CARBURETOR REMOVAL
Remove the fuel tank (page 2-5).
CONNECTING HOSE INSULATOR
Place an approved fuel container under the drain
hose.
Loosen the drain screw and drain the carburetor.
Loosen the carburetor insulator and connecting
hose band screws.
Remove the carburetor from the carburetor insula-
tor and connecting hose.

BAND SCREWS

5-6
 FUEL SYSTEM
Remove the throttle cables from the cable holder,
CABLE HOLDER THROTTLE DRUM
disconnect them from the throttle drum and remove
the carburetor.

THROTTLE CABLES

CARBURETOR DISASSEMBLY
Remove the fuel hose, air vent hose and drain hose
DRAIN HOSE FUEL HOSE
from the carburetor.

(’07 model shown) AIR VENT HOSE

THROTTLE VALVE
Remove the two screws and the top cover.
SCREWS
Remove the top cover gasket.

GASKET TOP COVER

Remove the link arm setting screw.
Remove the throttle drum and return spring from SETTING SCREW WASHER
the carburetor body.
Remove the washer between the link arm and car-
buretor body.
Remove the throttle valve assembly from the carbu-
retor body.

RETURN SPRING THROTTLE DRUM

5-7
FUEL SYSTEM
Remove the two screws and the link arm with the
spring from the throttle valve. THROTTLE VALVE LINK ARM

SCREWS (’07 model shown)

Remove the jet needle from the throttle valve.
THROTTLE VALVE
Check the jet needle for stepped wear or damage.
Check the throttle valve for scoring, scratches or
damage.

JET NEEDLE

FLOAT AND JETS

Remove the three screws and the float chamber.
FLOAT CHAMBER SCREWS
Remove the O-ring from the float chamber.

Remove the baffle plate.

BAFFLE PLATE

5-8
 FUEL SYSTEM
Remove the float pin, float and float valve.
FLOAT PIN
Check the float for damage.

FLOAT FLOAT VALVE

Inspect the float valve seat for scores, scratches,
clogging and damage. FLOAT VALVE

Check the tip of the float valve where it contacts the

valve seat for stepped wear or contamination.
Replace the float valve if the tip is worn or comtami-
nated.
Check the operation of the float valve.

VALVE SEAT

Handle all jets with Remove the following:

care. They can eas- – slow jet
ily be scored or – main jet MAIN JET SLOW JET
scratched. – needle jet holder
NEEDLE JET
– needle jet
HOLDER
Damage to the pilot Turn the pilot screw in and carefully count the num-
screw seat will ber of turns until it seats lightly. Make a note of this
occur if the pilot to use as a reference when reinstalling the pilot
screw is tightened screw.
against the seat.

NEEDLE JET PILOT SCREW

Remove the following:
– pilot screw
– spring NEEDLE JET
– washer
– O-ring
Inspect each jet for wear or damage.
Clean all jets with non-flammable or high flash point
solvent and blow open with compressed air.
Check the pilot screw for stepped wear or damage.
O-RING

WASHER

SPRING

5-9
FUEL SYSTEM
AIR CUT-OFF VALVE
Remove the following:
CHOKE LEVER
– screw
– setting plate
– choke lever

SETTING PLATE SCREW

– two screws
– air cut-off valve cover SCREWS

AIR CUT-OFF VALVE COVER

– spring
– air cut-off valve AIR CUT-OFF VALVE SPRING
– O-ring
Visually check the following:
– diaphragm for deterioration or pin holes
– needle on the diaphragm for excessive wear at
the tip
– orifice in the cover for clogging or restriction
– O-ring for deterioration or damage

O-RING
CARBURETOR CLEANING
Remove the following:
– throttle valve (page 5-7)
– float, all jets and pilot screw (page 5-8)
– air cut-off valve (page 5-10)
Cleaning the air and Blow open all air and fuel passages in the carbure-
fuel passages with tor body with compressed air.
a piece of wire will
damage the carbu-
retor body.

5-10
 FUEL SYSTEM
CARBURETOR ASSEMBLY
’07 model:

TOP COVER
GASKET

LINK ARM

CARBURETOR BODY
SETTING PLATE
AIR CUT-
OFF VALVE
CHOKE LEVER

NEEDLE JET SPRING

NEEDLE CLIP

SLOW JET SPRING

JET NEEDLE

O-RING
PILOT SCREW

NEEDLE JET HOLDER

FLOAT
MAIN JET
VALVE

THROTTLE VALVE
BAFFLE
PLATE
THROTTLE DRUM
FLOAT CHAMBER AIR CUT-OFF
VALVE COVER
O-RING
FLOAT PIN

FLOAT
O-RING

5-11
FUEL SYSTEM
After ’07:

TOP COVER
GASKET

LINK ARM

CARBURETOR BODY
SETTING PLATE
AIR CUT-
OFF VALVE
CHOKE LEVER

NEEDLE JET SPRING

NEEDLE CLIP

SLOW JET SPRING

JET NEEDLE

O-RING
PILOT SCREW

NEEDLE JET HOLDER

FLOAT
MAIN JET
VALVE

THROTTLE VALVE
BAFFLE
PLATE
THROTTLE DRUM
FLOAT CHAMBER AIR CUT-OFF
VALVE COVER
O-RING
FLOAT PIN

FLOAT
O-RING

AIR CUT-OFF VALVE

Install a new O-ring with the flat side facing the car-
buretor body. AIR CUT-OFF VALVE SPRING
Install the diaphragm into the carburetor body prop-
erly.
Place the spring onto the diaphragm with the
tapered side facing out.

O-RING

5-12
 FUEL SYSTEM
Be careful not to Install the air cut-off valve cover and tighten the two
pinch the dia- screws. SCREWS
phragm and O-ring.

AIR CUT-OFF VALVE COVER

Install the choke lever and setting plate, and tighten
CHOKE LEVER
the screw.
Check the operation of the choke lever (3 position
stops).

SETTING PLATE SCREW

JETS AND FLOAT
Damage to the pilot Install the pilot screw with the spring, washer and a
screw seat will new O-ring and return it to its original position as NEEDLE JET
occur if the pilot noted during removal.
screw is tightened
Perform the pilot screw adjustment if a new pilot
against the seat.
screw is installed (page 5-18).

O-RING

WASHER

SPRING

Handle all jets with Install the needle jet with the round end facing out,
care. They can eas- and the needle jet holder and main jet. MAIN JET SLOW JET
ily be scored or
Install the slow jet. NEEDLE JET
scratched.
HOLDER

NEEDLE JET

5-13
FUEL SYSTEM
Hang the float valve onto the float arm lip.
Install the float with the float valve and insert the FLOAT PIN
float pin.

FLOAT FLOAT VALVE

Install the baffle plate by aligning the groove with
the lug on the carburetor body as shown. BAFFLE PLATE

LUG AND GROOVE

FLOAT LEVEL INSPECTION

• Check the float level after checking the float

valve, valve seat and float.
Set the float level With the float valve seated and the float arm lip just
gauge so it is touching the valve, measure the float level with the FLOAT LEVEL GAUGE
perpendicular to the float level gauge.
float chamber face
and in line with the TOOL:
main jet. Carburetor float level gauge 07401-0010000

Float level: 12.5 mm (0.49 in)

If the float level is out of specification, adjust the
level by carefully bending the float arm lip.

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

Install the float chamber onto the carburetor body. FLOAT CHAMBER

O-RING

5-14
 FUEL SYSTEM
Install the three screws and tighten them.
SCREWS

THROTTLE VALVE
Install the needle clip on the jet needle.
THROTTLE VALVE
STANDARD CLIP POSITION:
3rd groove
Install the jet needle into the throttle valve.

CLIP

JET NEEDLE

CLIP

3rd

Install the spring onto the link arm.

LINK ARM

SPRING
(’07 model shown)

5-15
FUEL SYSTEM
Note the installation Install the link arm into the throttle valve and tighten
direction of the link the two screws. THROTTLE VALVE LINK ARM
arm assembly
(page 5-11)

SCREWS (’07 model shown)

Install the return spring over the throttle drum spin-
dle. SETTING SCREW WASHER
Install the plastic washer between the link arm and
carburetor body (throttle drum side) and insert the
throttle drum spindle into the carburetor body and
link arm.
Align the screw holes in the link arm and throttle
drum spindle, install the screw and tighten it.
Turn the throttle drum and check for smooth opera-
tion.

RETURN SPRING THROTTLE DRUM

Install a new gasket onto the top cover.
Install the top cover onto the carburetor body. TOP COVER

GASKET

Install the two screws and tighten them.

SCREWS

5-16
 FUEL SYSTEM
Connect the fuel hose, air vent hose and drain hose
DRAIN HOSE FUEL HOSE
to the carburetor.
Install the carburetor (page 5-17).

AIR VENT HOSE

CARBURETOR INSTALLATION
Connect the throttle cables to the throttle drum and
CABLE HOLDER THROTTLE DRUM
install them into the cable holder.

THROTTLE CABLES

Route the air vent Install the carburetor into the insulator and connect-
hose and drain ing tube by aligning the lug on the carburetor with INSULATOR
hose properly (page the groove in the insulator.
1-17).

LUG AND GROOVE

Tighten the connecting hose and insulator band
CONNECTING HOSE
screws.
Adjust the throttle grip free play (page 3-5).
Install the fuel tank (page 2-5).
Perform the following adjustments:
– engine idle speed (page 3-13)
– pilot screw if it was replaced (page 5-18)

BAND SCREWS

5-17
FUEL SYSTEM
PILOT SCREW ADJUSTMENT
BEST IDLE PROCEDURE

• The pilot screw is factory pre-set and no adjust-

ment is necessary unless the pilot screw is
replaced.
• Use a tachometer with graduations of 50 min-1
(rpm) or smaller that will accurately indicate 50
min-1 (rpm) change.
Damage to the pilot 1. Turn the pilot screw clockwise until it seats
screw seat will lightly, then back it out to specification given.
occur if the pilot This is an initial setting prior to the final pilot
screw is tightened screw adjustment.
against the seat.
PILOT SCREW OPENING:
U type: 1-5/8 turns out
BR type: 2-5/8 turns out
2. Warm up the engine to operating temperature.
Stop and go riding for 10 minutes is sufficient.
3. Stop the engine and connect a tachometer
according to its manufacturer’s instructions.
PILOT SCREW
4. Start the engine and adjust the idle speed with
the throttle stop screw.
IDLE SPEED:
U type: 1,400 ± 100 min-1 (rpm)
BR type: 1,500 ± 100 min-1 (rpm)
5. Turn the pilot screw in or out slowly to obtain the
highest engine speed.
6. Readjust the idle speed to the specified value
with the throttle stop screw.
7. Make sure that the engine does not miss or run
erratically. Repeat steps 5 and 6 until engine
speed increases smoothly. THROTTLE STOP SCREW
8. Readjust the idle speed to the specified value
with the throttle stop screw.

5-18
 FUEL SYSTEM
FUEL STRAINER
CLEANING
Turn the fuel valve OFF and disconnect the fuel BOLTS AND COLLARS STRAINER
hose from the carburetor. SCREEN
Place an approved fuel container under the fuel HOSE
hose. Turn the valve ON (RES) to drain the fuel tank.
Remove the following:
– two bolts and collars
– fuel valve O-RING
– O-ring
Clean the strainer screen on the fuel valve thor-
oughly with non-flammable or high flash point sol- FUEL VALVE
vent.
Replace the O-ring Install the fuel valve in the reverse order of removal.
with a new one.
After ’07: Connect
TORQUE: Fuel valve bolt: 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
the fuel hose prop- After filling the fuel tank, turn the fuel valve ON and
erly (page 2-5). check that there are no leaks.

5-19
MEMO
 6. ENGINE REMOVAL/INSTALLATION

SYSTEM COMPONENTS ··························· 6-2 ENGINE REMOVAL ···································· 6-4

SERVICE INFORMATION ··························· 6-3 ENGINE INSTALLATION···························· 6-8

6-1
ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS
ENGINE REMOVAL/INSTALLATION

60 N·m (6.1 kgf·m, 44 lbf·ft)

60 N·m (6.1 kgf·m,

44 lbf·ft

60 N·m (6.1 kgf·m,

44 lbf·ft

35 N·m (3.6
kgf·m, 26 lbf·ft)

35 N·m (3.6 kgf·m, 26 lbf·ft)

59 N·m (6.0 kgf·m, 44 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

35 N·m (3.6 kgf·m, 26 lbf·ft)

6-2
 ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components require engine removal for service.
– camshaft (page 7-2)
– cylinder head/valves (page 7-2)
– cylinder/piston (page 8-2)
– crankshaft (page 11-2)
– transmission (page 11-2)

SPECIFICATIONS
ITEM SPECIFICATIONS
Engine oil capacity After draining 1.0 liter (1.1 US qt, 0.9 lmp qt)
After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt)
Engine dry weight 31.2 kg (68.8 lbs)

TORQUE VALUES
Upper engine hanger nut (8 mm) 35 N·m (3.6 kgf·m, 26 lbf·ft)
Front engine hanger nut (8 mm) 35 N·m (3.6 kgf·m, 26 lbf·ft)
Front lower engine hanger nut (8 mm) 35 N·m (3.6 kgf·m, 26 lbf·ft)
Rear upper engine hanger nut (10 mm) 60 N·m (6.1 kgf·m, 44 lbf·ft)
Rear lower engine hanger nut (10 mm) 60 N·m (6.1 kgf·m, 44 lbf·ft)
Footpeg mounting bolt 59 N·m (6.0 kgf·m, 44 lbf·ft) ALOC bolt; replace with a new one.
Gearshift pedal pinch bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)

6-3
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (page 3-12).
Remove the following:
– left side cover (page 2-3) AXLE NUT
– exhaust pipe (page 2-6)
– carburetor (page 5-6)
Raise the rear wheel off the ground by supporting
the frame securely.
Loosen the rear axle nut and turn the drive chain
adjusters to loosen the drive chain.

ADJUSTER

Remove the following:

– pinch bolt SPROCKET COVER
– gearshift pedal
– two bolts
– drive sprocket cover

PEDAL

– two bolts
– fixing plate (by aligning the splines of the plate
and countershaft)
– drive sprocket (pull it off the countershaft and FIXING PLATE
remove from the drive chain)

CHAIN
SPROCKET
– two bolts
– each footpeg

FOOTPEG

6-4
 ENGINE REMOVAL/INSTALLATION
– brake adjusting nut ROD
– brake rod (from the joint pin)
– rod spring
– joint pin NUT

SPRING

JOINT PIN

– pedal return spring (lower the brake pedal)

SPRING

Disconnect the following:

– spark plug cap

PLUG CAP

Remove the wire – alternator 4P connector

clip and band. – exciter coil connector

CLIP

CONNECTORS

BAND

6-5
ENGINE REMOVAL/INSTALLATION
– starter motor cable (by removing the rubber cap RUBBER CAP
and terminal nut) MOTOR CABLE
– battery negative (–) cable (by removing the
motor mounting bolt)
– crankcase breather hose NUT

BOLT

HOSE

NEGATIVE CABLE

– clutch cable (from the clutch arm by removing

the two cable holder bolts)
CLUTCH CABLE
CABLE HOLDER

CLUTCH ARM

Support the motorcycle securely with a hoist or

equivalent.
Place the floor jack or other adjustable support
under the engine.
PLATES
• The jack height must be continually adjusted to
relieve stress for ease of bolt removal. RUBBER CAP

Remove the following mounting fasteners:

– rubber caps
– three upper engine hanger nuts and bolts
– hanger plates

– front engine hanger nuts and bolts

– hanger plates PLATES

6-6
 ENGINE REMOVAL/INSTALLATION
– front lower engine hanger nut and bolt
– collar (right side of the engine) COLLAR

– rear upper engine hanger nut and bolt (engine NUT AND BOLT
side)
– rear upper engine hanger bolts (frame side)
– hanger plate
– rear lower engine hanger nut, washer and bolt

During engine Carefully maneuver the engine and remove it out of

removal, hold the the frame to the left.
engine securely and
be careful not to
damage the frame
and engine.
NUT, WASHER
AND BOLT

PLATE

6-7
ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
• Note the installation direction of the engine
mounting bolts (page 6-2).
During engine Using the floor jack or other adjustable support,
installation, hold the carefully place the engine into the frame and
engine securely and maneuver it into place.
be careful not to
Carefully align the bolt holes in the frame and
damage the frame
engine.
and engine.
Align the mounting bolt holes and install the follow- NUT AND BOLT
ing fasteners:
– rear lower engine hanger bolt, and washer and
nut (10 mm)
– rear engine hanger plate with the two bolts
– rear upper engine hanger bolt and nut (10 mm)

NUT, WASHER
AND BOLT

PLATE

– front lower engine hanger bolt, collar (left side of

the engine) and nut (8-mm) COLLAR

6-8
 ENGINE REMOVAL/INSTALLATION
The hanger plates – front engine hanger plates with the two bolts and
are identified by the nuts (8-mm) PLATES
marks. Install with – front engine hanger bolt and nuts (8-mm)
the marked side
facing out; “R”:
right / ”L”: left

MARK

The hanger plates – upper engine hanger plates with the two bolts
are identified by the and nuts (8-mm) MARK
marks. Install with – upper engine hanger bolt and nuts (8-mm)
the marked side
After installing the all the engine mounting fasten-
facing out; “R”:
ers, tighten them to the specified torque. PLATES
right / ”L”: left
TORQUE: TAB
8 mm nut: 35 N·m (3.6 kgf·m, 26 lbf·ft)
10 mm nut: 60 N·m (6.1 kgf·m, 44 lbf·ft)
Hang the tab of each rubber cap onto the hanger
plate and install them over the upper engine hanger
bolts.

RUBBER CAP
Route the wires Install the removed parts from the engine removal
and cables properly procedure in the reverse order of removal (page 6-4)
(page 1-17). .

TORQUE: Footpeg: 59 N·m (6.0 kgf·m, 44 lbf·ft)

Gearshift pedal: 12 N·m (1.2 kgf·m, 9 lbf·ft)

• Replace the footpeg mounting bolts with new

ones.
• When installing the drive sprocket, install the
sprocket with the flat surface facing out. Set the
fixing plate into the countershaft groove and
move it to align the bolt holes in the plate and
FOOTPEG
sprocket, then install the bolts.
• When installing the gearshift pedal, install it so
the distance between the timing hole cap center
and pedal end is 79 mm (3 in).
FIXING PLATE SPROCKET
Check the following:
– clutch lever free play (page 3-21)
– drive chain slack (page 3-14)
– brake pedal free play (page 3-20)
Install the following:
– carburetor (page 5-17)
– exhaust pipe (page 2-7) 79 mm (3 in)
– side cover (page 2-3)
Fill the crankcase with engine oil (page 3-12).

6-9
MEMO
 7. CYLINDER HEAD/VALVES

SYSTEM COMPONENTS ··························· 7-2 CYLINDER HEAD DISASSEMBLY ··········· 7-10 7

SERVICE INFORMATION ··························· 7-3 VALVE GUIDE REPLACEMENT ··············· 7-13

TROUBLESHOOTING ································· 7-5 VALVE SEAT INSPECTION/

REFACING················································· 7-14
CYLINDER COMPRESSION························ 7-6
CYLINDER HEAD ASSEMBLY ················· 7-17
CYLINDER HEAD COVER/
CAMSHAFT REMOVAL ······························ 7-6 CYLINDER HEAD INSTALLATION··········· 7-18

CYLINDER HEAD REMOVAL ····················· 7-9 CAMSHAFT/CYLINDER HEAD

COVER INSTALLATION ··························· 7-19

7-1
CYLINDER HEAD/VALVES
SYSTEM COMPONENTS
CYLINDER HEAD/VALVES

27 N·m (2.8 kgf·m, 20 lbf·ft)

15 N·m (1.5 kgf·m, 11 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

18 N·m (1.8 kgf·m, 13 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

4 N·m (0.4 kgf·m,
3.0 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

7-2
 CYLINDER HEAD/VALVES
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves, rocker arms and camshaft. To service these parts, the engine
must be removed from the frame.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike
the cylinder head cover and cylinder head too hard during removal.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca-
tions.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
• Camshaft and rocker arm lubricating oil is fed through oil passage in the cylinder head. Clean the oil passage before
assembling cylinder head.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 450 min-1 (rpm) 1,294 kPa (13.2 kgf/cm2, 188 psi) –
Valve clearance IN/EX 0.1 (0.004) –
Valve, Valve stem O.D. IN 5.450 – 5.465 (0.2146 – 0.2152) 5.42 (0.213)
valve guide EX 5.430 – 5.445 (0.2138 – 0.2144) 5.40 (0.213)
Valve guide I.D. IN/EX 5.475 – 5.485 (0.2156 – 0.2159) 5.50 (0.217)
Stem-to-guide clear- IN 0.010 – 0.035 (0.0004 – 0.0014) 0.08 (0.003)
ance EX 0.030 – 0.055 (0.0012 – 0.0022) 0.10 (0.004)
Valve seat width IN/EX 1.1 – 1.3 (0.04 – 0.05) 1.5 (0.06)
Valve spring Free length Inner 39.2 (1.54) 38.0 (1.50)
Outer 44.9 (1.77) 43.5 (1.71)
Rocker arm Arm I.D. IN/EX 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)
Shaft O.D. IN/EX 11.966 – 11.984 (0.4711 – 0.4718) 11.93 (0.470)
Arm-to-shaft clear- IN/EX 0.016 – 0.052 (0.0006 – 0.0020) 0.08 (0.003)
ance
Camshaft Cam lobe height IN 31.610 – 31.690 (1.2445 – 1.2476)* 31.3 (1.23)
EX 31.452 – 31.532 (1.2383 – 1.2414)* 31.2 (1.23)
Cylinder head warpage – 0.10 (0.004)

TORQUE VALUES
Cylinder head cover cap nut 27 N·m (2.8 kgf·m, 20 lbf·ft) Apply engine oil to the threads and
seating surface.
Cylinder head cover bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Cylinder head socket bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Cam sprocket bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply engine oil to the threads and
seating surface.
Cam chain tensioner lifter mounting 12 N·m (1.2 kgf·m, 9 lbf·ft)
bolt
Cam chain tensioner lifter sealing plug 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
Cam chain tensioner pivot bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)

7-3
CYLINDER HEAD/VALVES
TOOLS
Valve guide driver, 5.5 mm Valve spring compressor Valve seat cutter, 33 mm (45° EX)
07742-0010100 07757-0010000 07780-0010800

Valve seat cutter, 35 mm (45° IN) Flat cutter, 30 mm (32° EX) Flat cutter, 33 mm (32° IN)
07780-0010400 07780-0012200 07780-0012900

Interior cutter, 30 mm (60° EX) Interior cutter, 34 mm (60° IN) Cutter holder, 5.5 mm
07780-0014000 07780-0014700 07781-0010101

Valve guide reamer, 5.47 mm

07984-0980001

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

7-5
CYLINDER HEAD/VALVES
CYLINDER COMPRESSION
Warm up the engine to normal operating tempera- COMPRESSION GAUGE
ture.
Stop the engine, disconnect the spark plug cap and
remove the spark plug (page 3-7).
Install the compression gauge into the spark plug
hole.
Shift the transmission in neutral.
Push the choke lever down fully (open).
Open the throttle all the way and crank the engine
with the starter motor until the gauge reading stops
rising. The maximum reading is usually reached
within 4 – 7 seconds.
COMPRESSION PRESSURE:
1,294 kPa (13.2 kgf/cm2, 188 psi) at 450 min-1(rpm)
Low compression can be caused by:
– blown cylinder head gasket
– improper valve adjustment
– valve leakage
– worn piston ring or cylinder
High compression can be caused by:
– carbon deposits in combustion chamber or on
piston head

CYLINDER HEAD COVER/CAMSHAFT

REMOVAL
Remove the engine from the frame (page 6-4). TIMING HOLE CAP
Remove the starter motor (page 17-6).
Remove the spark plug (page 3-7).
Remove the following and set the piston position to
Top Dead Center on the compression stroke (page
3-8):
– timing hole cap
– crankshaft hole cap
– valve adjusting hole caps

CRANKSHAFT HOLE CAP

Remove the following:
– two socket bolts and washers (loosen them alter-
nately) TENSIONER
– cam chain tensioner lifter LIFTER
– gasket

7-6
 CYLINDER HEAD/VALVES
– two cover bolts SPROCKET COVER
– cam sprocket cover
– gasket

Be careful not to let – two sprocket bolts (while holding the crankshaft)
the bolts fall into – cam sprocket with the cam chain (off the cam-
the crankcase. shaft)

SPROCKET

Attach a piece of – cam sprocket (from the cam chain)

wire to the cam CAM CHAIN
chain to prevent it
from falling into the
crankcase.

SPROCKET
Do not strike the – four 6-mm bolts
head cover too hard – four cap nuts and washers
and do not damage – cylinder head cover NUTS AND
the mating surfaces WASHERS
with a screwdriver HEAD COVER
during head cover
removal.

BOLTS

7-7
CYLINDER HEAD/VALVES
– camshaft DOWEL PINS
– dowel pins CAMSHAFT
– oil hole plug

PLUG

ROCKER ARM REMOVAL

Remove the following:
– screw (while holding the head cover tightly,
being careful not to damage the mating surface)
– set plate

SCREW SET PLATE

– rocker arm shafts (by screwing a 6-mm bolt and

pull it out) ROCKER ARMS
– rocker arms
SHAFT

6 mm BOLT

INSPECTION
CAMSHAFT
Check the sprocket teeth for wear or damage.
Turn the camshaft bearings with your finger.
The bearings should turn smoothly and quietly.
Also check that the inner races fit tightly on the cam-
shaft.
Check the cam surfaces for scoring, scratches or evi-
dence of insufficient lubrication.
Check the oil holes in the camshaft fro debris.

7-8
 CYLINDER HEAD/VALVES
Measure each cam lobe height.

SERVICE LIMITS: IN: 31.3 mm (1.23 in)

EX: 31.2 mm (1.23 in)
If the cam lobe is damaged or excessively worn,
inspect the oil passages and rocker arms.

CAM CHAIN TENSIONER LIFTER

The lifter shaft should not go into the lifter body
when it is pushed.
When the shaft (inside of the body) is turned clock-
wise with a screwdriver, the lifter shaft should be
pulled into the lifter body. The shaft should spring
out of the body as soon as the screwdriver is
released.

ROCKER ARM/SHAFT
Inspect the sliding surfaces of the rocker arms and
shaft for wear or damage.
If the rocker arm slipper surface is excessive worn
or damaged, inspect the cam lobe and oil passage.
Measure each rocker arm I.D.
SERVICE LIMITS: IN/EX: 12.05 mm (0.474 in)
Measure the O.D. of each shaft at the rocker arm
sliding area.
SERVICE LIMITS: IN/EX: 11.93 mm (0.470 in)
Calculate the rocker arm-to-shaft clearance.
SERVICE LIMITS: IN/EX: 0.08 mm (0.003 in)

CYLINDER HEAD REMOVAL

Remove the cylinder head cover and camshaft INSULATOR
(page 7-6).
Remove the following:
– two bolts
– carburetor insulator
– O-ring
– gasket

7-9
CYLINDER HEAD/VALVES
– pivot bolt and washer
– cam chain tensioner
TENSIONER

BOLT AND WASHER

Do not strike the – socket bolt and washer CYLINDER HEAD

cylinder head too – cylinder head
hard and do not
damage the mating
surface with a
screwdriver.

BOLT AND WASHER

– gasket CHAIN GUIDE
– dowel pins
– cam chain guide

DOWEL PINS
GASKET

CYLINDER HEAD DISASSEMBLY

To prevent loss of Remove the valve spring cotters using the valve
tension, do not spring compressor.
compress the valve
springs more than TOOL:
necessary. Valve spring compressor 07757-0010000
COTTERS

SPRING COMPRESSOR

7-10
 CYLINDER HEAD/VALVES
Mark all the parts Remove the following:
so they can be – spring retainer
placed back in their – inner and outer valve springs VALVE
original locations. – valve
– stem seal INNER SPRING
– spring seats
OUTER SPRING

RETAINER
STEM SEAL

SPRING SEATS

INSPECTION
CYLINDER HEAD
Be careful not to Remove the carbon deposits from the combustion COMBUSTION CHAMBER
damage the valve chamber.
seat and gasket
Check the spark plug hole and valve areas for
surfaces.
cracks.

Check the cylinder head for warpage with a straight

edge and feeler gauge across the stud holes.
SERVICE LIMIT: 0.10 mm (0.004 in)

VALVE SPRING
Check the valve springs for fatigue or damage.
Measure the valve spring free length.
SERVICE LIMITS: Inner: 38.0 mm (1.50 in)
Outer: 43.5 mm (1.71 in)

7-11
CYLINDER HEAD/VALVES
VALVE/VALVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valve for bending, burning or abnormal
wear.
Measure each valve stem O.D. and record it.
SERVICE LIMITS: IN: 5.42 mm (0.213 in)
EX: 5.40 mm (0.213 in)

Ream the guides to remove any carbon build-up

before measuring the guide.
Insert the reamer from the combustion chamber
side of the head and always rotate the reamer clock- VALVE GUIDE REAMER
wise.
TOOL:
Valve guide reamer, 5.47 mm 07984-0980001

Measure each valve guide I.D. and record it.

SERVICE LIMIT: IN/EX: 5.50 mm (0.217 in)
Subtract each valve stem O.D. from the correspond-
ing guide I.D. to obtain the stem-to-guide clearance.
VALVE GUIDE
SERVICE LIMITS: IN: 0.08 mm (0.003 in)
EX: 0.10 mm (0.004 in)

Inspect and reface If the stem-to-guide clearance exceeds the service

the valve seats limit, determine if a new guide with standard
whenever the valve dimensions would bring the clearance within toler-
guides are replaced ance. If so, replace any guides as necessary and
(page 7-14). ream to fit.
If the stem-to-guide clearance exceeds the service
limit with a new guide, also replace the valve.
CAM CHAIN TENSIONER AND CHAIN GUIDE
Check the tensioner and guide for excessive wear or
damage.
CHAIN TENSIONER

CHAIN GUIDE

7-12
 CYLINDER HEAD/VALVES
VALVE GUIDE REPLACEMENT
Chill the new valve guides in a freezer for about an
hour.
Be sure to wear Heat the cylinder head to 130°C–140°C (275°F–
heavy gloves to 290°F) with a hot plate or oven. Do not heat the cyl-
avoid burns when inder head beyond 150°C (300°F). Use temperature
handling the heated indicator sticks, available from welding supply
cylinder head. stores, to be sure the cylinder head is heated to the
Using a torch to proper temperature.
heat the cylinder
Support the cylinder head and drive the valve
head may cause VALVE GUIDE DRIVER
guides out of the cylinder head from the combus-
warpage.
tion chamber side using the special tool.

TOOL:
Valve guide driver, 5.5 mm 07742-0010100

While the cylinder head is still heated, remove the

new valve guides from the freezer and install new VALVE GUIDE DRIVER
O-rings onto the valve guides.
Drive each valve guide into the cylinder head from
the camshaft side until it is fully seated.
TOOL:
Valve guide driver, 5.5 mm 07742-0010100
Let the cylinder head cool to room temperature.

Take care not to tilt Ream the new valve guides.

or lean the reamer Insert the reamer from the combustion chamber
in the guide while side of the cylinder head and always rotate the
reaming. reamer clockwise. VALVE GUIDE REAMER
Use cutting oil on
the reamer during
TOOL:
this operation. Valve guide reamer, 5.47mm 07984-0980001
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve
seat (page 7-14).

7-13
CYLINDER HEAD/VALVES
VALVE SEAT INSPECTION/REFACING
Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coat of Prussian Blue to each valve
seat.
Tap the valve against the valve seat several times VALVE
without rotating the valve, to check for proper valve
seat contact.

The valve cannot be Remove the valve and inspect the valve seat face.
ground. If the valve The valve seat contact should be within the speci-
face is burned or fied width and even all around the circumference.
badly worn or if it
contacts the seat
STANDARD: 1.1 – 1.3 mm (0.04 – 0.05 in)
unevenly, replace SERVICE LIMIT: 1.5 mm (0.06 in)
the valve.
If the seat width is not within soecification, reface
the valve seat.

SEAT WIDTH

Inspect the valve seat face for:

• Dameged face:
– Replace the valve and reface the valve seat.
• Uneven seat width:
– Replace the valve and reface the valve seat.

DAMAGED FACE UNEVEN SEAT WIDTH

• Contact area (too high or too low)

– Reface the valve seat.

TOO LOW TOO HIGH

7-14
 CYLINDER HEAD/VALVES
REFACING

• Follow the refacer manufacturer's operating

instructions.
• Be careful not to grind the seat more than neces-
say.
45°

60°

32°

If the contact area is too high on the valve, the seat

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

32
CONTACT TOO LOW
OLD SEAT
WIDTH

60°

Use a 45° seat cutter to remove any roughness or

irregularities from the seat.
TOOLS: ROUGHNESS
Seat cutter, 35 mm (45° IN) 07780-0010400
Seat cutter, 33 mm (45° EX) 07780-0010800
Cutter holder, 5.5 mm 07781-0010101

Using a 32° flat cutter, remove 1/4 of the existing

valve seat material.
TOOLS:
Flat cutter, 33 mm (32° IN) 07780-0012900 OLD SEAT WIDTH
Flat cutter, 30 mm (32° EX) 07780-0012200
Cutter holder, 5.5 mm 07781-0010101

32°

7-15
CYLINDER HEAD/VALVES
Using a 60° interior cutter, remove 1/4 of the exist-
ing valve seat material.

TOOLS:
Interior cutter, 34 mm (60° IN) 07780-0014700 OLD SEAT WIDTH
Interior cutter, 30 mm (60° EX)07780-0014000
Cutter holder, 5.5 mm 07781-0010101

60°

Using a 45° seat cutter, cut the seat to the proper

width.
VALVE SEAT WIDTH: 1.1 – 1.3 mm (0.04 – 0.05 in) SEAT WIDTH
Make sure that all pitting and irregularities are
removed.

45°

Excessive lapping After cutting the seat, apply lapping compound and
pressure may engine oil to the valve face, and lap the valve using
deform or damage light pressure.
the seat. Change the angle of lapping tool frequently to pre- HAND-LAPPING TOOL
Do not allow lap- vent uneven seat wear. HAND-LAPPING TOOL
ping compound to
After lapping, wash any residual compound off the
enter the guides.
cylinder head and valve. Recheck the seat contact
after lapping.

7-16
 CYLINDER HEAD/VALVES
CYLINDER HEAD ASSEMBLY
VALVE COTTERS

SPRING RETAINER

OUTER SPRING

INNER SPRING

SPRING SEATS

STEM SEAL

VALVE GUIDE

INTAKE VALVE
EXHAUST VALVE

Blow through the oil passage (stud bolt hole) in the

cylinder head with compressed air. VALVE

Install the spring seats and new stem seals.

INNER SPRING
Lubricate the valve stem sliding surface with molyb-
denum oil solution. OUTER SPRING
Insert the valve into the guide while turning it
slowly to avoid damaging to the stem seal.
RETAINER
STEM SEAL

SPRING SEATS

Install the inner and outer valve springs with the

tightly wound coils facing the combustion chamber.
Install the spring retainer.

Combustion chamber side

COMBUSTION CHAMBER SIDE

7-17
CYLINDER HEAD/VALVES
To prevent loss of Install the valve cotters using the valve spring com-
tension, do not pressor.
compress the valve
springs more than TOOLS:
necessary. Valve spring compressor 07757-0010000
COTTERS

SPRING COMPRESSOR

Support the cylin- Tap the valve stems gently with two plastic ham-
der head so the mers to seat the cotters firmly.
valve heads will not
contact anything
that cause damage.

CYLINDER HEAD INSTALLATION

Clean the gasket mating surfaces of the cylinder and
cylinder head, being careful not to damage them. CHAIN GUIDE
Install the cam chain guide by aligning the guide
end with the groove in the crankcase and the bosses
with the grooves in the cylinder.

BOSSES

Install the two dowel pins and a new gasket.

GASKET

DOWEL PINS

7-18
 CYLINDER HEAD/VALVES
Route the cam chain through the cylinder head and CYLINDER HEAD
install the cylinder head.
Tighten the socket Install the socket bolt with the washer and tempo-
bolt after installing rarily tighten it.
the cylinder head
cover.

BOLT AND WASHER

Insert the cam chain tensioner into the cylinder.
Align the bolt holes and install the pivot bolt with a
new sealing washer.
TENSIONER
Tighten the pivot bolt.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

BOLT AND WASHER

CAMSHAFT/CYLINDER HEAD COVER

INSTALLATION
Clean the mating surface of the cylinder head and
cover thoroughly, being careful not to damage
them.
ROCKER ARM INSTALLATION
Apply molybdenum oil solution to the sliding sur-
face of the rocker arm shafts.

ROCKER ARM SHAFTS

7-19
CYLINDER HEAD/VALVES
Place the rocker arms into the head cover.
Install the rocker arm shafts through the head cover ROCKER ARMS
and rocker arms.

SHAFTS
Turn the rocker arm shafts so the cutouts are
toward the inside.
Install the set plate by aligning the plate ends with
the cutout of the shaft. Tighten the set plate screw. CUTOUTS

SCREW SET PLATE

CAMSHAFT/CYLINDER HEAD COVER

INSTALLATION
Carefully rotate the Turn the crankshaft counterclockwise and align the
crankshaft while “T” mark on the flywheel with the index notch in the
holding the cam crankcase cover. INDEX NOTCH
chain to avoid jam-
ming the cam chain
against the timing
sprocket of the
crankshaft.

“T” MARK

Apply molybdenum oil solution to the cam lobes DOWEL PINS

and bearings.
Place the camshaft onto the cylinder head with the CAMSHAFT
cam lobes facing down.
Install the two dowel pins and the oil hole plug.

PLUG

7-20
 CYLINDER HEAD/VALVES
Apply liquid sealant to the mating surfaces of the
cylinder head cover.
Pour engine oil into the oil pocket in the cylinder
head.

Do not get sealant Carefully install the head cover while holding the
to the oil passage in rocker arms to avoid interfering the arms with the
the cylinder head. camshaft.

HEAD COVER

CYLINDER HEAD
OIL PASSAGE

Apply engine oil to the cap nut threads and seating

surfaces, and install the following:
– four cap nuts with new sealing washers
– four flange bolts
Tighten the fasteners in order as follows, in a criss- NUTS AND
cross pattern in several steps. WASHERS
TORQUE: Cap nuts: 27 N·m (2.8 kgf·m, 20 lbf·ft)
Flange bolts: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Socket bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)

FLANGE SOCKET
BOLTS BOLT
Be sure to align the “T” mark on the flywheel with
the index notch (page 7-20). CHAIN SPROCKET
Set the cam sprocket onto the cam chain carefully
so the timing marks on the sprocket are aligned
with the mating lines.
Install the cam sprocket onto the camshaft.

TIMING MARKS

7-21
CYLINDER HEAD/VALVES
Make sure the tim- Apply engine oil to the sprocket bolt threads and
ing marks on the seating surfaces.
sprocket aligns with Align the bolt holes in the sprocket and camshaft
the mating lines flange. Install the sprocket bolts, being careful not to
when the “T” mark let them fall into the crankcase.
is aligned with the
Tighten the sprocket bolts alternately while holding
index notch.
the crankshaft.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

BOLTS

Turn the tensioner shaft (inside of the body) clock- TENSIONER LIFTER
wise fully with a screwdriver until it is locked to
retract the lifter shaft.
Install the tensioner lifter with a new gasket.

GASKET

Install the two mounting bolts with new sealing BOLTS AND WASHERS
washers and tighten them.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Turn the tensioner shaft counterclockwise slightly to
release it.
Coat a new O-ring with engine oil and install it into
the tensioner lifter groove.
Install the sealing plug and tighten it.
TORQUE: 4 N·m (0.4 kgf·m, 3.0 lbf·ft) O-RING

SEALING PLUG

Make sure the timing marks align with the mating

lines when the “T” mark on the flywheel is aligned GASKET
with the index notch. O-RING
Install a new gasket onto the cam sprocket cover.
Coat a new O-ring with engine oil and install it into
the cover groove.
Install the sprocket cover with the oil pocket facing
down.

OIL POCKET

7-22
 CYLINDER HEAD/VALVES
Install the two cover bolts and tighten them. SPROCKET COVER

Install the carburetor insulator if it was removed:

Coat a new O-ring with engine oil and install it into O-RING
the insulator groove.
Install the insulator with a new gasket and tighten
the two bolts.
Install the following:
– valve adjusting hole caps (page 3-10)
– crankshaft hole cap and timing hole cap (page 3-
10)
– spark plug (page 3-7)
– starter motor (page 17-11)
Install the engine in the frame (page 6-8).
GASKET

INSULATOR

7-23
MEMO
 8. CYLINDER/PISTON

SYSTEM COMPONENTS ··························· 8-2 CYLINDER/PISTON REMOVAL ················· 8-4

8
SERVICE INFORMATION ··························· 8-3 CYLINDER/PISTON INSTALLATION········· 8-7

TROUBLESHOOTING ································· 8-3

8-1
CYLINDER/PISTON
SYSTEM COMPONENTS
CYLINDER/PISTON

8-2
 CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• The engine must be removed from the frame to service the cylinder and piston.
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during
removal.
• Camshaft and rocker arm lubricating oil is fed through an oil passage in the cylinder. Clean the oil passage before
installing cylinder.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 65.500 – 65.510 (2.5787 – 2.5791) 65.60 (2.583)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Piston, Piston O.D. at 10 (0.4) from bottom 65.470 – 65.490 (2.5776 – 2.5783) 65.40 (2.575)
piston pin, Piston pin hole I.D. 15.002 – 15.008 (0.5906 – 0.5909) 15.04 (0.592)
piston ring Piston pin O.D. 14.994 – 15.000 (0.5903 – 0.5906) 14.96 (0.589)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring end gap Top 0.20 – 0.35 (0.008 – 0.014) 0.5 (0.02)
Second 0.35 – 0.50 (0.014 – 0.020) 0.65 (0.026)
Oil (side rail) 0.20 – 0.70 (0.08 – 0.028) 0.9 (0.04)
Piston ring-to-ring Top 0.025 – 0.060 (0.0010 – 0.0024) 0.09 (0.004)
groove clearance Second 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.20 (0.008)
Connecting rod small end I.D. 15.010 – 15.028 (0.5909 – 0.5917) 15.06 (0.593)
Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.10 (0.004)

TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
Compression too high, overheating or knocking
• Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnormal noise
• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Worn cylinder, piston or piston rings

8-3
CYLINDER/PISTON
CYLINDER/PISTON REMOVAL
CYLINDER REMOVAL
Remove the cylinder head (page 7-9). CYLINDER
Do not strike the Lift the cylinder and remove it, being careful not to
cylinder too hard damage the piston with the stud bolts.
and do not damage
the mating surface
with a screwdriver.

Remove the gasket and dowel pins.

GASKET DOWEL PINS

PISTON REMOVAL
Place a clean shop Remove the piston pin clip with pliers.
PISTON
towel over the
Push the piston pin out of the piston and connecting
crankcase to pre-
rod, and remove the piston.
vent the clip from
falling into the
crankcase.

CLIP PISTON PIN

Do not damage the Spread each piston ring and remove it by lifting up
piston rings by at a point opposite the gap.
spreading the ends
too far.

8-4
 CYLINDER/PISTON
Never use a wire Clean carbon deposits from the piston ring grooves
brush; it will scratch with a ring that will be discarded.
the groove.

INSPECTION
CYLINDER
Inspect the cylinder wall for scratches or wear.
Measure the cylinder I.D. at three levels in the X and
Y axis. Take the maximum reading to determine the
cylinder wear.
SERVICE LIMIT: 65.60 mm (2.583 in)
Calculate the cylinder-to-piston clearance.
Refer to page 8-6 for measurement of the piston
O.D.
SERVICE LIMIT: 0.20 mm (0.008 in)

Calculate the cylinder for taper and out-of-round at

three levels in an X and Y axis. Take the maximum
reading to determine the taper and out-of-round. Y

SERVICE LIMITS: TOP X

Taper: 0.10 mm (0.004 in)
Out-of-round: 0.10 mm (0.004 in)
The cylinder must be rebored and an oversize pis- MIDDLE
ton fitted if the service limits are exceeded.
The following oversize pistons are available:
– 0.25 mm (0.010 in) BOTTOM
– 0.50 mm (0.020 in)
The cylinder must be rebored so the clearance for
an oversize piston is 0.010 – 0.040 mm (0.0004 –
0.0016 in).
Check the top of the cylinder for warpage with a
straight edge and feeler gauge across the stud
holes.
SERVICE LIMIT: 0.10 mm (0.004 in)

8-5
CYLINDER/PISTON
PISTON/PISTON RING
Inspect the piston rings for smooth movement by
rotating the them. The rings should be able to move
in their grooves without catching.
Push the ring until the outer surface of the piston
ring is nearly flush with the piston and measure the
ring-to-ring groove clearance.
SERVICE LIMITS:
Top: 0.09 mm (0.004 in)
Second: 0.08 mm (0.003 in)

Insert the piston ring into the bottom of the cylinder

squarely using the piston crown. PISTON RING
Measure the ring end gap.
SERVICE LIMITS:
Top: 0.5 mm (0.02 in)
Second: 0.65 mm (0.026 in)
Oil (side rail): 0.9 mm (0.04 in)

Measure the piston O.D. at a point 10 mm (0.4 in)

from the bottom and 90° to the piston pin hole.
SERVICE LIMIT: 65.40 mm (2.575 in)
Compare this measurement against the maximum
cylinder I.D. measurement and calculate the cylin- 90°
der-to-piston clearance (page 8-5).

10 mm (0.4 in)
Measure the piston pin hole I.D. Take the maximum
reading to determine the I.D.
SERVICE LIMIT: 15.04 mm (0.592 in)
Measure the piston pin O.D. at three points.
SERVICE LIMIT: 14.96 mm (0.589 in)
Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.02 mm (0.001 in)

8-6
 CYLINDER/PISTON
CONNECTING ROD
Measure the connecting rod small end I.D.

SERVICE LIMIT: 15.06 mm (0.593 in)

Calculate the connecting rod-to-piston pin clear-
ance.
SERVICE LIMIT: 0.10 mm (0.004 in)

CYLINDER/PISTON INSTALLATION
PISTON RING INSTALLATION
Be careful not to Carefully install the piston rings into the piston ring
damage the piston grooves with the marks facing up.
and rings.

• Do not confuse the top and second rings.

• To install the oil ring, install the spacer first, then
install the side rails.
Stagger the piston ring end gaps 120° apart from
each other.
Stagger the side rail end gaps as shown.

TOP RING
(“R” MARK)

SECOND RING 120°

(“RN” MARK)
120°

SIDE RAILS

SPACER
TOP RING

SECOND RING
20 mm or more
OIL RING

8-7
CYLINDER/PISTON
PISTON INSTALLATION
Place a clean shop towel over the crankcase to pre-
vent the piston pin clip from falling into the crank- "IN" MARK PISTON
case.
Apply molybdenum oil solution to the piston pin
outer surface.
Install the piston with the “IN” mark toward the
intake side and insert the piston pin through the pis-
ton and connecting rod.

PISTON PIN
Instal new piston pin clips.

• Make sure the piston pin clips are seated

securely.
• Do not align the clip end gap with the piston cut-
out.

CLIP

GAP

CUTOUT

CYLINDER INSTALLATION
Clean the gasket surface of the crankcase thor-
oughly, being careful not to damage them, and
being careful not to allow gasket material into the
crankcase.
Blow through the oil passage (stud bolt hole) in the
cylinder with compressed air.
Apply liquid sealant to the crankcase mating areas
as shown.

8-8
 CYLINDER/PISTON
Install the two dowel pins and a new gasket.
Apply engine oil to the cylinder wall, piston outer
surface and piston rings.

DOWEL PINS
GASKET
Be careful not to Route the cam chain through the cylinder and install CYLINDER
damage the piston the cylinder over the piston while compressing the
rings and cylinder piston rings with your fingers.
wall.
Make sure that the cylinder touches the crankcase
evenly. Install the cylinder head (page 7-18).

PISTON RINGS

8-9
MEMO
 9. CLUTCH/GEARSHIFT LINKAGE

SYSTEM COMPONENTS ··························· 9-2 CLUTCH ······················································ 9-6

SERVICE INFORMATION ··························· 9-3 GEARSHIFT LINKAGE ······························ 9-12

9
TROUBLESHOOTING ································· 9-4 RIGHT CRANKCASE COVER
INSTALLATION ········································ 9-14
RIGHT CRANKCASE COVER
REMOVAL ··················································· 9-5

9-1
CLUTCH/GEARSHIFT LINKAGE
SYSTEM COMPONENTS
CLUTCH/GEARSHIFT LINKAGE

12 N·m (1.2 kgf·m, 9 lbf·ft)

93 N·m (9.5
kgf·m,69 lbf·ft)

12 N·m (1.2
kgf·m,9 lbf·ft)

83 N·m (8.5
kgf·m,61 lbf·ft)

9-2
 CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the clutch, gearshift linkage and right crankcase cover. These services can be per-
formed with the engine installed in the frame.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Clutch lever free play 10 – 20 (3/8 – 3/4) –
Clutch Spring free length 39.2 (1.54) 36.1 (1.42)
Disc thickness A 3.62 – 3.70 (0.143 – 0.146) 3.3 (0.13)
B 2.90 – 3.00 (0.114 – 0.118) 2.6 (0.10)
C 2.90 – 3.00 (0.114 – 0.118) 2.6 (0.10)
Plate warpage – 0.20 (0.008)
Clutch outer guide I.D. 19.983 – 19.996 (0.7867 – 0.7872) 20.02 (0.788)
Mainshaft O.D. at clutch outer guide 19.959 – 19.980 (0.7858 – 0.7866) 19.92 (0.784)

TORQUE VALUES
Clutch spring bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Clutch center lock nut 93 N·m (9.5 kgf·m, 69 lbf·ft) Apply engine oil to the threads and seating
surface. Stake.
Oil filter rotor lock nut 83 N·m (8.5 kgf·m, 61 lbf·ft) Apply engine oil to the threads and seating
surface.
Shift drum stopper arm pivot bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Gearshift pedal pinch bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)

TOOLS
Lock nut wrench, 20 x 24 mm Extension bar Clutch center holder
07716-0020100 07716-0020500 07GMB-KT70101

Gear holder 07724-0010100

9-3
CLUTCH/GEARSHIFT LINKAGE
TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the free play.
Clutch lever difficult to pull in
• Damaged, kinked or dirty clutch cable
• Improperly routed clutch cable
• Damaged clutch lifter mechanism
• Faulty clutch lifter plate bearing
Clutch will not disengage or motorcycle creeps with clutch disengaged
• Excessive clutch lever free play
• Clutch plate warped
• Oil level too high, improper oil viscosity, or additive used
• Check for oil additive
Clutch slips
• Clutch lifter sticking
• Worn clutch discs
• Weak clutch springs
• No clutch lever free play
• Engine oil additive used
Hard to shift
• Misadjusted clutch cable
• Damaged or bent shift fork
• Bent shift fork shaft
• Incorrect engine oil viscosity
• Incorrect gearshift spindle assembly
• Damaged shift drum guide grooves
Transmission jumps out of gear
• Worn shift drum stopper arm
• Worn or broken gearshift spindle return spring
• Bent shift fork shaft
• Damaged shift drum guide grooves
• Worn gear dogs or dog holes
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Bent gearshift spindle

9-4
 CLUTCH/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER REMOVAL
Drain the engine oil (page 3-12).
Disconnect the brake rod from the brake arm and
remove the brake pedal return spring to lower the
brake pedal fully.

RETURN SPRING BRAKE PEDAL

Remove the bolts and clutch cable holder, then dis-

BOLTS CLUTCH CABLE HOLDER
connect the clutch cable from the clutch lifter arm.
Loosen the right crankcase cover bolts in a criss-
cross pattern in 2 or 3 steps, and remove the bolts
and right crankcase cover.

RIGHT CRANKCASE COVER

Remove the gasket and dowel pins.
GASKET

DOWEL PINS

DISASSEMBLY
Remove the lifter piece.
LIFTER PIECE SPRING PIN
Measure and record the length of drive pin protru-
sion.
Drive the spring pin into the clutch lifter arm until
the pin end is flush with the lifter arm surface, using
the commercially available 3 mm pin driver.

RETURN SPRING

9-5
CLUTCH/GEARSHIFT LINKAGE
Remove the clutch lifter arm and return spring.
NEEDLE BEARING
Remove the dust seal.
Check the lifter piece and arm for wear or damage.
Check the return spring for fatigue or damage.
Check the needle bearings for wear or damage and
replace them if necessary.

DUST SEAL

CLUTCH LIFTER ARM

CLUTCH
DISASSEMBLY
Remove the following:
LOCK NUT WRENCH GEAR HOLDER
– right crankcase cover (page 9-5)
– oil filter rotor cover (page 3-13)
– oil pump (page 4-4)
Install the gear holder between the primary drive
and driven gears as shown, and loosen the oil filter
rotor lock nut.
TOOLS:
Gear holder 07724-0010100
Lock nut wrench, 20 x 24 mm 07716-0020100
Extension bar 07716-0020500
Remove the lock nut, lock washer and oil filter rotor. EXTENSION BAR
Loosen the clutch lifter plate bolts in a crisscross
pattern in several steps. LIFTER PLATE
Remove the bolts, liter plate and clutch springs.

BOLTS, SPRINGS
Be careful not to Unstake the clutch center lock nut.
UNSTAKE
damage the main-
shaft threads.

9-6
 CLUTCH/GEARSHIFT LINKAGE
Attach the clutch center holder to the pressure plate CLUTCH CENTER HOLDER LOCK NUT
using four clutch bolts to hold the clutch center.
Loosen the clutch center lock nut using the special
tool.
TOOLS:
Lock nut wrench, 20 x 24 mm 07716-0020100
Extension bar 07716-0020500
Clutch center holder 07GMB-KT70101
Remove the special tools, lock nut and lock washer.

EXTENSION BAR LOCK NUT WRENCH

Remove the following:
CLUTCH DISCS/PLATES
– clutch center
– spring seat
– judder spring
– clutch disc A
– clutch plates and discs B
– clutch disc C
– pressure plate

CLUTCH CENTER PRESSURE PLATE

– spline washer
CLUTCH OUTER
– clutch outer

SPLINE WASHER
– clutch outer guide
CLUTCH OUTER GUIDE

9-7
CLUTCH/GEARSHIFT LINKAGE
INSPECTION
Clutch lifter bearing
Turn the inner race of the lifter bearing with your
finger. LIFTER PLATE BEARING
The bearing should turn smoothly and quietly.
Also check that the outer race of the bearing fits
tightly in the lifter plate.
Replace the bearing if the inner race does not turn
smoothly, quietly, or if the outer race fits loosely in
the lifter plate.

Clutch spring
Replace the clutch Measure the clutch spring free length.
springs as a set.
SERVICE LIMIT: 36.1 mm (1.42 in)

Clutch center
Check the grooves of the clutch center for damage
or wear caused by the clutch plates. CLUTCH CENTER
Replace if necessary.

GROOVE
Clutch disc
Replace the clutch Check the clutch discs for signs of scoring or discol-
discs and plates as oration.
a set. Measure the thickness of each disc.

SERVICE LIMITS:
Disc A (large I.D.): 3.3 mm (0.13 in)
Disc B: 2.6 mm (0.10 in)
Disc C: 2.6 mm (0.10 in)

9-8
 CLUTCH/GEARSHIFT LINKAGE
Clutch plate
Replace the clutch Check the plate for discoloration.
discs and plates as Check the clutch plate for warpage on a surface
a set. plate using a feeler gauge.
SERVICE LIMIT: 0.20 mm (0.008 in)

Judder spring/spring seat

Check the judder spring and seat for damage or
warpage. SPRING SEAT JUDDER SPRING

Clutch outer/outer guide

Check the slots in the clutch outer for nicks, cuts or
indentations made by the clutch discs. CLUTCH OUTER
Check the primary driven gear teeth for wear or
damage.
Measure the clutch outer guide I.D.
SERVICE LIMIT: 20.02 mm (0.788 in)

OUTER GUIDE

Mainshaft
Measure the mainshaft O.D. at the clutch outer
guide.
SERVICE LIMIT: 19.92 mm (0.784 in)

9-9
CLUTCH/GEARSHIFT LINKAGE
ASSEMBLY
Apply molybdenum oil solution to the entire surface
CLUTCH OUTER GUIDE
of the clutch outer guide and install it onto the main-
shaft.

Install the clutch outer and spline washer.

CLUTCH OUTER

SPLINE WASHER
Install the spring seat and judder spring onto the
clutch center as shown. CLUTCH DISCS B PRESSURE
PLATE
Coat the clutch discs with clean engine oil.
CLUTCH
Assemble clutch discs A, B and C, clutch plates and CENTER
pressure plate onto clutch center. CLUTCH
DISC C
CLUTCH
PLATES

JUDDER
CLUTCH DISC A SPRING
SPRING SEAT

Install the tabs of Install the clutch center assembly into the clutch
CLUTCH OUTER SHALLOW SLOT
clutch disc A into outer.
the shallow slots in
the clutch outer.

CLUTCH CENTER ASSEMBLY

9-10
 CLUTCH/GEARSHIFT LINKAGE
Install the lock washer.
Apply oil to the threads and seating surface of a
new lock nut and install it with the chamfered side
facing in. LOCK NUT

LOCK WASHER
Attach the clutch center holder to the pressure plate
CLUTCH CENTER HOLDER EXTENSION BAR
using four clutch bolts to hold the clutch center.
Tighten the clutch center lock nut using the special
tool.
TOOLS:
Lock nut wrench, 20 x 24 mm 07716-0020100
Extension bar 07716-0020500
Clutch center holder 07GMB-KT70101

TORQUE: 93 N·m (9.5 kgf·m, 69 lbf·ft)

LOCK NUT WRENCH

Be careful not to Stake the lock nut into the mainshaft groove.
STAKE
damage the main-
shaft threads.

Install the clutch springs, lifter plate and bolts.

LIFTER PLATE
Tighten the lifter plate bolts in a crisscross pattern
in several steps.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

BOLTS, SPRINGS

9-11
CLUTCH/GEARSHIFT LINKAGE
Install the oil filter rotor and lock washer onto the
OIL FILTER ROTOR
crankshaft.
Apply oil to the threads and seating surface of the
lock nut and install it with the chamfered side facing LOCK NUT
in.

LOCK WASHER
Install the gear holder between the primary drive
and driven gears as shown, and tighten the oil filter EXTENSION BAR
rotor lock nut.
TOOLS:
Gear holder 07724-0010200
Lock nut wrench, 20 x 24 mm 07716-0020100
Extension bar 07716-0020500

TORQUE: 83 N·m (8.5 kgf·m, 61 lbf·ft)

Install the following:
– oil pump (page 4-7)
– oil filter rotor cover (page 3-13)
– right crankcase cover (page 9-14) LOCK NUT WRENCH GEAR HOLDER

GEARSHIFT LINKAGE
REMOVAL
Remove the following: GEARSHIFT PEDAL
– right crankcase cover (page 9-5)
– clutch assembly (page 9-6)
– bolt and gearshift pedal

BOLT
Pull the gearshift spindle out of the crankcase.
Remove the thrust washer. GEARSHIFT SPINDLE

9-12
 CLUTCH/GEARSHIFT LINKAGE
Remove the following:
GEARSHIFT CAM RETURN SPRING
– gearshift cam bolt
– gearshift cam
– dowel pin from the shift drum
– stopper arm bolt
– stopper arm
– washer
– return spring BOLT

STOPPER ARM BOLT

INSPECTION
Check the gearshift spindle for wear or bend.
Check the spindle plate for wear, damage or defor- PLATE GEARSHIFT SPINDLE
mation.
Check the return spring for fatigue or damage.

RETURN SPRING
INSTALLATION
Install the return spring, washer, stopper arm and
DOWEL PIN STOPPER ARM WASHER
bolt, and tighten the bolt.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Install the dowel pin into the shift drum hole.

RETURN SPRING BOLT

Hold the stopper arm using a screwdriver and install
GEARSHIFT CAM DOWEL PIN
the gearshift cam by aligning the pin hole with the
dowel pin.

HOLE STOPPER ARM

9-13
CLUTCH/GEARSHIFT LINKAGE
Install the gearshift cam bolt and tighten it.
GEARSHIFT CAM BOLT

Install the thrust washer onto the gearshift spindle

WASHER LUG
and insert the spindle into the crankcase while
aligning the return spring ends with the lug.
Install the following:
– clutch assembly (page 9-10)
– right crankcase cover (page 9-15)

GEARSHIFT SPINDLE SPRING ENDS

Install the gearshift pedal so the distance between
the timing hole cap center and pedal top surface is GEARSHIFT PEDAL
79 mm (3.1 in).
Install the pedal pinch bolt and tighten it.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

BOLT

RIGHT CRANKCASE COVER

INSTALLATION
ASSEMBLY
Apply oil to a new dust seal lip and install it into the
right crankcase cover. CLUTCH LIFTER ARM
Apply oil to the clutch lifter arm sliding surface and
install it into the right crankcase cover.

DUST SEAL

9-14
 CLUTCH/GEARSHIFT LINKAGE
Install the return spring onto the lifter arm end.
LIFTER PIECE SPRING PIN
From the opposite side, drive the spring pin until it
projects the same amount as recorded at disassem-
bly, using the commercially available 3 mm pin
driver.
Hook the return spring ends as shown.
Install the lifter piece into the lifter arm groove while
aligning the groove with the lifter piece hole.

RETURN SPRING
INSTALLATION
Be careful not to Clean off any gasket material from the mating sur-
damage the mating faces of the right crankcase and cover. GASKET
surfaces.
Install the dowel pins and new gasket.

DOWEL PINS

Connect the clutch cable to the clutch lifter arm and

BOLTS CLUTCH CABLE HOLDER
install the right crankcase cover.
Install the clutch cable guide and eleven bolts, and
tighten the bolts in a crisscross pattern in 2 or 3
steps.

RIGHT CRANKCASE COVER

Install the brake pedal return spring.
Connect the brake rod to the brake arm.
Adjust the brake pedal free play (page 3-20).
Adjust the clutch lever free play (page 3-21).
Fill the crankcase with the recommended engine oil
(page 3-12).

RETURN SPRING BRAKE PEDAL

9-15
MEMO
 10. ALTERNATOR/STARTER CLUTCH

SYSTEM COMPONENTS ························· 10-2 FLYWHEEL REMOVAL ····························· 10-6

SERVICE INFORMATION ························· 10-3 STARTER CLUTCH ··································· 10-7

LEFT CRANKCASE COVER REMOVAL ··· 10-4 FLYWHEEL INSTALLATION ···················· 10-9
10
ALTERNATOR STATOR ··························· 10-5 LEFT CRANKCASE COVER
INSTALLATION ······································ 10-10

10-1
ALTERNATOR/STARTER CLUTCH
SYSTEM COMPONENTS
ALTERNATOR/STARTER CLUTCH

74 N·m (7.5 kgf·m, 55 lbf·ft)

5 N·m (0.5
kgf·m, 3.7 lbf·ft)

10-2
 ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
GENERAL
• This section covers the removal and installation of the alternator stator, flywheel and starter clutch. These services can
be done with the engine installed in the frame.
• Refer to the following:
– alternator stator inspection (page 15-8)
– starter motor servicing (page 17-6)

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.56 (1.794)

TORQUE VALUES
Starter clutch bolt 16 N·m (1.6 kgf·m, 12 lbf·ft) Apply a locking agent to the threads.
Flywheel bolt 74 N·m (7.5 kgf·m, 55 lbf·ft) Apply oil to the threads and seating sur-
face.
Ignition pulse generator mounting bolt 5 N·m (0.5 kgf·m, 3.7 lbf·ft) Apply a locking agent to the threads.

TOOLS
Flywheel holder Flywheel puller
07725-0040000 07733-0020001

10-3
ALTERNATOR/STARTER CLUTCH
LEFT CRANKCASE COVER REMOVAL
Remove the left side cover (page 2-3).
ALTERNATOR CONNECTORS
Disconnect the alternator wire connector and 4P
connector.

Remove the two bolts and drive sprocket cover.

DRIVE SPROCKET COVER

BOLTS

Remove the two bolts and starter reduction gear

BOLTS
cover.
Remove the O-ring from the reduction gear cover.

REDUCTION GEAR COVER

Remove the starter reduction gear shaft and gear.
GEAR SHAFT

STARTER REDUCTION GEAR

10-4
 ALTERNATOR/STARTER CLUTCH
Remove the collar and disconnect the wire from the
LEFT CRANKCASE COVER GUIDE PLATE
neutral switch.
Remove the bolt and alternator wire clamp.
Loosen the left crankcase cover bolts in a crisscross
pattern in 2 or 3 steps, and remove the bolts and left
crankcase cover.

NEUTRAL
BOLTS SWITCH
Remove the dowel pins and gasket. DOWEL PINS O-RING
GASKET
Remove the O-ring from the starter motor.

ALTERNATOR STATOR
REMOVAL
Remove the wire clamp and grommet from the left
crankcase cover. GROMMET

CLAMP
Remove the three alternator stator mounting bolts
SOCKET BOLTS
and two ignition pulse generator mounting bolts.
Remove the stator assembly from the left crankcase
cover.

IGNITION PULSE
GENERATOR BOLTS

10-5
ALTERNATOR/STARTER CLUTCH
INSTALLATION
Install the stator assembly into the left crankcase
SOCKET BOLTS
cover.
Apply oil to the stator mounting bolt threads and
seating surfaces.
Install the stator mounting bolts and tighten them.
Apply locking agent to the ignition pulse generator
mounting bolt threads.
Install the ignition pulse generator mounting bolts
and tighten them.
TORQUE: 5 N·m (0.5 kgf·m, 3.7 lbf·ft)

BOLTS
Apply sealant to the seating surface of the wire
grommet, and install it into the left crankcase cover GROMMET
groove properly.
Install the wire clamp aligning the hole with the
boss on the left crankcase cover.

Align CLAMP

FLYWHEEL REMOVAL
Remove the left crankcase cover (page 10-4).
STARTER IDLE GEAR
Remove the starter idle gear and shaft.

SHAFT
Hold the flywheel with the special tool and loosen
FLYWHEEL HOLDER BOLT, WASHER
the flywheel bolt.

TOOL:
Flywheel holder 07725-0040000
Remove the flywheel bolt and washer.

10-6
 ALTERNATOR/STARTER CLUTCH
Remove the flywheel using the special tool.
FLYWHEEL PULLER
TOOL:
Flywheel puller 07733-0020001

Remove the woodruff key from the crankshaft key

DRIVEN GEAR COLLAR
groove.
Remove the driven gear collar from the crankshaft.

WOODRUFF KEY

STARTER CLUTCH
REMOVAL
Remove the flywheel (page 10-6).
STARTER DRIVEN GEAR
Remove the starter driven gear while turning it
counterclockwise.

Hold the flywheel using the special tool and remove

FLYWHEEL HOLDER BOLTS
the starter clutch bolts.

TOOL:
Flywheel holder 07725-0040000
Remove the starter clutch assembly from the fly-
wheel.
Remove the sprag clutch from the starter clutch
outer.

10-7
ALTERNATOR/STARTER CLUTCH
INSPECTION
Check the sprag clutch for abnormal wear, damage
or irregular movement. CLUTCH OUTER
SPRAG CLUTCH
Check the sprag contacting surface of the clutch
outer for abnormal wear or damage.

Check the sprag contacting surface of the starter

driven gear for abnormal wear or damage.
Measure the starter driven gear boss O.D.
SERVICE LIMIT: 45.56 mm (1.794 in)

INSTALLATION
Apply oil to the sprag clutch and install it into the
clutch outer as shown. SPRAG CLUTCH
Install the clutch outer onto the flywheel.

CLUTCH OUTER
Apply locking agent to the starter clutch bolt
FLYWHEEL HOLDER BOLTS
threads.
Align the bolt holes in the clutch outer and flywheel,
and install the starter clutch bolts.
Hold the flywheel using the special tool and tighten
the starter clutch bolts.
TOOL:
Flywheel holder 07725-0040000

TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft)

10-8
 ALTERNATOR/STARTER CLUTCH
Install the starter driven gear while turning it coun-
terclockwise. STARTER DRIVEN GEAR

Make sure that the starter driven gear turns counter-

clockwise smoothly and does not turn clockwise.
Install the flywheel (page 10-9).

FLYWHEEL INSTALLATION
Install the driven gear collar onto the flywheel.
DRIVEN GEAR COLLAR
Clean the crankshaft and flywheel tapered areas.
Install the woodruff key into the crankshaft key
groove.

WOODRUFF KEY
Install the flywheel onto the crankshaft, aligning the
key way with the woodruff key. KEY WAY

FLYWHEEL
Apply engine oil to the flywheel bolt threads and
FLYWHEEL HOLDER WASHER
seating surface.
Install the washer and flywheel bolt.
Hold the flywheel with the special tool and tighten
the flywheel bolt.
BOLT
TOOL:
Flywheel holder 07725-0040000

TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft)

10-9
ALTERNATOR/STARTER CLUTCH
Apply oil to the starter idle gear shaft, and install the
STARTER IDLE GEAR
idle gear and shaft.
Install the left crankcase cover (page 10-10).

SHAFT

LEFT CRANKCASE COVER

INSTALLATION
Clean the mating surfaces of the left crankcase and O-RING
GASKET DOWEL PINS
cover.
Coat a new O-ring with oil and install it into the
starter motor groove.
Install the dowel pins and a new gasket.

Install the left crankcase cover onto the crankcase.

LEFT CRANKCASE COVER GUIDE PLATE
Install the left crankcase cover bolts and tighten
them in a crisscross pattern in 2 or 3 steps.
Route the alternator wire properly.
Install the alternator wire clamp and tighten the
bolt.
Connect the wire to the neutral switch and install
the collar.

NEUTRAL
BOLTS SWITCH
Apply oil to the starter reduction gear shaft, and
install the reduction gear and shaft. GEAR SHAFT

STARTER REDUCTION GEAR

10-10
 ALTERNATOR/STARTER CLUTCH
Coat a new O-ring with oil and install it into the
REDUCTION GEAR COVER
groove in the starter reduction gear cover.
Install the starter reduction gear cover.

O-RING

Install the two bolts and tighten them.

BOLTS

REDUCTION GEAR COVER

Install the drive sprocket cover and tighten the bolts.
DRIVE SPROCKET COVER

BOLTS

Connect the alternator wire connector and 4P con-

nector. ALTERNATOR CONNECTORS

Install the left side cover (page 2-3).

10-11
MEMO
11. CRANKCASE/TRANSMISSION/CRANKSHAFT

SYSTEM COMPONENTS ························· 11-2 TRANSMISSION······································· 11-8

SERVICE INFORMATION ························· 11-3 CRANKSHAFT ········································ 11-13

TROUBLESHOOTING ······························· 11-6 CRANKCASE BEARING

REPLACEMENT ······································ 11-15
CRANKCASE SEPARATION····················· 11-7 11
CRANKCASE ASSEMBLY ······················ 11-18

11-1
CRANKCASE/TRANSMISSION/CRANKSHAFT
SYSTEM COMPONENTS
CRANKCASE/TRANSMISSION/CRANKSHAFT

11-2
 CRANKCASE/TRANSMISSION/CRANKSHAFT
SERVICE INFORMATION
GENERAL
• The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine
must be removed from the frame (page 6-4).
• Be careful not to damage the crankcase mating surfaces when servicing.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Runout – 0.03 (0.001)
Connecting rod big end radial clear- 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
ance
Connecting rod big end side clear- 0.05 – 0.30 (0.002 – 0.012) 0.80 (0.031)
ance
Transmission Gear I.D. M5, M6, C2 23.020 – 23.041 (0.9063 – 0.9071) 23.08 (0.909)
C1 19.520 – 19.541 (0.7685 – 0.7693) 19.57 (0.770)
C3, C4 22.020 – 22.041 (0.9063 – 0.9071) 22.08 (0.869)
Gear busing C1 O.D. 19.479 – 19.500 (0.7669 – 0.7677) 19.43 (0.765)
I.D. 16.516 – 16.534 (0.6502 – 0.6509) 16.60 (0.654)
M5, M6, O.D. 22.979 – 23.000 (0.9047 – 0.9055) 22.93 (0.903)
C2 I.D. 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
Mainshaft at M5 19.959 – 19.980 (0.7858 – 0.7866) 19.90 (0.783)
O.D.
Counter- at C1 16.466 – 16.484 (0.7864 – 0.7869) 16.41 (0.646)
shaft O.D. at C2 19.974 – 19.987 (0.8645 – 0.8654) 19.94 (0.785)
Shift fork, Shift fork shaft O.D. 11.976 – 11.994 (0.4715 – 0.4722) 11.96 (0.471)
shift fork shaft Shift fork I.D. 12.000 – 12.021 (0.4724 – 0.4733) 12.05 (0.474)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)

TORQUE VALUE
Mainshaft bearing set plate bolt 23 N·m (2.3 kgf·m, 17 lbf·ft) Apply locking agent to the threads.

11-3
CRANKCASE/TRANSMISSION/CRANKSHAFT
TOOLS
Universal bearing puller Driver Attachment, 72 x 75 mm
07631-0010000 07749-0010000 07746-0010600

Pilot, 35 mm Thread adapter Assembly collar

07746-0040800 070MF-KPS0100 07965-VM00100

Thread shaft Remover shaft Remover head, 15 mm

07965-VM00200 07936-KC10100 07936-KC10200

Remover weight Pilot, 28 mm Attachment, 52 x 55 mm

07741-0010201 07746-0041100 07746-0010400

11-4
 CRANKCASE/TRANSMISSION/CRANKSHAFT
Pilot, 20 mm Attachment, 22 x 24 mm Pilot, 15 mm
07746-0040500 07746-0010800 07746-0040300

Attachment, 28 x 30 mm Attachment, 32 x 35 mm Attachment, 42 x 47 mm

07946-1870100 07746-0010100 07746-0010300

11-5
CRANKCASE/TRANSMISSION/CRANKSHAFT
TROUBLESHOOTING
Excessive engine noise
• Worn connecting rod big end bearing
• Worn crankshaft main journal bearing
• Worn transmission gears
• Worn transmission bearings
Transmission jumps out of gear
• Worn gear dogs or dog holes
• Worn shift drum guide groove
• Worn shift fork guide pin
• Worn gear shifter groove
• Worn shift fork
• Broken shift fork shaft
Hard to shift
• Incorrect clutch adjustment
• Bent shift fork
• Bent shift fork shaft
• Bent shift fork claw
• Damaged shift drum guide grooves
• Damaged shift fork guide pin

11-6
 CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKCASE SEPARATION
Remove the following:
PRIMARY DRIVE GEAR WOODRUFF KEY
– engine (page 6-4)
– starter motor (page 17-6)
– cylinder head (page 7-9)
– cylinder, piston (page 8-4)
– oil pump (page 4-4)
– clutch (page 9-6)
– gearshift linkage (page 9-12)
– flywheel (page 10-6)
– primary drive gear
– woodruff key

– bolt and cam chain setting plate

CAM CHAIN
– cam chain

SETTING PLATE BOLT

– right crankcase bolt
RIGHT CRANKCASE BOLT

Loosen the left crankcase bolts in a crisscross pat-

LEFT CRANKCASE BOLTS
tern in 2 or 3 steps, and remove them.

11-7
CRANKCASE/TRANSMISSION/CRANKSHAFT
Place the left crankcase down, separate the right
RIGHT CRANKCASE
crankcase from the left crankcase.

LEFT CRANKCASE
Remove the gasket and dowel pins.
DOWEL PINS

GASKET

TRANSMISSION
DISASSEMBLY
Separate the crankcase halves (page 11-7).
SHIFT FORK SHAFT
Pull out the shift fork shaft.

Remove the shift forks and shift drum.

SHIFT DRUM

SHIFT FORKS

11-8
 CRANKCASE/TRANSMISSION/CRANKSHAFT
Remove the mainshaft and countershaft as an
assembly. COUNTERSHAFT MAINSHAFT

Do not expand the Disassemble the mainshaft and countershaft.

snap ring more than
COUNTERSHAFT MAINSHAFT
necessary for
removal.

INSPECTION
Check the gear shifter groove, dogs, dog holes and
teeth for abnormal wear or damage.
Measure the I.D. of each gear.
SERVICE LIMITS:
M5, M6, C2: 23.08 mm (0.909 in)
C1: 19.57 mm (0.770 in)
C3, C4: 22.08 mm (0.869 in)
Check the bushings for abnormal wear or damage.
Measure the I.D. and O.D. of the gear bushing.
SERVICE LIMITS:
C1 bushing: O.D.: 19.43 mm (0.765 in)
I.D.: 16.60 mm (0.654 in)
M5, M6, C2 bushing: O.D.: 22.93 mm (0.903 in)
I.D.: 20.50 mm (0.789 in)
Check the spline grooves and sliding surfaces of the
mainshaft and countershaft for abnormal wear or
damage. M5
Measure the O.D. of the mainshaft and counter-
shaft.
SERVICE LIMITS: At M5: 19.90 mm (0.783 in)
At C1: 16.41 mm (0.646 in)
At C2: 19.94 mm (0.785 in)

C2 C1

11-9
CRANKCASE/TRANSMISSION/CRANKSHAFT
Inspect the shift drum end for scoring, scratches or
evidence of insufficient lubrication.
Check the shift drum guide grooves for abnormal
wear or damage.

Check the shift fork shaft for abnormal wear or dam-

age.
Measure the shift fork shaft O.D.
SERVICE LIMIT: 11.96 mm (0.471 in)

Check the shift forks for abnormal wear or damage.

Measure the I.D. of the shift fork.
SERVICE LIMIT: 12.05 mm (0.474 in)
Measure the shift fork claw thickness.
SERVICE LIMIT: 4.50 mm (0.177 in)

11-10
 CRANKCASE/TRANSMISSION/CRANKSHAFT
ASSEMBLY
MAINSHAFT

M6 GEAR (32T) SNAP RINGS

SPLINE WASHER SPLINE WASHER
THRUST WASHER

M1 GEAR (13T)

M2 GEAR (17T) M6 COLLAR M3/M4 GEAR

(20T27T)

M5 GEAR (25T)
M5 COLLAR THRUST WASHER
MAINSHAFT

COUNTERSHAFT
SPLINE WASHER C3 GEAR (29T) THRUST WASHER C1 GEAR (36T)
C6 GEAR (26T) SPLINE WASHER SNAP RING

THRUST WASHER

SNAP LOCK WASHER SPLINE WASHER C1 COLLAR

C4 GEAR (31T) C2 COLLAR
C5 GEAR (24T)
C2 GEAR (33T)

COUNTERSHAFT

THRUST WASHERS

11-11
CRANKCASE/TRANSMISSION/CRANKSHAFT
Apply molybdenum oil solution to the rotating sur-
faces of the transmission gears. COUNTERSHAFT MAINSHAFT

Assemble the mainshaft and countershaft.

• Always instal the washer and snap ring with the

chamfered (rolled) edge facing away from the
thrust load.
• Do not reuse worn snap ring which could easily
spin in the groove.
• Install the snap ring so that its end gap aligns
with the groove in the splines.
• Make sure that the snap ring is fully seated in the
shaft groove after installing it. : Gear rotating surfaces

Install the mainshaft and countershaft as an assem-

bly into the left crankcase. COUNTERSHAFT MAINSHAFT

Each shift fork has an identification marks; “L”

(Left), “C” (Center), “R” (Right). MARKS

Install the left shift fork into the shifter gear groove
with the mark facing up (right crankcase side).
Install the center and right shift forks into the shifter
gear grooves with the marks facing down (left
crankcase side).

Install the shift drum by aligning the shift fork guide

SHIFT DRUM
pins with the drum guide grooves.

SHIFT FORKS

11-12
 CRANKCASE/TRANSMISSION/CRANKSHAFT
Install the shift fork shaft through the shift forks and
SHIFT FORK SHAFT
into the crankcase.

CRANKSHAFT
REMOVAL
Remove the transmission (page 11-8).
CRANKSHAFT
Remove the crankshaft from the left crankcase
using a hydraulic press while holding it.
Drive the crankshaft bearing out of the left crank-
case.

Remove the left crankshaft bearing using the special

tool if it comes out with the crankshaft. Discard the UNIVERSAL
bearing. BEARING
PULLER
TOOL:
Universal bearing puller 07631-0010000

INSPECTION
Set the crankshaft on a stand or V-blocks and mea-
sure the runout using a dial indicator.
SERVICE LIMIT: 0.03 mm (0.001 in)

70 mm (2.76 in) 89.6 mm (3.53 in)

11-13
CRANKCASE/TRANSMISSION/CRANKSHAFT
Measure the connecting rod big end side clearance.

SERVICE LIMIT: 0.80 mm (0.031 in)

Measure the connecting rod big end radial clear-

ance.
SERVICE LIMIT: 0.05 mm (0.002 in)

INSTALLATION
Drive a new left crankshaft bearing into the left
crankcase. DRIVER

TOOLS:
Driver 07749-0010000
Attachment, 72 x 75 mm 07746-0010600
Pilot, 28 mm 07746-0041100

ATTACHMENT PILOT
Set the special tools onto the crankshaft and left
crankshaft bearing. THREAD
ADAPTER
TOOLS:
Thread adapter 070MF-KPS0100
Assembly collar 07965-VM00100
Thread shaft 07965-VM00200
Draw the crankshaft into the left crankshaft bearing
THREAD
inner race (left crankcase).
SHAFT
Install the transmission (page 11-11).
ASSEMBL
Y COLLAR

11-14
 CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKCASE BEARING REPLACEMENT
Remove the following:
– transmission (page 11-8)
– crankshaft (page 11-13)
Turn the inner race of each crankcase bearing with
your finger. The bearing should turn smoothly and
quietly.
Also check that the bearing outer race fits tightly in
the crankcase.
Replace the bearing if the inner race does not turn
smoothly, quietly or it the outer race fits loosely in
the crankcase.

Always wear insu- Before removing the bearings, heat the crankcase
lated gloves when evenly using a heat gun.
handling a heated
crankcase.
RIGHT CRANKCASE BEARINGS
Remove the socket bolt and bearing setting plate.
BOLT, SETTING PLATE MAINSHAFT
Drive the mainshaft, crankshaft and shift drum bear- BEARING
ings out of the right crankcase.

SHIFT DRUM
CRANKSHAFT BEARING BEARING
Remove the countershaft bearing using the special
REMOVER WEIGHT REMOVER
tools.
SHAFT
TOOLS:
Remover shaft 07936-KC10100
Remover head, 15 mm 07936-KC10200
Remover weight 07741-0010201

COUNTERSHAFT
REMOVER HEAD BEARING

11-15
CRANKCASE/TRANSMISSION/CRANKSHAFT
Drive new bearings (crankshaft and mainshaft bear-
ings) into the right crankcase using the special tools. DRIVER

TOOLS:
Crankshaft bearing:
Driver 07749-0010000
Attachment, 72 x 75 mm 07746-0010600
Pilot, 35 mm 07746-0040800
Mainshaft bearing:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 20 mm 07746-0040500
Press new needle bearings (countershaft and shift
drum needle bearing) into the right crankcase using ATTACHMENT PILOT
the special tools.
TOOLS:
Countershaft bearing:
Driver 07749-0010000
Attachment, 22 x 24 mm 07746-0010800
Pilot, 15 mm 07746-0040300
Shift drum bearing:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 20 mm 07746-0040500
Apply locking agent to the socket bolt threads.
SOCKET BOLT
Install the bearing setting plate and bolt, then
tighten the bolt.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)

SETTING PLATE

LEFT CRANKCASE BEARINGS

Remove the left countershaft oil seal.
COUNTERSHAFT OIL SEAL

11-16
 CRANKCASE/TRANSMISSION/CRANKSHAFT
Drive the countershaft bearing out of the left crank-
COUNTERSHAFT BEARING
case.

Remove the mainshaft bearing using the special

REMOVER WEIGHT REMOVER
tools.
SHAFT
TOOLS:
Remover shaft 07936-KC10100
Remover head, 15 mm 07936-KC10200
Remover weight 07741-0010201

MAINSHAFT
REMOVER HEAD BEARING
Drive new bearings (mainshaft and countershaft
DRIVER
bearings) into the left crankcase.
TOOLS:
Mainshaft bearing:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 15 mm 07746-0040300
Countershaft bearing:
Driver 07749-0010000
Attachment, 42 X 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500

ATTACHMENT PILOT

Install a new countershaft oil seal into the left crank-

case. COUNTERSHAFT OIL SEAL

11-17
CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKCASE ASSEMBLY
Be careful not to Clean the crankcase mating surfaces thoroughly.
DOWEL PINS
damage the crank-
Install the dowel pins and a new gasket.
case mating sur-
face.

GASKET

Install the right crankcase over the left crankcase.

RIGHT CRANKCASE

Do not force the crankcase halves together; if there

is excessive force required, something is wrong.
Remove the right crankcase and check for mis-
aligned parts.

LEFT CRANKCASE
Install the left crankcase bolts and tighten them in a
LEFT CRANKCASE BOLTS
crisscross pattern in 2 or 3 steps.

Install the right crankcase bolt and tighten it.

RIGHT CRANKCASE BOLT

11-18
 CRANKCASE/TRANSMISSION/CRANKSHAFT
Install the cam chain over the timing sprocket.
CAM CHAIN
Install the cam chain set plate and tighten the bolt.

SETTING PLATE BOLT

Install the woodruff key into the crankshaft key
groove.

Install the primary drive gear by aligning its groove

PRIMARY DRIVE GEAR WOODRUFF KEY
with the woodruff key on the crankshaft.
After assembly, check the rotation of the crankshaft,
mainshaft and countershaft.
Install the following:
– flywheel (page 10-9)
– gearshift linkage (page 9-13)
– clutch (page 9-10)
– oil pump (page 4-7)
– cylinder, piston (page 8-7)
– cylinder head (page 7-18)
– starter motor (page 17-11)
– engine (page 6-8)

11-19
MEMO
12. FRONT WHEEL/SUSPENSION/STEERING

SYSTEM COMPONENTS ························· 12-2 FRONT WHEEL ········································· 12-9

SERVICE INFORMATION ························· 12-3 FORK ······················································· 12-13

TROUBLESHOOTING ······························· 12-5 STEERING STEM···································· 12-21

HANDLEBAR ············································· 12-6

12

12-1
FRONT WHEEL/SUSPENSION/STEERING
SYSTEM COMPONENTS
FRONT WHEEL/SUSPENSION/STEERING

26 N·m (2.7 kgf·m, 19 lbf·ft)

108 N·m (11.0 kgf·m, 80 lbf·ft)

27 N·m (2.8 kgf·m, 20 lbf·ft)

73.5 N·m (7.5 kgf·m, 54 lbf·ft)

31.5 N·m (3.2 kgf·m,

23 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

30 N·m (3.1 kgf·m, 22 lbf·ft)

9.8 N·m (1.0
kgf·m, 7.2 lbf·ft)

12-2
 FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
GENERAL
• Raise the front wheel off the ground by supporting the frame securely when servicing. A box or work stand is required
to support the motorcycle.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• Refer to for hydraulic brake system information (page 14-2).

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire pressure 100 kPa (1.00 kgf/cm2, 15 psi) –
Axle runout – 0.20 (0.008)
Wheel rim Radial – 2.0 (0.08)
runout Axial – 2.0 (0.08)
Wheel hub-to-rim distance 20.3 ± 1 (0.80 ± 0.04) –
Fork Spring free length 597.6 (23.53) 586 (23.1)
Tube runout – 0.20 (0.008)
Recommended fluid Honda Ultra Cushion Oil 10W or equiv- –
alent
Fluid level ’07 model 144 (5.7) –
After ’07 142 (5.6) –
Fluid capacity ’07 model 380 ± 2.5 cm3 (12.9 ± 0.08 US oz, 13.4 ± –
0.09 lmp oz)
After ’07 382 ± 2.5 cm3 (12.9 ± 0.08 US oz, 13.4 ± –
0.09 lmp oz)

TORQUE VALUES
Handlebar upper holder bolt 26 N·m (2.7 kgf·m, 19 lbf·ft)
Master cylinder holder bolt 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
Steering stem nut 108 N·m (11.0 kgf·m, 80 lbf·ft)
Steering bearing adjustment nut See page 12-24
Fork top bridge pinch bolt 27 N·m (2.8 kgf·m, 20 lbf·ft)
Fork bottom bridge pinch bolt 31.5 N·m (3.2 kgf·m, 23 lbf·ft)
Fork cap 23 N·m (2.3 kgf·m, 17 lbf·ft)
Fork socket bolt 20 N·m (2.0 kgf·m, 15 lbf·ft) Apply a locking agent to the threads.
Brake caliper mounting bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt: replace with a new one.
Front axle 73.5 N·m (7.5 kgf·m, 54 lbf·ft)
Front axle holder nut 12 N·m (1.2 kgf·m, 9 lbf·ft) U-nut.
Front brake disc bolt 20 N·m (2.0 kgf·m, 15 lbf·ft) ALOC bolt: replace with a new one.
Wheel hub cover screw 0.74 N·m (0.1 kgf·m, 0.5 lbf·ft)
Spoke nipple 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Rim lock nut 12.2 N·m (1.2 kgf·m, 9.0lbf·ft)
Brake hose clamp bolt 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
Clutch lever pivot bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Clutch lever pivot nut 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

12-3
FRONT WHEEL/SUSPENSION/STEERING
TOOLS
Attachment, 32 x 35 mm Attachment, 42 x 47 mm Pilot, 15 mm
07746-0010100 07746-0010300 07746-0040300

Bearing remover shaft Remover head, 15 mm Fork seal driver weight

07746-0050100 07746-0050400 07747-010100

Driver Stem socket wrench Ball race remover

07749-0010000 07916-KA50100 07944-1150001

Steering stem driver Fork seal driver attachment, Bearing race remover
07946-4300101 37 mm I.D. 07948-4630100
07747-0010600

or 07947-3710101

12-4
 FRONT WHEEL/SUSPENSION/STEERING
Spoke wrench, 5.8 x 6.1 mm
07701-0020300

TROUBLESHOOTING
Hard steering
• Steering bearing adjustment nut too tight
• Worn or damaged steering head bearings
• Worn or damaged steering head bearing races
• Bent steering stem
• Insufficient tire pressure
• Faulty front tire
Steers to one side or does not track straight
• Bent fork leg
• Damaged or loose steering head bearings
• Bent frame
• Worn wheel bearings
• Bent front axle
• Wheel installed incorrectly
• Worn swingarm pivot components (page 13-21)
Front wheel wobbles
• Bent rim
• Worm or damaged wheel bearings
• Faulty front tire
• Loose or broken spokes
• Loose front axle fasteners
Wheel turns hard
• Faulty wheel bearings
• Bent axle
• Brake drag (page 14-4)
Soft suspension
• Weak fork springs
• Low fluid level in fork
• Insufficient fluid weight (low viscosity)
• Low tire pressure
Hard suspension
• Bent fork tubes
• Fork slider binds
• High fluid level in fork
• Incorrect fluid weight (high viscosity)
• Clogged fork fluid passage
• High tire pressure
Front suspension noise
• Loose fork fasteners
• Worn slider or fork tube bushing
• Low fluid level in fork

12-5
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the following:
– breather hose
– four wire bands

HOSE

WIRE BANDS

– screw and washer SWITCH

– ground wire terminal
– switch clamps WIRE
– engine stop switch

CLAMPS

SCREW AND WASHER

– clutch switch connectors
LEVER BRACKET
– two screws
– bracket holder
– clutch lever bracket

HOLDER

CONNECTORS

Keep the reservoir – two bolts MASTER

upright to prevent – master cylinder holder CYLINDER
air from entering – brake master cylinder
the hydraulic sys- HOLDER
tem.

12-6
 FRONT WHEEL/SUSPENSION/STEERING
– two screws
SWITCH
– throttle housing cover
– two screws
– starter switch

HOUSING COVER
– four bolts
– handlebar upper holders
– handlebar
– throttle grip (from the handlebar) HANDLEBAR

HOLDERS

INSTALLATION

• Route the cables and wires properly (page 1-17).

Apply grease to the cable rolling area and sliding
surface of the throttle grip pipe flange.
Connect the throttle cables to the throttle grip pipe.
Apply grease to the cable slider sliding area.
Install the slider into the housing and attach it to the CABLES
cables.
Install the throttle grip over the handlebar.

GRIP

SLIDER

Align the punch Install the handlebar and upper holders with the
mark on the handle- punch marks facing forward. Tighten the front bolts
PUNCH MARKS
bar with the with first, then tighten the rear bolts.
the top edge of the HANDLEBAR
lower holder. TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft)

Align
HOLDERS

12-7
FRONT WHEEL/SUSPENSION/STEERING
Align the locating Install the starter switch. Tighten the front screw
pin on the switch first, then tighten the rear screw.
housing with the
hole in the handle-
bar.
SWITCH

Align

Place the throttle cables on the rolling surface of the

throttle grip pipe and set the throttle housing into
the grip pipe groove (page 12-7).

Align the seam of Install the throttle housing cover. Tighten the upper
the housing with screw first, then tighten the lower screw.
the punch mark on
the handlebar.

COVER

Align the edge of Install the brake master cylinder and holder with the MASTER
the master cylinder “UP” mark facing up. Tighten the upper bolt first, CYLINDER
with the punch then tighten the lower bolt.
mark on the handle-
bar. TORQUE: 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft) HOLDER

Align “UP”

Apply Honda Bond A to the inside surface of the left

handlebar grip and to the clean surfaces of the han-
dlebar. GRIP
Allow the adhesive Wait 3–5 minutes and install the grips. Rotate the
to dry for 1 hour grips for even application of the adhesive.
before using.

12-8
 FRONT WHEEL/SUSPENSION/STEERING
Align the edge of Install the clutch lever bracket and holder. Tighten
LEVER BRACKET
the bracket with the the front bolt first, then tighten the rear bolt.
punch mark on the
Connect the clutch switch connectors.
handlebar.

Align

HOLDER

CONNECTORS

Align the end of the Hook the clamps into the slits in the switch and
clamp with the install them onto the handlebar. Install the screw SWITCH SLIT
punch mark on the with the washer and wire terminal, and tighten it.
handlebar.
WIRE

SCREW AND
CLAMPS WASHER

Align

Secure the wires with the four wire bands.

Insert the breather hose into the steering stem.

HOSE

WIRE BANDS

FRONT WHEEL
REMOVAL
Loosen the axle holder nuts on the right fork leg and
loosen the front axle.
Raise the front wheel off the ground by placing a
HOLDER
work stand or box under the frame.
Do not operate the Remove the axle and the front wheel.
brake lever after
removing the
wheel. To do so will
cause difficulty in
fitting the brake
disc between the
brake pads.
NUTS
AXLE

12-9
FRONT WHEEL/SUSPENSION/STEERING
Remove the side collars.

COLLARS

INSPECTION
AXLE
Set the axle in V-blocks. Turn the axle and measure
the runout using a dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.20 mm (0.008 in)

WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the bear- Remove and discard the bearings if they do not turn
ings in pairs. smoothly, quietly, or if they fit loosely in the hub.

WHEEL RIM
Check the rim runout by placing the wheel in a tru-
ing stand.
Spin the wheel by hand, and read the runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Check the spokes and tighten any that are loose
(page 12-12).

12-10
 FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY
Remove the dust seals from both sides of the hub.
DISC
Remove the four bolts and brake disc.

DUST SEAL

Install the remover head into the bearing.

From the opposite side of the wheel, install the
remover shaft and drive the bearing out of the
wheel hub. REMOVER SHAFT
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 15 mm 07746-0050400
Bearing remover shaft 07746-0050100

REMOVER HEAD

ASSEMBLY

BEARING (6202)
DUST SEAL

BRAKE DISC

HUB COVER

DISTANCE COLLAR

BEARING
(6202) DUST SEAL

12-11
FRONT WHEEL/SUSPENSION/STEERING
WHEEL CENTER ADJUSTMENT
Adjust the hub position so that the distance from
the left end surface of the hub center to the side of
rim is 20.3 ± 1 mm (0.80 ± 0.04 in) as shown.
Tighten the spokes in 2 or 3 progressive steps. 20.3 ± 1 mm
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300

TORQUE: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)

Check the rim runout (page 12-10).

BASE POINT

Pack new bearing cavities with grease.

Drive in a new right side bearing (opposite the disc)
squarely with the sealed side facing up until it is
DRIVER
fully seated.
Install the distance collar.
Drive in a new left side (brake disc side) bearing
with the sealed side facing up until it is fully seated.
TOOLS:
Driver 07749-0010000 ATTACHMENT
Attachment, 32 x 35 mm 07746-0010100
Pilot, 15 mm 07746-0040300
PILOT

Do not get grease Install the brake disc with the stamp facing out. BOLTS
on the brake disc or Install new disc bolts and tighten them in a criss- DISC
stopping power will cross pattern in several steps.
be reduced.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)
Install the hub cover with the four washer-screws if
it was removed.
TORQUE: 0.74 N·m (0.1 kgf·m, 0.5 lbf·ft)

HUB COVER

Apply grease to new dust seal lips and install the

dust seals until they are flush with the wheel hub.
DUST SEAL

12-12
 FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Left side (disc side): Install the side collars.
flange collar /
Right side: longer COLLARS
than the left collar

Install the axle holder with the “UP” mark facing up

and loosely tighten the four holder nuts.
Apply thin coat of grease to the axle outer surface.
HOLDER
Be careful not to Place the front wheel between the fork legs so the
damage the pads. brake disc is positioned between the pads. Insert the
axle from the right side.
Tighten the axle.
“UP”
TORQUE: 73.5 N·m (7.5 kgf·m, 54 lbf·ft)

NUTS
AXLE

With the front brake applied, pump the forks up and

down several times to seat the axle and check the
brake operation.
Tighten the axle holder nuts.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

FORK
REMOVAL
Remove the front wheel (page 12-9).
CLAMPS
Support the caliper Remove the following (left fork only):
so it does not hang – two bolts and brake hose clamps
from the brake – two bolts and brake caliper
hose. Do not twist
the brake hose.

CALIPER

12-13
FRONT WHEEL/SUSPENSION/STEERING
When the fork is ready to be disassembled, loosen FORK CAP
the fork cap, but do not remove it.
Loosen the fork bottom bridge pinch bolts while
supporting the fork leg.
Pull the fork leg down and remove it out of the fork
bridges.
PINCH BOLTS

FORK

DISASSEMBLY
Loosen the boot band screw.
Release the boot off the fork slider groove and SCREW
remove it. BOOT

The fork cap is Remove the following:

under spring pres- – fork cap FORK CAP
sure; use care – O-ring (from the fork cap)
when loosening it.

– fork spring
Pour out the fork fluid by pumping the fork tube up
FORK SPRING
and down several times.

12-14
 FRONT WHEEL/SUSPENSION/STEERING
Hold the fork slider in a vise with soft jaws or shop
towels.
If the fork piston Remove the following:
turns with the – fork socket bolt
socket bolt, tempo- – sealing washer
rarily install the fork
spring and fork cap.

SOCKET BOLT
SOCKET BOLT/SEALING AND WASHER
WASHER

– fork piston
– rebound spring REBOUND SPRING

FORK PISTON

Be careful not to – dust seal

scratch the fork – stopper ring
tube.
STOPPER RING

DUST SEAL
Using quick successive motions, pull the fork tube
out of the fork slider.
The guide bushing will be forced out by the fork
tube bushing.
Remove the following:
– oil lock piece (from the fork slider)

FORK TUBE

12-15
FRONT WHEEL/SUSPENSION/STEERING
– oil seal
– back-up ring OIL SEAL
– guide bushing
GUIDE BUSHING
Do not remove the Carefully remove the fork tube bushing by prying
fork tube bushing the slit with a flat blade screwdriver until the bush-
unless it is neces- ing can be pulled off by hand.
sary to replace it
with a new one
(page 12-17).

BACK-UP RING

FORK TUBE BUSHING

INSPECTION
FORK SPRING
Measure the fork spring free length.
SERVICE LIMIT: 586 mm (23.1 in)

FORK TUBE/SLIDER/PISTON
Check the fork tube, slider, oil lock piece and fork OIL LOCK PIECE
piston for score marks, and excessive or abnormal FORK SLIDER
wear.
Check the fork piston ring for wear or damage. FORK TUBE
Check the rebound spring for fatigue or damage.
Replace any damaged component if necessary.

PISTON RING

FORK PISTON REBOUND SPRING

Set the fork tube in V-blocks and measure the fork

tube runout with a dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.20 mm (0.008 in)

12-16
 FRONT WHEEL/SUSPENSION/STEERING
BUSHINGS
Visually inspect the guide and fork tube bushings.
Replace the bushings if there is excessive scoring or
scratching, or if the teflon is worn so the copper sur-
face appears on more than 3/4 of the entire surface. BUSHING

Check the back-up ring; replace it if there is any dis-

tortion at the points shown. BACK-UP RING

Check points

COPPER SURFACES

ASSEMBLY
Before assembly, wash all parts with a high flash or
non-flammable solvent and wipe them off com-
pletely.

DUST SEAL FORK TUBE

STOPPER RING
FORK PISTON
OIL SEAL BOOT BAND
PISTON RING
BOOT FORK CAP
BACK-UP RING

GUIDE BUSHING O-RING

FORK SLIDER

FORK SPRING
SEALING
WASHER
FORK TUBE BUSHING

REBOUND SPRING
FORK SOCKET BOLT
OIL LOCK PIECE

Do not open the Install a new fork tube bushing if it has been
bushing more than removed. REBOUND SPRING
necessary.
FORK TUBE BUSHING
• Remove the burrs from the bushing mating sur-
face, being careful not to peel off the coating.
FORK SLIDER
Install the following:
– rebound spring (onto the fork piston)
– fork piston (into the fork tube)
– oil lock piece (onto the fork piston) FORK TUBE
Install the fork tube into the fork slider.
FORK PISTON

OIL LOCK PIECE

12-17
FRONT WHEEL/SUSPENSION/STEERING
Hold the fork slider in a vise with soft jaws or shop
towels.
If the fork piston Apply a locking agent to the fork socket bolt
turns with the threads.
socket bolt, tempo- Install the socket bolt with a new sealing washer
rarily install the fork and tighten it.
spring and fork cap
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

SOCKETWASHER
SOCKET BOLT/SEALING BOLT AND

Place the guide bushing over the fork tube and rest DRIVER
it on the slider. Put the back-up ring and an old WEIGHT
bushing or equivalent tool on the guide bushing. STOPPER RING
Drive the bushing into place, using the special tools.
Wrap vinyl tape around the fork tube top end to
avoid damaging the oil seal lip. OIL SEAL
Apply fork fluid to a new oil seal lip. Install the oil
seal with the marked side facing up. BACK-
Drive the oil seal until the stopper ring groove is vis- UP RING
ible.
GUIDE
TOOLS: BUSHING
Fork seal driver weight 07747-0010100
Driver attachment, 37 mm I.D. 07747-0010600 or ATTACHMENT
Fork seal driver, 37 mm I.D. 07947-3710101
Install the stopper ring into the groove in the fork
slider, being careful not to scratch the fork tube.
Coat a new dust seal with fork fluid and install it.
STOPPER RING

DUST SEAL

Pour the specified amount of recommended fork

fluid into the fork tube.
RECOMMENDED FORK FLUID:
Honda Ultra Cushion Oil 10W or equivalent

FORK FLUID CAPACITY:

’07 model:
380 ± 2.5 cm3 (12.9 ± 0.08 US oz, 13.4 ± 0.09 Imp oz)
After ’07:
382 ± 2.5 cm3 (12.9 ± 0.08 US oz, 13.4 ± 0.09 Imp oz)
Slowly pump the fork tube several times to remove
the trapped air from the lower portion of the fork
tube.

12-18
 FRONT WHEEL/SUSPENSION/STEERING
Compress the fork tube fully. Measure the oil level
from the top of the fork tube.

FORK OIL LEVEL: ’07 model: 144 mm (5.7 in)

After ’07: 142 mm (5.6 in)

OIL LEVEL

Pull the fork tube up and install the fork spring with
the tightly wound coil side facing down.

Down

Tighten the fork cap Coat a new O-ring with fork fluid and install it into FORK CAP
after installing the the fork cap groove.
fork tube into the Hold the fork cap securely and install it into the fork O-RING
fork bridges. tube, being careful not to cross-thread the cap.

Install the fork boot over the fork leg. Set the lower BAND
end into the boot groove in the slider. SCREW
BOOT
Tighten the band Install the boot band so the screw head is facing the
screw after install- outside when the band end is facing rearward.
ing the fork tube
into the fork
bridges.

12-19
FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Route the wires Install the fork tube into the bottom and top bridges.
and cables properly Align the top of the fork tube with the upper surface FORK CAP
(page 1-17). or the top bridge.
Tighten the bottom bridge pinch bolts. Align
TORQUE: 31.5 N·m (3.2 kgf·m, 23 lbf·ft)
Tighten the fork cap to the specified torque if it was
removed.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)
Tighten the fork top bridge pinch bolts.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)

PINCH BOLTS

Turn the fork boot so the air vent holes are facing SCREW
rearward.
Extend the boot and seat the upper end against the
bottom bridge firmly.
Tighten the band screw with the band ends toward
rear.

HOLES

Left fork only: Install the brake caliper with new mounting bolts
and tighten the bolts. CLAMPS
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)
Install the brake hose clamps and tighten the bolts.
TORQUE: 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
Install the following front wheel (page 12-13).

CALIPER

12-20
 FRONT WHEEL/SUSPENSION/STEERING
STEERING STEM
REMOVAL
Remove the following:
– front wheel (page 12-9)
– front fender (page 2-4)
– headlight (page 18-4) GUIDE
– bolt and throttle cable guide
– handlebar (page 12-6)

BOLT

Loosen the steering stem nut.

Remove the fork legs (page 12-13).

STEM NUT

WASHER
TOP BRIDGE
Remove the following:
– fork pinch bolts
– brake hose guides
– headlight stay GUIDES
Disconnect the ignition switch connectors (page 18- BOLTS
5).
Remove the stem nut and washer, and the top
bridge.

STAY

Loosen the steering bearing adjustment nut.

TOOL: SOCKET WRENCH
Stem socket wrench 07916-KA50100
While holding the steering stem, remove the adjust-
ment nut.

ADJUSTMENT NUT

12-21
FRONT WHEEL/SUSPENSION/STEERING
Remove the following:
– stem STEM
– dust seal
– upper steering bearing

DUST SEAL

UPPER BEARING

Always replace the Remove the upper and lower bearing outer races OIL SEAL REMOVER
bearings and races using the special tools.
as a set.
TOOL:
Ball race remover 07944-1150001
Bearing race remover 07948-4630100

BALL RACE REMOVER

Install the stem nut onto the stem to prevent the

threads from being damaged when removing the DUST SEAL
lower steering bearing.
Remove the bearing with a chisel or equivalent tool,
being careful not to damage the stem.
LOWER BEARING
Remove the dust seal.

NUT

12-22
 FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION

STEM NUT

ADJUSTMENT NUT
WASHER

UPPER DUST SEAL

TOP BRIDGE

UPPER STEERING BEARING

UPPER OUTER RACE

STEERING STEM

LOWER OUTER RACE

LOWER STEERING BEARING

LOWER DUST SEAL

• Use urea based multi-purpose grease with

extreme pressure agent for the steering bearings
STEM DRIVER
and dust seals.
Example: Excelite EP2 (Kyodo Yushi) or equivalent
Apply grease to a new lower dust seal lip and install
it over the steering stem.
Press a new lower steering bearing using a special
tool.
TOOL: BEARING
Steering stem driver 07946-4300101

DUST SEAL
(Apply grease)

Drive in new upper and lower bearing outer races

DRIVER
into the steering head pipe.
TOOL:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
ATTACHMENT

12-23
FRONT WHEEL/SUSPENSION/STEERING
Apply 3–5 g (0.1–0.2 oz) of grease to each new bear- STEM
ing and fill it up.
Apply grease to a new upper dust seal lip. DUST SEAL
Insert the steering stem into the steering head pipe, (Apply grease)
and install the following while holding the stem.
– upper steering bearing
– dust seal
– adjustment nut

LOWER BEARING UPPER BEARING

(Apply 3–5 g of grease) (Apply 3–5 g of grease)
Tighten the adjustment nut to the initial torque.
TOOL: SOCKET WRENCH
Stem socket wrench 07916-KA50100

TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft)

Turn the steering stem right and left, lock-to-lock
several times to seat the bearings.
Loosen the adjustment nut.

ADJUSTMENT NUT

Retighten the adjustment nut to the specified

torque. SOCKET WRENCH
TORQUE: 3.5 N·m (0.4 kgf·m, 2.6 lbf·ft)

Install the top bridge, washer and stem nut.

Temporarily install the fork legs into the bottom and
top bridges. STEM NUT WASHER
Tighten the stem nut.
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)
Make sure the steering stem moves smoothly with-
out play or binding.

TOP BRIDGE

FORK

12-24
 FRONT WHEEL/SUSPENSION/STEERING

Route the cables, Install the headlight stays and hose guides with the
wires and hose fork pinch bolts.
properly (page 1-
Install the fork legs properly (page 12-20).
17).
Keep the master Install the following: GUIDES
– front fender (page 2-4) BOLTS
cylinder reservoir
upright to prevent – front wheel (page 12-13)
air from entering – handlebar (page 12-7)
the hydraulic sys-
tem.

STAYS

Install the throttle cable guide and tighten the bolt. THROTTLE CABLES
Connect the ignition switch connectors (page 18-5).
Install the headlight (page 18-4). GUIDE

BOLT

12-25
MEMO
 13. REAR WHEEL/BRAKE/SUSPENSION

SYSTEM COMPONENTS ························· 13-2 REAR DRUM BRAKE ······························ 13-11

SERVICE INFORMATION ························· 13-3 BRAKE PEDAL ········································ 13-14

TROUBLESHOOTING ······························· 13-5 SHOCK ABSORBER/LINKAGE ·············· 13-16

REAR WHEEL ············································ 13-6 SWINGARM············································ 13-21

13

13-1
REAR WHEEL/BRAKE/SUSPENSION
SYSTEM COMPONENTS
REAR WHEEL/BRAKE/SUSPENSION

44 N·m (4.5 kgf·m, 32 lbf·ft)

88 N·m (9.0
kgf·m, 65 lbf·ft)
44 N·m (4.5
kgf·m, 32 lbf·ft)

44 N·m (4.5
kgf·m, 32 lbf·ft)

44 N·m (4.5 kgf·m,

78 N·m (8.0 32 lbf·ft)
kgf·m, 58 lbf·ft)

108 N·m (11.0 kgf·m, 80 lbf·ft)

13-2
 REAR WHEEL/BRAKE/SUSPENSION
SERVICE INFORMATION
GENERAL

Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

• Raise the rear wheel off the ground by supporting the frame securely when servicing. A box or work stand is required to
support the motorcycle.
• A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated
drum with a high quality brake degreasing agent.
• Use only genuine Honda replacement bolts and nuts for all suspension linkage and swingarm pivot mounting points;
ordinary bolts lack adequate strength for these applications. Also take note of the installation direction of these bolts
since they must be installed correctly.
• Refer to procedure for drive chain servicing (page 3-14).

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire pressure 100 kPa (1.00 kgf/cm2, 15 psi) –
Axle runout – 0.2 (0.01)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance 22.3 ± 1.0 (0.88 ± 0.04) –
Drive chain Size/link DID DID520V6/110 –
RK RK520SMOZ2/110 –
Slack 20 – 30 (3/4 – 1-1/4) –
Brake Pedal free play 20 – 30 (3/4 – 1-1/4) –
Drum I.D. 110.0 – 110.2 (4.33 – 4.34) 111 (4.4)
Lining thickness 4.2 (0.17) 2.0 (0.08)

TORQUE VALUES
Rear axle nut 108 N·m (11.0 kgf·m, 80 lbf·ft) U-nut
Driven sprocket nut 32 N·m (3.3 kgf·m, 24 lbf·ft) U-nut
Swingarm pivot nut 88 N·m (9.0 kgf·m, 65 lbf·ft) U-nut
Shock absorber mounting bolt (upper) 44 N·m (4.5 kgf·m, 32 lbf·ft)
Shock absorber mounting nut (lower) 44 N·m (4.5 kgf·m, 32 lbf·ft) U-nut
Shock arm-to-swingarm nut 78 N·m (8.0 kgf·m, 58 lbf·ft) U-nut
Shock arm-to-shock link nut 44 N·m (4.5 kgf·m, 32 lbf·ft) U-nut
Shock link-to-frame nut 44 N·m (4.5 kgf·m, 32 lbf·ft) U-nut
Drive chain slider screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) ALOC screw; replace with new one
Spoke nipple 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Rim lock nut 12.2 N·m (1.2 kgf·m, 9 lbf·ft)
Rear brake arm nut 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

13-3
REAR WHEEL/BRAKE/SUSPENSION
TOOLS
Bearing remover weight Driver Attachment, 37 x 40 mm
07741-0010201 07749-0010000 07746-0010200

Attachment, 42 x 47 mm Attachment, 24 x 26 mm Attachment, 22 x 24 mm

07746-0010300 07746-0010700 07746-0010800

Pilot, 17 mm Pilot, 20 mm Bearing remover shaft

07746-0040400 07746-0040500 07746-0050100

Remover head, 17 mm Needle bearing remover Bearing remover handle

07746-0050500 07931-MA70000 07936-3710100

or 07936-3710600

13-4
 REAR WHEEL/BRAKE/SUSPENSION
Bearing remover, 17 mm Driver Spoke wrench, 5.8 x 6.1 mm
07936-3710300 07949-3710001 07701-0020300

TROUBLESHOOTING
Rear wheel wobbles
• Bent rim
• Worn or damaged rear wheel bearings
• Faulty rear tire
• Loose or broken spokes
• Worn or damaged swingarm bearings
• Bent frame or swingarm
• Axle fastener not tightened properly
Wheel turns hard
• Brake drag
• Faulty wheel bearings
• Bent axle
• Drive chain too tight (page 3-14)
Soft suspension
• Weak shock absorber springs
• Oil leakage from damper unit
• Low tire pressure
Hard suspension
• Bent shock absorber damper rod
• Damaged suspension or swingarm pivot bearings
• Bent swingarm pivot or frame
• High tire pressure
Steers to one side or does not track straight
• Drive chain adjusters not adjusted equally
• Bent axle
• Bent frame
• Worn swingarm pivot components
• Wheel installed incorrectly
• Worn wheel bearings
Rear suspension noise
• Loose suspension fasteners
• Worn or damaged suspension pivot bearings
• Faulty shock absorber

13-5
REAR WHEEL/BRAKE/SUSPENSION
REAR WHEEL
REMOVAL
Disconnect the brake rod by removing the adjusting
nut, and remove the spring and joint pin. SPRING

Loosen the axle nut. ADJUSTING NUT

ROD

JOINT PIN

AXLE NUT
ADJUSTER
Raise the rear wheel off the ground by placing a
work stand or box under the frame.
Turn the drive chain adjusters so the wheel can be
AXLE
moved all the way forward. Move the wheel for
maximum chain slack.
Derail the drive chain from the driven sprocket.
Remove the following:
– axle nut
– left adjuster
– axle
– right adjuster
– rear wheel CHAIN
ADJUSTER

– brake panel BRAKE PANEL

– side collar

COLLAR

13-6
 REAR WHEEL/BRAKE/SUSPENSION
INSPECTION
AXLE
Set the axle in V-blocks. Turn the axle and measure
the runout using a dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.2 mm (0.01 in)

WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the bear- Remove and discard the bearings if they do not turn
ings in pairs. smoothly, quietly, or if they fit loosely in the hub.

WHEEL BEARING
WHEEL RIM
Check the rim runout by placing the wheel in a tru-
ing stand.
Spin the wheel by hand, and read the runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Check the spokes and tighten any that are loose
(page 13-9).

DRIVEN SPROCKET
Check the condition of the driven sprocket teeth.
Replace the sprocket if it is worn or damaged.

• If the driven sprocket requires replacement,

inspect the drive chain and drive sprocket. OK No good
• Never install a new drive chain on worn sprock-
ets or a worn chain on new sprockets. Both chain
and sprocket must be in good condition, or the
replacement chain or sprocket will wear rapidly.

13-7
REAR WHEEL/BRAKE/SUSPENSION
DISASSEMBLY
Remove the following:
– dust seal SPROCKET
– sprocket nuts and washers
– bolts
– driven sprocket DUST SEAL

Install the remover head into the bearing.

From the opposite side of the wheel, install the
bearing remover shaft and drive the bearing out of REMOVER SHAFT
the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 17 mm 07746-0050500
Bearing remover shaft 07746-0050100

REMOVER HEAD

ASSEMBLY

BEARING (6203)

DRIVEN SPROCKET

DISTANCE COLLAR

BEARING (6303)
DUST SEAL

13-8
 REAR WHEEL/BRAKE/SUSPENSION
WHEEL CENTER ADJUSTMENT
Adjust the hub position so that the distance from
the left end surface of the hub center to the side of
rim is 22.3 ± 1 mm (0.88 ± 0.04 in) as shown.
Tighten the spokes in 2 or 3 progressive steps. 22.3 ± 1 mm
(0.88 ± 0.04 in)
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300

TORQUE: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)

Check the rim runout (page 13-7). BASE POINT

Pack new bearing cavities with grease.

Drive in a new right side (brake drum side) bearing
squarely with the sealed side facing up until it is
fully seated.
DRIVER
TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 17 mm 07746-0040400
Install the distance collar. ATTACHMENT
Drive in a new left side (brake disc side) bearing
with the sealed side facing up until it is fully seated.
TOOLS: PILOT
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 17 mm 07746-0040400
Install the driven sprocket onto the hub. Install the SPROCKET
sprocket bolts and nut with the washers, and tighten
them.
DUST SEAL
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)
Apply grease to a new dust seal lips and install the
dust seal until it is flush with the wheel hub.

INSTALLATION
Do not get grease Install the brake panel into the wheel hub. BRAKE PANEL
on the brake drum
and shoe linings.

13-9
REAR WHEEL/BRAKE/SUSPENSION
Install the side collar.

COLLAR

Apply thin coat of grease to the axle outer surface.

Place the rear wheel in the swingarm by aligning
the brake panel groove with the swingarm boss.

Align

Install the left chain adjuster onto the axle. Insert the
axle from the left side through the swingarm and
wheel.
AXLE

CHAI
ADJUSTER

Install the right chain adjuster and axle nut.

Move the wheel forward and install the drive chain SPRING
over the driven sprocket. ADJUSTING NUT
Install the spring onto the brake rod and the joint
pin into the brake arm. Connect the brake rod to the
brake arm with the adjusting nut. ROD
Adjust the drive chain slack (page 3-14).
Adjust the brake pedal free play (page 3-20).
JOINT PIN

AXLE NUT
ADJUSTER

13-10
 REAR WHEEL/BRAKE/SUSPENSION
REAR DRUM BRAKE
REMOVAL
Remove the rear wheel and the brake panel (page
13-6).
INSPECTION
Measure the rear brake drum I.D.

SERVICE LIMIT: 111 mm (4.4 in)

Measure the brake lining thickness.

SERVICE LIMIT: 2.0 mm (0.08 in)

DISASSEMBLY
Always replace the Expand the brake shoes and remove them from the SHOES
brake shoes in brake panel.
pairs.
Remove the shoe springs from the brake shoes.

SPRINGS

13-11
REAR WHEEL/BRAKE/SUSPENSION
Remove the following:
– arm cover
– nut and bolt ARM COVER
– brake arm
– wear indicator
NUT
BRAKE ARM

INDICATOR BOLT

– brake cam
– lock washer
– dust seals BRAKE CAM

WASHER

ASSEMBLY
ARM COVER

BRAKE SHOES

BRAKE ARM

SHOE SPRINGS

WEAR INDICATOR

DUST SEALS

LOCK WASHER

BRAKE CAM

13-12
 REAR WHEEL/BRAKE/SUSPENSION
Pack new dust seal lips with grease. Install the dust
seals with the flat surface facing out until they are
seated.
LUG
Install the lock washer, aligning tabs with the lug on
the brake panel.

DUST SEALS

WASHER

Apply grease to the spindle groove in the brake

cam. Insert the brake cam through the washer and BRAKE CAM
brake panel.

Install the wear indicator by aligning the wide tooth

with the wide groove in the brake cam.
BRAKE CAM

INDICATOR

Align

Install the brake arm by aligning the punch marks.

Install the bolt from the punch mark side and
tighten the nut.
ARM COVER
TORQUE: 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
NUT
Install the arm cover over the brake arm as shown.

BRAKE ARM Align BOLT

13-13
REAR WHEEL/BRAKE/SUSPENSION
Apply grease to the anchor pin and brake cam slid-
ing surfaces. SPRINGS

Assemble the brake shoes and springs as shown.

Install the shoe assembly onto the brake panel. SHOES

Wipe any excess grease from the brake cam and

anchor pin.
Install the brake panel onto the hub, and then install
the rear wheel (page 13-9).

BRAKE PEDAL
REMOVAL
Remove the following:
– brake adjusting nut
– brake rod (from the joint pin) SPRING
– rod spring ADJUSTING NUT
– joint pin

ROD

JOINT

– pedal return spring

– cotter pin COTTER PIN
– washer
WASHER

SPRING

– brake pedal
– dust seals

BRAKE PEDAL

DUST SEALS

13-14
 REAR WHEEL/BRAKE/SUSPENSION
– cotter pin
– joint pin (to separate the brake rod and pedal) JOINT PIN
ROD

PEDAL

COTTER
PIN

INSTALLATION
Connect the brake rod to the pedal with the joint pin
and a new cotter pin. JOINT PIN
ROD

PEDAL

Align
COTTER
PIN

Apply grease to new dust seal lips. Install the dust

seals with the lip facing the swingarm side (same
direction).
Apply grease to the groove in the pedal pivot and
install the brake pedal.

PEDAL
DUST SEALS

Install the washer and a new cotter pin.

Install the return spring in the direction as shown. COTTER PIN

WASHER

SPRING

13-15
REAR WHEEL/BRAKE/SUSPENSION
Install the spring onto the brake rod and the joint
pin into the brake arm. Connect the brake rod to the SPRING
brake arm with the adjusting nut. ADJUSTING NUT
Adjust the brake pedal free play (page 3-20).
ROD

JOINT PIN

SHOCK ABSORBER/LINKAGE
REMOVAL
Raise the rear wheel off the ground by placing a
work stand or box under the frame and support the
swingarm.
Remove the chain slider screw and setting washer.
Pull the slider down to release the locating pin from
the swingarm.

CHAIN SLIDER

SCREW AND WASHER

Remove the following:
– shock arm-to-shock link nut and bolt
– lower mounting nut and bolt (shock absorber)
– shock arm-to-swingarm nut and bolt
– shock arm
– shock link-to-frame nut and bolt
– shock link

SHOCK LINK
SHOCK ARM

– upper mounting bolt

– shock absorber

SHOCK ABSORBER

13-16
 REAR WHEEL/BRAKE/SUSPENSION
– pivot collars
– dust seals

COLLARS
DUST SEALS

INSPECTION
Check the pivot collars and bearings for wear or
BEARINGS BEARINGS
damage.

COLLARS

Replace the shock Check the following:

absorber as an – damper rod for bend or damage.
assembly. – damper unit for leakage or other damage.
– bump rubber for wear or damage.
– bushing for wear or damage
If the shock absorber is replaced, refer to disposal BUMP RUBBER
procedure described on page 13-18.

BUSHING

DAMPER ROD

13-17
REAR WHEEL/BRAKE/SUSPENSION
SHOCK ABSORBER DISPOSAL
Center punch the damper case at the point from the
upper mounting hole is 40 mm (1.6 in) to the mark
the drilling point.
Wrap the shock absorber inside a plastic bag and
support it upright in a vise as shown.
Through the open end of the bag, insert a drill
motor with a sharp 2 – 3 mm (5/64 – 1/8 in) drill bit. 40 mm
(1.6 in)

• Do not use a dull drill bit which could cause

a build-up of excessive heat and pressure
inside the damper, leading to explosion and
severe personal injury.
• The shock absorber contains nitrogen gas
and oil under high pressure. Do not drill any
further down the damper case than the mea-
surement given above, or you may drill into
the oil chamber; oil escaping under high
pressure may cause serious personal injury.
• Always wear eye protection to avoid getting
metal shavings in your eyes when the gas
pressure is released. The plastic bag is only
intended to shield you from the escaping
gas.

Hold the bag around the drill motor and briefly run
the drill motor inside the bag; this will inflate the PLASTIC BAG
bag with air from the motor and help keep the bag
from the getting caught in the bit when you start.

SUSPENSION LINKAGE BEARING

REPLACEMENT
SHOCK LINK
Remove the needle bearings using the special tools.

TOOLS:
Bearing remover, 17 mm 07936-3710300 BEARING
Remover handle 07936-3710100 REMOVER
Remover weight 07741-0010201
REMOVER
WEIGHT

Apply grease to the needle rollers of new bearings.

DRIVER 6.0 ± 0.2 mm
Press in the bearing Carefully press each needle bearing in the pivot (0.24 ± 0.01 in)
with the marked until the depth from the link outer surface is 6.0 mm
side facing up. (0.24 in).
TOOLS:
Driver 07749-0010000
Attachment, 22 x 24 mm 07746-0010800
Pilot, 17 mm 07746-0040400

ATTACHMEN
T AND PILOT

13-18
 REAR WHEEL/BRAKE/SUSPENSION
SHOCK ARM
Press the needle bearings out of the shock arm
using the special tools. DRIVER
TOOLS:
Swingarm side:
Driver 07949-3710001
Attachment, 24 x 26 mm 07746-0010700
Pilot, 20 mm 07746-0040500
Shock Link and Shock Absorber side:
Driver 07949-3710001
Attachment, 22 x 24 mm 07746-0010800
Pilot, 17 mm 07746-0040400
ATTACHMEN
T AND PILOT

Apply grease to the needle rollers of new bearings.

Shock link side shown:
Press in the bearing Carefully press each needle bearing in the pivot
with the marked until the depth from the arm outer surface is 6.0 mm
side facing up. (0.24 in), using the same tools. 6.0 ± 0.2 mm
(0.24 ± 0.01 in)

INSTALLATION
Make sure the needle rollers in the bearings are in
position.
Apply grease to new dust seal lips. COLLARS
Install the dust seals with the flat surface facing out
until they are fully seated.
Install the pivot collars.
DUST SEALS

SHOCK ARM

COLLAR

DUST SEALS
SHOCK LINK

13-19
REAR WHEEL/BRAKE/SUSPENSION
Place the shock absorber into the frame. Install the
mounting bolt and tighten it.

TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

SHOCK ABSORBER

Insert all the pivot Install the shock arm in the swingarm.
bolts from the left Adjust the swingarm height and connect the shock
side. arm to the shock absorber.
Install the nuts and tighten them.
TORQUE:
Shock arm-to-swingarm:
78 N·m (8.0 kgf·m, 58 lbf·ft)
Shock absorber:
44 N·m (4.5 kgf·m, 32 lbf·ft)

Insert the pivot bolt Install the shock link in the frame. SHOCK ARM
from the left side.

Insert the pivot bolt Adjust the swingarm height and connect the shock
from the left side. link to the shock arm.
Install the nuts and tighten them.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

SHOCK LINK

Install the chain slider by inserting the locating pin

into the swingarm hole.
Secure the slider with the setting washer and a new
screw.
TORQUE: 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)

CHAIN SLIDER

SCREW AND WASHER

13-20
 REAR WHEEL/BRAKE/SUSPENSION
SWINGARM
REMOVAL
Remove the following:
– rear wheel (page 13-6)
– shock linkage (page 13-16)
Remove the brake pedal return spring. WHEEL

RETURN SPRING

LINKAGE

Remove the two bolts and chain guide.

CHAIN GUIDE

Remove the swingarm pivot nut and bolt, then

remove the swingarm from the frame.
PIVOT NUT
SWINGARM

BOLT

Remove the following:

– dust seal cap
– pivot collar SCREWS
– drive chain slider (by removing the screw and SEAL CAPS
setting washer) if necessary

DRIVE CHAIN SLIDER

CHAIN SLIDER

13-21
REAR WHEEL/BRAKE/SUSPENSION
Check the pivot collar and needle bearings for wear
BEARINGS
or damage.

COLLAR

PIVOT BEARING REPLACEMENT

Remove the pivot bearings using the special tool.
TOOL:
Needle bearing remover 07931-MA70000 BEARING REMOVER
or
Bearing remover, 20 mm 07936-3710600
Remover handle 07936-3710100
Remover weight 07741-0010201

Apply grease to the needle rollers of new bearings.

DRIVER
Press in the bearing Carefully press each needle bearing in the pivot 8 mm
with the marked until the depth from the pivot outer surface is 8 mm (0.3 in)
side facing up. (0.3 in).
TOOLS:
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Pilot, 20 mm 07746-0040500
ATTACHMEN
T AND PILOT

13-22
 REAR WHEEL/BRAKE/SUSPENSION
INSTALLATION
Install the drive chain slider by aligning the groove
with the lug and set the upper locating pin into the
hole in the swingarm.
Secure the upper side of the chain slider with the BEARING
setting washer and a new screw (secure the lower
side after installing the shock linkage).
TORQUE: 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
Make sure the needle rollers in the bearings are in COLLAR
position.

Pack the pivot with Install the pivot collar.

grease as shown.
Apply grease to new dust seal cap lips. Install the
seal caps over the pivot securely.

DRIVE CHAIN SLIDER

SCREWS PINS

SETTING WASHERS GROOVE

PIVOT COLLAR

DUST SEAL CAPS

Set the swingarm in the frame through the drive

chain and insert the pivot bolt from the left side.
Install the pivot nut and tighten it. PIVOT BOLT
TORQUE: 88 N·m (9.0 kgf·m, 65 lbf·ft) SWINGARM

NUT

13-23
REAR WHEEL/BRAKE/SUSPENSION
Install chain guide and tighten the bolts.

CHAIN GUIDE

Install the return spring in the direction as shown.

Install the following:
– shock linkage (page 13-19)
– rear wheel (page 13-9)

SPRING

13-24
 14. HYDRAULIC BRAKE

SYSTEM COMPONENTS ························· 14-2 BRAKE PAD/DISC ···································· 14-6

SERVICE INFORMATION ························· 14-3 MASTER CYLINDER ································· 14-9

TROUBLESHOOTING ······························· 14-4 BRAKE CALIPER ····································· 14-13

BRAKE FLUID REPLACEMENT/

AIR BLEEDING ·········································· 14-5

14

14-1
HYDRAULIC BRAKE
SYSTEM COMPONENTS
HYDRAULIC BRAKE

1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

34 N·m (3.5 kgf·m, 25 lbf·ft)

5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

22 N·m (2.2 kgf·m, 16 lbf·ft)

34 N·m (3.5 kgf·m, 25 lbf·ft)

5.4 N·m (0.6 kgf·m, 4.4 lbf·ft)

2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)

17.2 N·m (1.8 kgf·m,13 lbf·ft)

30 N·m (3.1 kgf·m,22 lbf·ft)

14-2
 HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid as they may not be compatible.
• Never allow contaminants (dirt, water, etc.) to enter an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always check brake operation before riding the motorcycle.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Specified brake fluid DOT 4 –
Brake disc thickness 3.0 ± 0.2 (0.12 ± 0.01) 2.5 (0.10)
Brake disc runout – 0.10 (0.004)
Master cylinder I.D. 12.700 (0.5000) –
Master piston O.D. 12.684 (0.4994) –
Caliper cylinder I.D. 27.000 (1.0630) –
Caliper piston O.D. 26.968 (1.0617) –

TORQUE VALUES
Caliper bleed valve 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
Master cylinder reservoir cap screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Pad pin 17.2 N·m (1.8 kgf·m, 13 lbf·ft)
Pad pin plug 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
Brake lever pivot bolt 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
Brake lever pivot nut 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)
Master cylinder holder bolt 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Caliper pin bolt A 22 N·m (2.2 kgf·m, 16 lbf·ft) Apply locking agent to the threads.
Brake caliper mounting bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt; replace with a new one.
Brake hose clamp bolt 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

14-3
HYDRAULIC BRAKE
TOOL
Snap ring pliers
07914-SA50001

TROUBLESHOOTING
Brake lever soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pad/disc
• Worn caliper piston seal
• Worn master cylinder piston cups
• Worn brake pad/disc
• Contaminated caliper
• Contaminated master cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Bent brake lever
Brake lever hard
• Clogged/restricted brake system
• Sticking/worn caliper piston
• Worn caliper piston seal
• Sticking/worn master cylinder piston
• Bent brake lever
Brake drags
• Contaminated brake pad/disc
• Misaligned wheel
• Badly worn brake pad/disc
• Warped/deformed brake disc
• Caliper not sliding properly
• Clogged/restricted fluid passage
• Sticking caliper piston

14-4
 HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Turn the handlebar until the reservoir is parallel to
SCREWS
the ground before removing the reservoir cap.
Remove the screws, reservoir cap and diaphragm.

RESERVOIR CAP
Connect a bleed hose to the caliper bleed valve.
BLEED VALVE
Loosen the bleed valve and pump the brake lever
until no more fluid flows out of the bleed valve.

BRAKE FLUID FILLING/AIR BLEEDING

Fill the master cylinder reservoir with DOT 4 brake
BRAKE BLEEDER
fluid from a sealed container.
Connect a commercially available brake bleeder to
the bleed valve.
If air enters the Operate the brake bleeder and loosen the bleed
bleeder from valve.
around the bleed
If an automatic refill system is not used, add fluid
valve threads, seal
when the fluid level in the reservoir is low.
the threads with
teflon tape. Perform the bleeding procedure until the system is
completely flushed/bled.
Close the bleed valve and operate the brake lever. If
it still feels spongy, bleed the system again.

If the brake bleeder is not available, perform the fol-

lowing procedure. BLEED VALVE

Pump up the system pressure with the brake lever

until the lever resistance is felt.
Connect a bleed hose to the bleed valve and bleed
the system as follows:
Do not release the 1. Squeeze the brake lever all the way and loosen
brake lever until the the bleed valve 1/2 of a turn. Wait several sec-
bleed valve has onds and then close the bleed valve.
been closed.
2. Release the brake lever slowly and wait several
seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.

14-5
HYDRAULIC BRAKE
After bleeding the system completely, tighten the
bleed valve.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
Fill the reservoir to the casting ledge with DOT 4
CASTING LEDGE
brake fluid from a sealed container.

Install the diaphragm and reservoir cap, and tighten

SCREWS
the screws.
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

RESERVOIR CAP

BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Check the fluid Push the caliper pistons all the way in by pushing
level in the master the caliper body inward to allow installation of new
cylinder reservoir as brake pads.
this operation
causes the fluid
level to rise.

CALIPER BODY

14-6
 HYDRAULIC BRAKE
Remove the pad pin plug.

PAD PIN PLUG

Remove the pad pin.

PAD PIN
Remove the pad pin and the brake pads.
Make sure the pad spring is installed in position.

BRAKE PADS
Install new pads so that their ends rest on the pad
retainer on the caliper bracket properly. PAD RETAINER

14-7
HYDRAULIC BRAKE
Install the pad pin by pushing the pads against the
pad spring to align the pad pin holes in the pads
and caliper.
Tighten the pad pin.
TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft)

PAD PIN

Install and tighten the pad pin plug.

TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
Operate the brake lever to seat the caliper pistons
against the pads.

PAD PIN PLUG

BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness at several points.
SERVICE LIMIT: 2.5 mm (0.10 in)
Replace the brake disc if the smallest measurement
is less than service limit.

Check the brake disc for warpage.

SERVICE LIMIT: 0.10 mm (0.004 in)
Check the wheel bearings for excessive play, if the
warpage exceeds the service limit.
Replace the brake disc if the wheel bearings are nor-
mal.

14-8
 HYDRAULIC BRAKE
MASTER CYLINDER
DISASSEMBLY
Drain the brake fluid from the hydraulic system SEALING WASHERS
(page 14-5).
Disconnect the brake hose by removing the oil bolt
and sealing washers.

OIL BOLT
Remove the master cylinder holder bolts, holder
MASTER HOLDER
and master cylinder.
CYLINDER

BOLTS
Remove the dust cover from the brake lever.
DUST COVER

Remove the pivot nut, bolt, brake lever and spring.

PIVOT BOLT

BRAKE LEVER

SPRING NUT

14-9
HYDRAULIC BRAKE
Remove the boot from the master cylinder and mas-
ter piston. BOOT

Remove the snap ring using the special tool.

SNAP RING
TOOL:
Snap ring pliers 07914-SA50001

SNAP RING PLIERS

Remove the master piston and spring.

Clean the master cylinder, reservoir and master pis-
ton in clean brake fluid.

MASTER PISTON

SPRING
INSPECTION
Check the master piston for scoring, scratches or
MASTER PISTON
damage.
Check the piston cups for wear, deterioration or
damage.

PISTON CUPS

14-10
 HYDRAULIC BRAKE
Check the master cylinder for scoring, scratches or
damage.

MASTER CYLINDER
ASSEMBLY

SNAP RING
PIVOT BOLT
MASTER PISTON
BOOT
MASTER CYLINDER
SPRING

BRAKE LEVER

LEVER SPRING PIVOT NUT

DUST COVER

Coat the master piston and piston cups with clean

MASTER CYLINDER
DOT 4 brake fluid.
Install the spring onto the piston end.
SPRING
Do not allow the Install the spring and master piston into the master
piston cup lips to cylinder.
turn inside out.
CUPS

MASTER PISTON

14-11
HYDRAULIC BRAKE
Be certain the snap Install the snap ring into the groove in the master
ring is firmly seated cylinder. SNAP RING
in the groove.
TOOL:
Snap ring pliers 07914-SA50001

SNAP RING PLIERS

Install the boot into the master cylinder and the

groove in the master piston BOOT
Apply silicone grease to the brake lever-to-master
piston contact area.

Instal the brake lever spring and lever.

LEVER SPRING

BRAKE LEVER
Apply silicone grease to the brake lever pivot bolt
sliding surface.
Install the pivot bolt and tighten it. PIVOT BOLT
TORQUE:
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
Install the pivot nut and tighten it.
TORQUE: 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

PIVOT NUT

14-12
 HYDRAULIC BRAKE
Install the dust cover to the brake lever.
DUST COVER

Install the master cylinder and the holder with the

MASTER HOLDER
“UP” mark facing up.
CYLINDER
Align the end of the master cylinder with the punch
mark on the handlebar, and tighten the upper bolt “UP” MARK
first, then tighten the lower bolt.
TORQUE: 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

PUNCH MARK

BOLTS

Rest the brake hose joint between the stoppers on

the master cylinder. SEALING WASHERS
Connect the brake hose with the oil bolt and new
sealing washers, and tighten the oil bolt.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
Fill and bleed the hydraulic system (page 14-5).

HOSE JOINT OIL BOLT

BRAKE CALIPER
DISASSEMBLY
Drain the brake fluid from the hydraulic system
MOUNTING BOLTS OIL BOLT
(page 14-5).
Remove the brake pads (page 14-6).
Disconnect the brake hose from the brake caliper by
removing the oil bolt and sealing washer.
Remove the two mounting bolts and brake caliper.

SEALING WASHERS

14-13
HYDRAULIC BRAKE
Remove the caliper bracket from the caliper body.
CALIPER BRACKET CALIPER PIN BOOT
Remove the caliper pin boot and pad retainer from
the caliper bracket.
Remove the pad spring and bracket pin boot from
the caliper body.

RETAINER

PAD SPRING BRACKET PIN BOOT

Place a shop towel over the pistons.
Do not use high Position the caliper body with the pistons down and
pressure air or bring apply small squirts of air pressure to the fluid inlet
the nozzle too close to remove the pistons.
to the inlet.

Be careful not to Push the dust and piston seals in and lift them out.
damage the piston
PISTON SEALS
Clean the seal grooves, caliper cylinders and pis-
sliding surface.
tons with clean brake fluid.

DUST SEALS
INSPECTION
Check the caliper cylinder for scoring, scratches or
damage.

14-14
 HYDRAULIC BRAKE
Check the caliper pistons for scoring, scratches or
damage.

ASSEMBLY

CALIPER PIN BOOT CALIPER PIN BOLT A

CALIPER BRACKET BLEED VALVE

DUST SEAL PISTON SEAL

REATAINER

CALIPER BODY

CALIPER PISTONS BRACKET PIN BOOT

PAD PIN
BRAKE PADS PAD SPRING PAD PIN PLUG

Coat new piston and dust seals with clean brake

fluid and install them into the seal grooves in the
caliper cylinder.
SEALS
Coat the caliper pistons with clean brake fluid and
install them into the caliper cylinders with the open-
ing sides toward the pads.

PISTONS

14-15
HYDRAULIC BRAKE
Install the pad spring onto the caliper body as
CALIPER BRACKET
shown. BOOTS
Apply silicone grease to the insides of new pin
boots, and install them into the caliper body and
bracket.
Install the pad retainer onto the caliper bracket.
Install the caliper bracket to the caliper body.

RETAINER

PAD SPRING
Install the brake caliper onto the left fork leg.
MOUNTING BOLTS OIL BOLT
Install new mounting bolts and tighten them.
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)
Connect the brake hose to the brake caliper with the
oil bolt and new sealing washers.
Rest the hose joint onto the stopper and tighten the
oil bolt.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
Install the brake pads (page 14-6).
Fill and bleed the hydraulic system (page 14-5).

SEALING WASHERS

14-16
 15. BATTERY/CHARGING SYSTEM

COMPONENT LOCATION ························ 15-2 CHARGING SYSTEM INSPECTION········· 15-6

SYSTEM DIAGRAM·································· 15-2 HEADLIGHT VOLTAGE INSPECTION ····· 15-7

SERVICE INFORMATION ························· 15-3 REGULATOR/RECTIFIER ························· 15-8

TROUBLESHOOTING ······························· 15-5 ALTERNATOR COIL ································· 15-8

BATTERY··················································· 15-6

15

15-1
BATTERY/CHARGING SYSTEM
COMPONENT LOCATION
BATTERY/CHARGING SYSTEM

REGULATOR/RECTIFIER

FUSE 7.5 A

ALTERNATOR BATTERY

SYSTEM DIAGRAM

15-2
 BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
GENERAL

• The battery gives off explosive gases; keep sparks, flames and 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.
– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician
immediately.

• Always turn OFF the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is ON and current is present.
• This model comes with a maintenance free (MF) battery. The maintenance free battery must be replaced when it
reaches the end of its service life.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• The battery sealing caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.
• The maintenance free battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for a long period. These same con-
ditions contribute to shortening the life span of the battery. Even under normal use, the performance of the battery
deteriorates after 2–3 years.
• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventu-
ally die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results
from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is
shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these
conditions, the electrolyte level goes down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to
prevent sulfation from occurring.
• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,
always charge the battery. Also, the battery life is lengthened when it is initially charged.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 15-5).
• Refer to the procedures for alternator removal and disassembly (page 10-5).
BATTERY CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• For battery charging, do not exceed the charging current and time specified on the battery. Use excessive current or
extending the charging time may damage the battery.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instruction in the Operation Manual for the recommended battery tester for details about battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
Recommended battery tester BM-210 or equivalent

15-3
BATTERY/CHARGING SYSTEM
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 4 Ah or 5 Ah
Current leakage 0.1 mA max.
Voltage Fully charged 13.0 – 13.2 V
(20°C/68°F) Needs Below 12.3 V
charging
Charging current Normal 0.5 A/5 – 10 h
Quick 5.0 A/0.5 h
Alternator Capacity 60 W/5,000 min-1 (rpm)
Charging coil resistance (20°C/68°F) 0.5 – 1.2 Ω
Lighting coil resistance (20°C/68°F) 0.1 – 1.0 Ω

15-4
 BATTERY/CHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery (page 15-6).
Check the battery condition using the recommended battery tester.
RECOMMENDED BATTERY TESTER: BM-210 or equivalent
Is the battery in good condition?
NO – Faulty battery.
YES – GO TO STEP 2.
2. CURRENT LEAKAGE TEST
Install the battery (page 15-6).
Check the battery current leakage test (Leak test; page 15-6).
Is the current leakage below 0.1 mA?
YES – GO TO STEP 4.
NO – GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIRE CONNECTOR
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Is the current leakage below 0.1 mA?
YES – Faulty regulator/rectifier
NO – • Shorted wire harness
• Faulty engine stop switch
4. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter (page 15-6).
Start the engine.
Measure the charging voltage (page 15-7).
Compare the measurements to the results of the following calculation.
STANDARD: Measured BV < Measured CV < 15.5 V
BV: Battery Voltage
CV: Charging Voltage
Is the measured charging voltage within the standard voltage?
YES – Faulty battery
NO – GO TO STEP 5.
5. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier connector (page 15-8).
Are the measurements correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related wire
• Loose or poor contacts of related terminal
• Shorted wire harness

15-5
BATTERY/CHARGING SYSTEM
BATTERY
REMOVAL/INSTALLATION
Remove the left side cover (page 2-3). POSITIVE CABLE
Remove the battery holder plate. NEGATIVE CABLE

Disconnect the negative (–) cable and then the posi-

tive (+) cable, and remove the battery.
Connect the posi- Install the battery in the reverse order of removal.
tive terminal first
After installing the battery, coat the terminals with
and then the nega-
clean dielectric grease.
tive cable.

HOLDER PLATE

VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE: (+)
Fully charged: 13.0 – 13.2 V
Under charged: Below 12.3 V

(–)

CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE INSPECTION
Remove the left side cover (page 2-3).
(–) PROBE
With the ignition switch turned to “OFF”, discon-
nect the negative (–) cable from the battery.
Connect the ammeter (+) probe to the negative (–)
cable and the ammeter (–) probe to the battery (–)
terminal.
With the ignition switch turned to “OFF”, check for
current leakage.

• When measuring current using a tester, set it to a

high range, and then bring the range down to an (–) TERMINAL
appropriate level. Current flow higher than the
range selected may blow the fuse in the tester.
• While measuring current, do not turn the ignition (–) CABLE (+) PROBE
switch to “ON”. A sudden surge of current may
blow the fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 0.1 mA max.
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one
by one and measuring the current.

15-6
 BATTERY/CHARGING SYSTEM
CHARGING VOLTAGE INSPECTION
Remove the left side cover (page 2-3).
Be sure the battery is in good condition before per-
forming this test. (+)
Warm up the engine to normal operating tempera-
ture.
Connect the multimeter between the battery posi-
tive (+) and negative (–) terminals.
(–)

• To prevent a short, make absolutely certain

which are the positive (+) and negative (–) termi-
nals or cables.
• Do not disconnect the battery or any cable in the
charging system without first turning the ignition
switch to “OFF”. Failure to follow this precaution
can damage the tester or electrical components.
Measure the voltage on the multimeter when the
engine runs at 5,000 min-1 (rpm).
STANDARD: Measured BV < Measured CV < 15.5 V
BV = Battery Voltage (page 15-6)
CV = Charging Voltage

HEADLIGHT VOLTAGE INSPECTION

Warm up the engine to normal operating tempera-
ture.
Remove the fuel tank (page 2-5). Blue (+)

Connect the fuel tank to the carburetor with a suit-

able fuel hose.
Select the AC range With the connectors connected, Connect the
on the multimeter. multimeter (+) probe to the Blue wire terminal and
the (–) probe to the Green wire terminal.
Start the engine, gradually increase the engine
speed and measure the voltage.
REGULATED VOLTAGE:
12.6 – 13.6 V/5,000 min-1 (rpm) Green (–)
If the voltage is abnormal, check the lighting and
ground lines (page 15-8).

15-7
BATTERY/CHARGING SYSTEM
REGULATOR/RECTIFIER
SYSTEM INSPECTION
Remove the fuel tank (page 2-5).
Disconnect the regulator/rectifier 4P connector, and
check it for loose contacts or corroded terminals.
Check the following at the wire harness side con-
nector. If the charging voltage reading is out of the
specification (page 15-7).
Item Terminal Specification
Battery Red (+) Battery voltage
charging and should register
line ground (-)
Charging coil White and 0.5 – 1.2 Ω
line* ground at (20°C/68°F)
Lighting coil Blue and 0.1 – 1.0 Ω 4P CONNECTOR
line* ground at (20°C/68°F)
Ground line Green and Continuity
ground should exist
* Disconnect the headlight (Blue) wire connector (located
in the connector boot) when checking these lines.

If all lines are normal and there are no loose connec-

tions at the regulator/rectifier connector, replace the
regulator/rectifier unit.

REMOVAL/INSTALLATION
Remove the fuel tank (page 2-5).
REGULATOR/RECTIFIER
Disconnect the alternator 4P connector.
Remove the bolt and regulator/rectifier from the
frame.
Install the regulator/rectifier in the reverse order of
removal.

4P CONNECTOR BOLT

ALTERNATOR COIL
INSPECTION
Remove the left side cover (page 2-3).
4P CONNECTOR
Disconnect the alternator 4P connector.
Measure the resistance between each wire terminal
of the alternator side connector and ground.
STANDARD (20°C/68°F):
Charging coil (White): 0.5 – 1.2 Ω
Lighting coil (Yellow): 0.1 – 1.0 Ω
Replace the alternator stator if resistance is out of
specification.
Refer to the procedure for alternator stator replace-
ment (page 10-5).

15-8
 16. IGNITION SYSTEM

COMPONENT LOCATION ························ 16-2 IGNITION SYSTEM INSPECTION············ 16-5

SYSTEM DIAGRAM·································· 16-2 IGNITION TIMING ···································· 16-8

SERVICE INFORMATION ························· 16-3 IGNITION COIL ········································· 16-9

TROUBLESHOOTING ······························· 16-4 ICM (IGNITION CONTROL MODULE) ····· 16-9

16

16-1
IGNITION SYSTEM
COMPONENT LOCATION
IGNITION SYSTEM

IGNITION SWITCH

ENGINE STOP SWITCH

IGNITION COIL

SPARK PLUG

IGNITION CONTROL
MODULE (ICM)

IGNITION PULSE GENERATOR

ALTERNATOR

SYSTEM DIAGRAM

16-2
 IGNITION SYSTEM
SERVICE INFORMATION
GENERAL

• The Ignition Control Module (ICM) may be damaged if dropped. Also, if the connector is disconnected when current is
flowing, the excessive voltage may damage the ICM. Always turn the ignition switch to OFF before servicing.
• Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
• When servicing the ignition system, always follow the steps in the troubleshooting sequence on (page 16-4).
• The ignition timing cannot be adjusted since the ICM is factory preset.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine
cranking speed as well as no spark at the spark plug.

SPECIFICATION
ITEM SPECIFICATION
Spark plug Standard DPR8EA-9 (NGK) X24EPR-U9 (DENSO)
For cold climate (below 5°C/41°F) DPR7EA-9 (NGK) X22EPR-U9 (DENSO)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil peak voltage 70 V minimum
Alternator exciter coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing “F” mark 12° BTDC at idle

TORQUE VALUES
Timing hole cap 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
Crankshaft hole cap 8 N·m (0.8 kgf·m, 5.9 lbf·ft)

TOOL
Peak voltage adaptor
07HGJ-0020100

with commercially available digital

multimeter (impedance 10 MΩ/min-
imum)
or Imrie diagnostic tester (model
625)

16-3
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system.
– Faulty spark plug
– Loose spark plug cap or spark plug wire
– Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
No spark at plug
Unusual condition Probable cause (check in numerical order)
Ignition coil Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/
primary DCV.
voltage 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling time of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Poorly connected connectors or an open circuit in the
ignition system.
5. Faulty exciter coil. (Measure the peak voltage.)
6. Faulty ignition coil.
7. Faulty ignition control module (ICM) (in case when
above No. 1 – 6 are normal).
No peak voltage. 1. Incorrect peak voltage adaptor connections.
2. Short circuit in the Black/white wire.
3. Faulty ignition switch or engine stop switch.
4. Loose or poorly connected ICM connectors.
5. Open circuit or poor connection in the green wire of
the ICM.
6. Faulty peak voltage adaptor.
7. Faulty exciter coil. (Measure the peak voltage).
8. Faulty ignition pulse generator. (Measure the peak volt-
age.)
9. Faulty ICM (in case when above No.1 – 8 are normal).
Peak voltage is normal, but no spark 1. Faulty spark plug or leaking ignition coil secondary cur-
jumps at the plug. rent.
2. Faulty ignition coil.
Exciter coil Low peak voltage. 1. The multimeter impedance is too low.
2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling time of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Faulty exciter coil (in case when above No.1 – 3 are
normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty exciter coil.
Ignition pulse Low peak voltage. 1. The multimeter impedance is too low.
generator 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling time of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Faulty ignition pulse generator (in case when above
No.1 – 3 are normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty ignition pulse generator.

16-4
 IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark at the plug, check all connec-
tions for loose or poor contact before measuring
the peak voltage.
• Use a commercially available digital multimeter
with an impedance of 10 MΩ/DCV minimum.
• The display value differs depending upon the
internal impedance of the multimeter.
• If using the Imrie diagnostic tester (model 625),
follow the manufacturer’s instructions.
Connect the peak voltage adaptor to the digital mul-
timeter, or use the Imrie diagnostic tester. DIGITAL MULTIMETER

TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)

PEAK VOLTAGE ADAPTOR

IGNITION COIL PRIMARY PEAK VOLTAGE

• Check all system connections before this inspec-

tion. Poor connected connectors can cause incor-
rect readings.
• Check the cylinder compression and check that
the spark plug is installed correctly in the cylin-
der head.
Remove the fuel tank (page 2-5).
Disconnect the spark plug cap from the spark plug.
Connect a known good spark plug to the spark plug
cap and ground it to the cylinder head as done in a
spark test.

GOOD KNOWN SPARK PLUG

With the ignition coil primary wire connected, con-
nect the peak voltage tester or adaptor probes to the IGNITION COIL
ignition coil primary terminal and body ground.
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum) (–) (+)

CONNECTION:
Black/yellow wire terminal (–) – Body ground (+)
Shift the transmission into neutral.
Turn the ignition switch to “ON”.

16-5
IGNITION SYSTEM
Crank the engine with the starter motor and read
ignition coil primary peak voltage.
PEAK VOLTAGE: 70 V minimum
If the peak voltage is lower than the standard value,
follow the checks described in the troubleshooting
chart (page 16-4).

ALTERNATOR EXCITER COIL PEAK

VOLTAGE

• Check the cylinder compression and check that

the spark plug is installed correctly in the cylin-
der head.
Disconnect the ignition control module (ICM) 2P and
Black/red 2P CONNECTOR
4P connectors.
Connect the peak voltage tester or adaptor probes
to the exciter coil wire terminal of the 2P connector
and body ground.
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)

CONNECTION:
Black/red wire terminal (+) – Body ground (–)
Shift the transmission into neutral.
Turn the ignition switch to “ON”.
Crank the engine with the starter motor and read
exciter coil peak voltage.
PEAK VOLTAGE: 100 V minimum
If the peak voltage measured at the ICM connector is
abnormal, measure the peak voltage at the alterna-
tor exciter coil connector.
Remove the left side cover (page 2-3).
EXCITER COIL CONNECTOR (Black/red)
Disconnect the alternator exciter coil connector
(Black/red) and connect the tester probes to the
alternator exciter coil side connector terminal and
body ground. (+)
In the same manner as at the ICM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnor-
mal and the one measured at the alternator
exciter coil is normal, the wire harness has an
open or short circuit, or loose connection. (–)
• If both peak voltages are abnormal, follow the
checks described in the troubleshooting chart
(page 16-4).
Refer to procedure for alternator stator replacement
(page 10-5).

16-6
 IGNITION SYSTEM
IGNITION PULSE GENERATOR PEAK
VOLTAGE

• Check the cylinder compression and check that

the spark plug is installed correctly in the cylin-
der head.
Disconnect the ICM 2P and 4P connectors.
Blue/yellow
Connect the peak voltage tester or adaptor probes
to the ignition pulse generator wire terminal of the
4P connector and body ground.
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)

CONNECTION:
Blue/yellow wire terminal (+) – Body ground (–)
Shift the transmission into neutral. 4P CONNECTOR
Turn the ignition switch to “ON”.
Crank the engine with the starter motor and read
ignition pulse generator peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ICM connector is
abnormal, measure the peak voltage at the alterna-
tor connector.
Remove the left side cover (page 2-3).
PULSE GENERATOR CONNECTOR (Blue/yellow)
Disconnect the ignition pulse generator connector
(Blue/yellow) and connect the tester probes to the
pulse generator side connector terminal and body
ground.
In the same manner as at the ICM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnor-
mal and the one measured at the ignition pulse
generator is normal, the wire harness has an
open or short circuit, or loose connection.
• If both peak voltages are abnormal, follow the
checks described in the troubleshooting chart
(page 16-4).
Refer to procedure for alternator stator replacement
(page 10-5).

16-7
IGNITION SYSTEM
IGNITION TIMING
Warm up the engine.
TIMING HOLE CAP
Stop the engine and remove the timing hole cap.

Read the instruc- Connect a timing light to the spark plug wire.
TIMING LIGHT
tions for timing light
Start the engine and let it idle.
operation.
IDLE SPEED:
U type: 1,400 ± 100 min-1 (rpm)
BR type: 1,500 ± 100 min-1 (rpm)

The ignition timing is correct if the “F” mark on the

flywheel aligns with the index mark on the left INDEX MARK
crankcase cover.

“F” MARK

Coat a new O-ring with engine oil and install it onto

the timing hole cap. O-RING
Install the timing hole cap and tighten it.
TORQUE: 6 N·m (0.6 kgf·m, 4.4 lbf·ft)

TIMING HOLE CAP

16-8
 IGNITION SYSTEM
IGNITION COIL
REMOVAL/INSTALLATION
Remove the fuel tank (page 2-5).
PRIMARY WIRE IGNITION COIL
Disconnect the spark plug cap from the spark plug.
Remove the bolts, ground terminal and ignition coil.
Disconnect the primary wire connector from the
ignition coil.
Installation is in the reverse order of removal.

GROUND WIRE BOLTS

ICM (IGNITION CONTROL MODULE)

REMOVAL/INSTALLATION
Remove the headlight without disconnecting the
bulb socket (page 18-4). IGNITION CONTROL
MODULE
Disconnect the ICM 4P and 2P connectors.
Remove the ICM from the bracket.
Installation is in the reverse order of removal.

CONNECTORS

16-9
MEMO
 17. ELECTRIC STARTER

COMPONENT LOCATION ························ 17-2 STARTER MOTOR (’07 model)················ 17-6

SYSTEM DIAGRAM·································· 17-2 STARTER MOTOR (After ’07) ················ 17-12

SERVICE INFORMATION ························· 17-3 STARTER RELAY SWITCH····················· 17-19

TROUBLESHOOTING ······························· 17-4

17

17-1
ELECTRIC STARTER
COMPONENT LOCATION
ELECTRIC STARTER

IGNITION SWITCH STARTER SWITCH

CLUTCH SWITCH
STARTER MOTOR

BATTERY

NEUTRAL SWITCH
STARTER RELAY SWITCH

SYSTEM DIAGRAM

17-2
 ELECTRIC STARTER
SERVICE INFORMATION
GENERAL

If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
• When checking the starter system, always follow the steps in the troubleshooting (page 17-4).
• The starter motor can be serviced with the engine in the frame.
• Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing seri-
ous injury.
• Refer to procedure for starter clutch (page 10-7).
• Refer to information for ignition switch (page 18-4).
• Refer to inspection for engine stop switch (page 18-5).
• Refer to inspection for clutch switch (page 18-6).
• Refer to inspection for starter switch (page 18-6).
• Refer to inspection for neutral switch (page 18-7).

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Starter motor brush length ’07 model 12.5 (0.49) 9.0 (0.35)
After ’07 12.0 (0.47) 6.5 (0.26)

17-3
ELECTRIC STARTER
TROUBLESHOOTING
Starter motor does not turn
1. Fuse Inspection
Check for blown fuse (7.5 A).
Is the fuse blown?
YES – Replace the fuse.
NO – GO TO STEP 2.
2. Battery Inspection
Make sure the battery is fully charged and in good condition.
Is the battery in good condition?
YES – GO TO STEP 3.
NO – Charge or replace the battery (page 15-5).
3. Battery Cable Inspection
Check the battery cables for loose or poorly connected terminal, and for an open circuit.
Is the battery cable in good condition?
YES – • Loose or poorly connected battery cables.
• Open circuit in the battery cable.
NO – GO TO STEP 4.
4. Starter Motor Cable Inspection
Check the starter motor cable for loose or poorly connected terminal, and for an open circuit.
Is the loose or poorly?
YES – • Loose or poorly connected starter motor cable.
• Open circuit in the starter motor cable.
NO – GO TO STEP 5.
5. Starter Relay Switch Operation Inspection
Check the operation of the starter relay switch (page 17-19).
Does the starter relay switch click?
YES – GO TO STEP 6.
NO – GO TO STEP 7.
6. Starter Motor Inspection
Connect the starter motor terminal to the battery positive terminal directly. (A large amount of cur-
rent flows, so do not use a thin wire.)
Does the starter motor turn?
YES – Faulty starter relay switch.
NO – Faulty starter motor.
7. Relay Coil Ground Line Inspection
Check the ground line of the starter relay switch (page 17-19).
Is the ground line normal?
YES – GO TO STEP 8.
NO – • Faulty neutral switch (page 18-7).
• Faulty clutch switch (page 18-6).
• Loose or poor contact of the related connector terminal.
• Open circuit in the wire harness.

17-4
 ELECTRIC STARTER
8. Relay Coil Power Input Line Inspection
Check the power input line of the starter relay switch (page 17-19).
Is the power input line normal?
YES – GO TO STEP 9.
NO – • Faulty ignition switch.
• Faulty starter switch.
• Loose or poor contact of the related connector terminal.
• Open circuit in the wire harness.
9. Starter Relay Switch Inspection
Check the function of the starter relay switch (page 17-19).
Does the starter relay switch function properly?
NO – Faulty starter relay switch.
YES – Loose or poor contact of the starter relay switch connector.

Starter motor turns engine slowly

• Low battery voltage
• Poorly connected battery cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected ground cable terminal
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter gear train
Starter relay switch clicks, but engine does not turn over
• Crankshaft does not turn due to engine problems

17-5
ELECTRIC STARTER
STARTER MOTOR (’07 model)
REMOVAL
Remove the exhaust pipe (page 2-6).
RUBBER CAP TERMINAL NUT
Disconnect the negative (–) cable from the battery
(page 15-6).
Slide the rubber cap off the starter motor terminal,
and remove the terminal nut and starter motor
cable.
Remove the two mounting bolts, ground cable and
the starter motor from the crankcase.

GROUND
CABLE BOLTS
Remove the O-ring from the starter motor.
O-RING

DISASSEMBLY/INSPECTION
Remove the following:
– starter motor case bolts, set plates and O-rings
SET PLATES, O-RINGS

BOLTS

Record the location – front cover

SEAL RING INSULATE FRONT COVER
and number of – seal ring
shims. – lock washer D WASHER
– insulated washer
– shims

SHIMS LOCK WASHER

17-6
 ELECTRIC STARTER
Record the location – rear cover assembly
REAR COVER ASSEMBLY SEAL RING
and number of – seal ring
shims. – shims
– armature SHIMS

ARMATURE
Check for continuity between the cable terminal and
the insulated brush.
There should be continuity.

Check for continuity between the cable terminal and

rear cover.
There should be no continuity.

Remove the following:

BRUSH HOLDER INSULATORS
– nut
– washer
– insulators
– O-ring
– brush holder
– insulator plate

WASHER NUT

17-7
ELECTRIC STARTER
Remove the insulated brush from the brush holder.
Measure the brush length.
SERVICE LIMIT: 9.0 mm (0.35 in)

Do not use emery Inspect the commutator bars of the armature for
or sand paper on discoloration. COMMUTATOR BARS
the commutator.

ARMATURE
Check for continuity between pair of commutator
bars.
These should be continuity.

Check for continuity between each commutator bar

and the armature shaft.
There should be no continuity.

17-8
 ELECTRIC STARTER
ASSEMBLY
SHIMS

ARMATURE

LOCK WASHER

SHIMS

SEAL RING WASHER

O-RING INSULATOR PLATE

INSULATORS
SET PLATE BRUSH/
TERMINAL O-RING

INSULATED WASHER

FRONT COVER
REAR COVER

BRUSH HOLDER

SEAL RING

MOTOR CASE

Install the brushes in the brush holder as shown.

Install the insulator plate onto the cable terminal. INSULATOR PLATE

BRUSHES BRUSH HOLDER

Install the brush holder assembly to the rear cover,
TAB, GROOVE BRUSH HOLDER
aligning the tab with the groove in the rear cover.

REAR COVER

17-9
ELECTRIC STARTER
Install the following:
– new O-ring
– insulators INSULATORS
– washer
– nut

NUT

O-RING
WASHER
Install the armature into the motor case while hold-
MOTOR CASE
ing the armature tightly to keep the magnet of the
case from pulling the armature against it.

The coil may be damaged if the magnet pulls the

armature against the case.

ARMATURE
Install the shims Install the shims onto the armature shaft.
REAR COVER ASSEMBLY SEAL RING
properly as noted Install a new seal ring onto the motor case.
during removal. Apply a thin coat of grease to the armature shaft Align
end.
Install the rear cover assembly aligning the brush
holder tab with the motor case groove, while push- SHIMS
ing the brushes into the brush holder.

Install the shims Install the shims and insulated washer onto the
SEAL RING FRONT COVER
properly as noted armature shaft.
during removal. Install a new seal ring onto the motor case.
Apply grease to the oil seal lip and needle bearing in
the front cover.
Install the lock washer onto the front cover.
Install the front cover being careful not to damage
the oil seal lip.

SHIMS INSULATED
WASHER LOCK WASHER

17-10
 ELECTRIC STARTER
Install the set plates and new O-rings onto the
motor case bolts. SET PLATES, O-RINGS

Install the motor case bolts and tighten them

securely.

BOLTS

INSTALLATION
Coat a new O-ring with oil and install it into the
starter motor groove.
O-RING

Install the starter motor into the left crankcase cover

RUBBER CAP TERMINAL NUT
and onto the crankcase.
Install the mounting bolts with the ground cable,
and tighten the bolts securely.
Install the starter motor cable and terminal nut onto
the motor terminal and tighten the nut securely.
Install the rubber cap over the motor terminal prop-
erly.
Connect the battery negative (–) cable (page 15-6).
Install the exhaust pipe (page 2-7).

GROUND
CABLE BOLTS

17-11
ELECTRIC STARTER
STARTER MOTOR (After ’07)
REMOVAL
Remove the exhaust pipe (page 2-6).
STARTER MOTOR
Disconnect the negative (–) cable from the battery
(page 15-6).
RUBBER CAP
Remove the following;
– rubber cap
– terminal nut and starter motor cable
– two mounting bolts and ground cable
– starter motor TERMINAL
NUT

GROUND
CABLE BOLTS
– O-ring

O-RING

DISASSEMBLY/INSPECTION
Remove the following:
– motor case bolts

BOLTS

– rear cover assembly REAR COVER

– seal ring ASSEMBLY
SEAL RING

17-12
 ELECTRIC STARTER
– front cover
– seal ring SEAL RING
– armature
FRONT COVER

ARMATURE

Check the oil seal and bearings in the front cover for
wear or damage.

OIL SEAL

BEARINGS

Check the commutator bars of the armature for dis-

coloration.

• Do not use emery or sand paper on the commu-

tator.

COMMUTATOR BARS
Check for continuity between pairs of commutator
Continuity:
bars.
There should be continuity.

17-13
ELECTRIC STARTER
Check for continuity between each commutator bar
No Continuity:
and the armature shaft.
There should be no continuity.

Check for continuity between the insulated brush

Continuity:
and cable terminal.
There should be continuity.

Check for continuity between the cable terminal and

No Continuity:
motor case.
There should be no continuity.

Remove the four brushes and springs from the

brush holder.

SPRING

BRUSH

17-14
 ELECTRIC STARTER
Measure the brush length.

SERVICE LIMIT: 6.5 mm (0.26 in)

Remove the following from the rear cover:

– washer-screw
– brush set B

WASHER-SCREW

BRUSH SET B

– nut TERMINAL BOLT

– washer
– insulator BRUSH HOLDER
– terminal stopper
– O-ring
– terminal bolt
– brush set A INSULATOR
– brush holder BRUSH SET A
WASHER

NUT
O-RING

TERMINAL STOPPER

17-15
ELECTRIC STARTER
ASSEMBLY
TERMINAL
STOPPER
O-RING
BRUSH HOLDER
NUT
BRUSH SPRINGS

BRUSH SET A
WASHER

INSULATOR

TERMINAL BOLT
REAR COVER

SEAL RING

BRUSH SET B ARMATURE

WASHER-SCREW

MOTOR CASE

SEAL RING

FRONT COVER

Install the following onto the rear cover:

– brush holder TERMINAL BOLT
– brush set A
– terminal bolt BRUSH HOLDER
– new O-ring
– terminal stopper (in the direction as shown)
– insulator
– washer INSULATOR
– nut BRUSH SET A
WASHER

NUT
O-RING

TERMINAL STOPPER

TERMINAL STOPPER

17-16
 ELECTRIC STARTER
– brush set B
– washer-screw SPRINGS
– four brush springs

WASHER-
SCREW

BRUSH SET B

Install the brushes into the brush holder.

BRUSHES

BRUSHES

With the commutator bar facing the groove in the MOTOR CASE
motor case, install the armature in the motor case.
When installing the armature into the motor case,
hold the armature tightly to prevent the magnet of
the case from pulling the armature against it. ARMATURE

The coil may be damaged if the magnet pulls the

armature against the case.
GROOVE

Install a new seal ring onto the motor case.

Install the front cover onto the armature shaft and SEAL RING
motor case.
FRONT COVER

17-17
ELECTRIC STARTER
Install a new seal ring onto the motor case. REAR COVER
Install the rear cover assembly by aligning the tab Align ASSEMBLY
with the groove.

SEAL RING
Align the index lines on the front cover and motor
case, install the motor case bolts and tighten them.

Align

BOLTS

INSTALLATION
Coat a new O-ring with oil and install it in the motor
groove.

O-RING

Install the starter motor into the crankcase cover.

STARTER MOTOR
Install the two mounting bolts with the ground cable
and tighten them.
RUBBER CAP
Install the starter motor cable and terminal nut, and
tighten the nut.
Install the rubber cap onto the terminal stopper.
Connect the battery negative (–) cable (page 15-6).
TERMINAL
Install the exhaust pipe (page 2-7). NUT

GROUND
CABLE BOLTS

17-18
 ELECTRIC STARTER
STARTER RELAY SWITCH
Remove the left side cover (page 2-3).
OPERATION INSPECTION
Shift the transmission into neutral.
Turn the ignition switch to “ON” and push the
starter switch.
The coil is normal if the starter relay switch clicks.
If you don't hear the switch click, inspect the relay
switch circuits (page 17-19).

STARTER RELAY SWITCH

CIRCUIT INSPECTION
Remove the starter relay switch from the stays of
4P CONNECTOR
the battery case.
GROUND LINE
Disconnect the starter relay switch 4P connector.
Check for continuity between the Green/red wire
terminal of the wire harness side connector and
ground.
If there is continuity when the transmission is in
neutral or when the clutch lever is squeezed, the
ground circuit is normal.
POWER INPUT LINE
Connect the starter relay switch 4P connector. STARTER RELAY SWITCH
Turn the ignition switch to “ON”.
Measure the voltage between the Yellow/red wire
terminal (+) and ground (–).
If the battery voltage appears only when the starter
switch is pushed, the circuit is normal.

FUNCTION INSPECTION
Disconnect the negative (–) cable from the battery
(page 15-6).
Remove the starter relay switch from the stays of
the battery case.
Remove the battery and starter motor cables from
the starter relay switch.
Disconnect the starter relay switch 4P connector.
Connect an ohmmeter to the starter relay switch
cable terminals. BATTERY
Connect the fully charged 12 V battery positive ter-
minal to the Yellow/red wire terminal and negative
terminal to the Green/red wire terminal of the
starter relay switch.
There should be continuity between the cable termi-
nals while the battery is connected, and no continu-
ity when the battery is disconnected.

17-19
MEMO
 18. LIGHT/SWITCHES

COMPONENT LOCATION ························ 18-2 ENGINE STOP SWITCH ··························· 18-5

SERVICE INFORMATION ························· 18-3 CLUTCH SWITCH ····································· 18-6

HEADLIGHT··············································· 18-4 STARTER SWITCH ··································· 18-6

IGNITION SWITCH···································· 18-4 NEUTRAL SWITCH··································· 18-7

18

18-1
LIGHT/SWITCHES
COMPONENT LOCATION
LIGHT/SWITCHES

IGNITION SWITCH

ENGINE STOP SWITCH

CLUTCH SWITCH
STARTER SWITCH

NEUTRAL SWITCH

18-2
 LIGHT/SWITCHES
SERVICE INFORMATION
GENERAL
• A continuity test can be made with the switches installed on the motorcycle.
• The following color codes used are indicated throughout this section.

Bu = Blue G = Green Lg = Light Green R = Red

Bl = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow

SPECIFICATIONS
ITEM SPECIFICATION
Headlight bulb 12 V - 35 W
Main fuse 7.5 A

18-3
LIGHT/SWITCHES
HEADLIGHT
BULB REPLACEMENT
Remove the following:
NUTS BOLTS HEADLIGHT
– two cap nuts and bolts
– headlight assembly (from the rubber mounts in
the stay)

STAY

Remove the dust cover.

While pushing in, turn the bulb socket counterclock-
Align DUST COVER
wise to remove it.
Remove the bulb and replace it with a new one.
Install the dust Installation is in the reverse order of removal.
cover tightly against
the headlight with
its wire harness fac-
ing the left.

BULB
SOCKET

IGNITION SWITCH
INSPECTION
Remove the fuel tank (page 2-5).
IGNITION SWITCH WIRE CONNECTORS
Disconnect the ignition switch wire connectors.

18-4
 LIGHT/SWITCHES
Check for continuity between the ignition switch
side connector terminals in each switch position.
Continuity should exist between the color coded
wires as follows: IGNITION SWITCH

IGNITION SWITCH

OFF ON

REMOVAL/INSTALLATION
Remove the following:
– headlight (page 18-4) CLIP
– fuel tank (page 2-5)
Remove the wire band and release the switch wire BAND
from the wire clip.
Disconnect the ignition switch connectors.
Remove the ignition switch from the top bridge by
pushing the two stoppers.
Install a new ignition switch by aligning the locating
tab with the groove in the top bridge.
Route the ignition Install the removed parts in the reverse order of
switch wires prop- removal.
erly (page 1-17). IGNITION SWITCH

LOCATING TAB

STOPPER

GROOVE

ENGINE STOP SWITCH

Remove the fuel tank (page 2-5).
WIRE CONNECTOR AND 2P CONNECTOR
Disconnect the engine stop switch wire connector
and clutch switch 2P connector.

18-5
LIGHT/SWITCHES
Check for continuity between the connector termi-
nals.
There should be continuity with the engine stop
switch depressed, and no continuity with the switch
released.

ENGINE STOP SWITCH

CLUTCH SWITCH
Disconnect the clutch switch connectors.
Check for continuity between the clutch switch ter-
minals.
CLUTCH SWITCH
There should be continuity with the clutch lever
squeezed, and no continuity with the clutch lever
released.

STARTER SWITCH
Remove the fuel tank (page 2-5).
STARTER SWITCH 2P CONNECTOR
Disconnect the starter switch 2P connector.

Check for continuity between the starter switch con-

nector terminals.
There should be continuity with the starter switch
depressed, and no continuity with the switch
released.

STARTER SWITCH

18-6
 LIGHT/SWITCHES
NEUTRAL SWITCH
INSPECTION
Remove the two bolts and drive sprocket cover.

BOLTS

DRIVE SPROCKET COVER

Remove the spacer from the neutral switch and dis-
NEUTRAL SWITCH
connect the wire while pushing the setting washer.
Check for continuity between the neutral switch ter-
minal and engine ground.
There should be continuity when the transmission
is in neutral, and no continuity when the transmis-
sion is in any gear except neutral.

WIRE SPACER
REPLACEMENT
Remove the spacer and disconnect the wire from
the neutral switch (page 18-7). NEUTRAL SWITCH

Coat a new O-ring with oil and install it onto the

neutral switch groove.
Install the neutral switch into the crankcase until it is
fully seated.
Install the removed parts in the reverse order of
removal.

O-RING

18-7
MEMO
 19. WIRING DIAGRAM

WIRING DIAGRAM ··································· 19-2

19

19-1
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM

19-2
 20. TROUBLESHOOTING

ENGINE DOES NOT START OR POOR PERFORMANCE

IS HARD TO START·································· 20-2 AT HIGH SPEED ······································· 20-6

ENGINE LACKS POWER ·························· 20-3 POOR HANDLING ···································· 20-6

POOR PERFORMANCE AT LOW

AND IDLE SPEED······································ 20-5

20

20-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
TROUBLESHOOTING

1. Fuel Line Inspection

Check fuel flow to carburetor.
Does fuel reach the carburetor?
NO – • Clogged fuel hose or fuel strainer
• Clogged fuel valve
• Clogged fuel fill cap breather
YES – GO TO STEP 2.
2. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug wet?
YES – • Flooded carburetor
• Throttle valve open
• Dirty air cleaner
• Improperly adjusted pilot screw
NO – GO TO STEP 3.
3. Spark Test
Perform spark test.
Is there weak or no spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Broken or shorted spark plug wire
• Faulty ignition coil
• Faulty igniting pulse generator
• Faulty exciter coil
• Faulty ignition switch
• Faulty engine stop switch
• Faulty ignition control module (ICM)
NO – GO TO STEP 4.
4. Engine Starting Condition
Start engine by following normal procedure.
Does the engine start then stops?
YES – • Improper choke operation
• Incorrectly adjusted carburetor
• Leaking carburetor insulator
• Improper ignition timing (Faulty ICM or ignition pulse generator)
• Contaminated fuel
NO – GO TO STEP 5.
5. Cylinder Compression
Test cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing

20-2
 TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspection
Raise wheel off the ground and spin by hand.
Does the wheel spin freely?
NO – • Brake dragging
• Worn or damaged wheel bearings
• Bent axle
YES – GO TO STEP 2.
2. Tire Pressure Inspection
Check tire pressure.
Are the tire pressures low?
YES – • Faulty tire valve
• Punctured tire
NO – GO TO STEP 3.
3. Clutch Inspection
Accelerate rapidly from low to second.
Does the engine speed change accordingly when clutch is engaged?
NO – • Clutch slipping
• Worn clutch discs
• Warped clutch plates
• Weak clutch spring
• Sticking clutch lifter mechanism
• Additive in engine oil
YES – GO TO STEP 4.
4. Engine Condition Inspection
Accelerate lightly.
Does the engine speed increase?
NO – • Fuel/air mixture too rich or lean
• Clogged air cleaner
• Restricted fuel flow
• Clogged muffler
• Clogged fuel fill cap breather
YES – GO TO STEP 5.
5. Engine Condition Inspection
Accelerate or run at high speed.
Is there knocking?
YES – • Worn piston and cylinder
• Use of poor quality fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advance (Faulty ICM)
• Lean fuel mixture
NO – GO TO STEP 6.
6. Ignition Timing Inspection
Check ignition timing.
Is the ignition timing correct?
NO – • Faulty ignition control module (ICM)
• Faulty ignition pulse generator
YES – GO TO STEP 7.

20-3
TROUBLESHOOTING
7. Engine Oil Inspection
Check oil level and condition.
Is there correct level and good condition?
NO – • Oil level too high
• Oil level too low
• Contaminated oil
YES – GO TO STEP 8.
8. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug fouled or discolored?
NO – • Plugs not serviced frequently enough
• Incorrect spark plug used
• Incorrect spark plug gap
YES – GO TO STEP 9.
9. Cylinder compression Inspection
Test the cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged head gasket
• Improper valve timing
NO – GO TO STEP 10.
10. Carburetor Inspection
Check carburetor for clogging.
Is the carburetor for clogged?
YES – • Carburetor not serviced frequently enough
NO – GO TO STEP 11.
11. Lubrication Inspection
Remove cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
NO – • Clogged oil passage
• Clogged oil strainer

20-4
 TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Pilot Screw Inspection
Check carburetor pilot screw adjustment.
Is the adjustment correct?
NO – See page 5-18
YES – GO TO STEP 2.
2. Intake Air Leak Inspection
Check for leaking carburetor insulator.
Is there leaking?
YES – • Loose carburetor insulator bands
• Damaged insulator
NO – GO TO STEP 3.
3. Spark Test
Perform spark test.
Is there weak or intermittent spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Broken or shorted spark plug wire
• Faulty ignition coil
• Faulty ignition pulse generator
• Faulty exciter coil
• Faulty engine stop switch
• Faulty ignition switch
• Faulty ignition control module (ICM)
NO – GO TO STEP 4.
4. Ignition Timing Inspection
Check ignition timing.
Is the ignition timing correct?
NO – • Faulty ignition control module (ICM)
• Faulty ignition pulse generator

20-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1. Fuel Line Inspection
Disconnect fuel line at carburetor.
Does fuel flow freely?
NO – • Clogged fuel line
• Clogged fill cap breather
• Faulty fuel valve
• Clogged fuel strainer
YES – GO TO STEP 2.
2. Carburetor Inspection
Check carburetor for clogging.
Is the carburetor clogged?
YES – • Carburetor not serviced frequently enough
NO – GO TO STEP 3.
3. Ignition Timing Inspection
Check ignition timing.
Is the ignition timing correct?
NO – • Faulty ignition control module (ICM)
• Faulty ignition pulse generator
YES – GO TO STEP 4.
4. Valve Timing Inspection
Check valve timing.
Is the valve timing correct?
NO – • Cam sprocket not installed properly
YES – GO TO STEP 5.
5. Valve Spring Inspection
Check valve springs.
Are the valve springs weak?
YES – • Faulty valve spring

POOR HANDLING
Steering is heavy
• Steering bearing adjustment nut too tight
• Damaged steering head bearings
Either wheel is wobbling
• Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Excessively worn swingarm pivot bearings
• Bent frame
Motorcycle pulled to one side
• Front and rear wheels not aligned
• Bent fork
• Bent swingarm
• Bent axle
• Bent frame

20-6
 21. INDEX
AIR CLEANER·································································3-6 FRONT WHEEL/SUSPENSION/
A

AIR CLEANER HOUSING ··············································5-6 STEERING SPECIFICATIONS ······································· 1-9

ALTERNATOR COIL·····················································15-8 FUEL LINE······································································ 3-5
ALTERNATOR STATOR ··············································10-5 FUEL STRAINER·························································· 5-19
ALTERNATOR/STARTER CLUTCH FUEL SYSTEM SPECIFICATIONS ································ 1-7
SPECIFICATIONS···························································1-8 FUEL TANK···································································· 2-5
BATTERY······································································15-6 GEARSHIFT LINKAGE················································· 9-12
B G

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

SPECIFICATIONS·························································1-10 HANDLEBAR································································ 12-6
H

BRAKE CALIPER ························································14-13 HEADLIGHT ································································· 18-4

BRAKE FLUID·······························································3-18 HEADLIGHT VOLTAGE INSPECTION ························ 15-7
BRAKE FLUID REPLACEMENT/AIR BLEEDING ·········14-5 HYDRAULIC BRAKE SPECIFICATIONS······················ 1-10
BRAKE PAD/DISC ························································14-6 ICM (IGNITION CONTROL MODULE) ························ 16-9
I

BRAKE PEDAL····························································13-14 IGNITION COIL ···························································· 16-9

BRAKE SHOE/PAD WEAR ···········································3-19 IGNITION SWITCH ······················································ 18-4
BRAKE SYSTEM ··························································3-19 IGNITION SYSTEM INSPECTION······························· 16-5
CABLE & HARNESS ROUTING···································1-17 IGNITION SYSTEM SPECIFICATIONS ······················· 1-10
C

CAMSHAFT/ IGNITION TIMING ······················································· 16-8

CYLINDER HEAD COVER INSTALLATION ·················7-19 LEFT CRANKCASE COVER INSTALLATION············ 10-10
L

CARBURETOR ASSEMBLY·········································5-11 LEFT CRANKCASE COVER REMOVAL ······················ 10-4

CARBURETOR DISASSEMBLY·····································5-7 LUBRICATION & SEAL POINTS ································· 1-15
CARBURETOR INSTALLATION ··································5-17 LUBRICATION SYSTEM DIAGRAM ····························· 4-2
CARBURETOR REMOVAL·············································5-6 LUBRICATION SYSTEM SPECIFICATIONS ················· 1-7
CHARGING SYSTEM INSPECTION ····························15-6 MAINTENANCE SCHEDULE········································· 3-4
M

CLUTCH··········································································9-6 MASTER CYLINDER···················································· 14-9

CLUTCH SPECIFICATIONS ···········································1-8 MODEL IDENTIFICATION ············································· 1-2
CLUTCH SWITCH·························································18-6 NEUTRAL SWITCH······················································ 18-7
N

CLUTCH SYSTEM························································3-21 NUTS, BOLTS, FASTENERS······································· 3-23

COMPONENT LOCATION OIL PUMP ······································································ 4-4
O

BATTERY/CHARGING SYSTEM·····························15-2 PILOT SCREW ADJUSTMENT ··································· 5-18

P

ELECTRIC STARTER ···············································17-2 REAR DRUM BRAKE················································· 13-11

R

IGNITION SYSTEM ·················································16-2 REAR FENDER ······························································· 2-4

LIGHT/SWITCHES ···················································18-2 REAR WHEEL······························································· 13-6
CRANKCASE ASSEMBLY ·········································11-18 REAR WHEEL/SUSPENSION SPECIFICATIONS ········· 1-9
CRANKCASE BEARING REPLACEMENT ·················11-15 REGULATOR/RECTIFIER············································· 15-8
CRANKCASE BREATHER ··············································3-7 RIGHT CRANKCASE COVER INSTALLATION ··········· 9-14
CRANKCASE SEPARATION········································11-7 RIGHT CRANKCASE COVER REMOVAL······················ 9-5
CRANKCASE/TRANSMISSION/CRANKSHAFT SEAT ·············································································· 2-3
S

SPECIFICATIONS···························································1-9 SERVICE INFORMATION

CRANKSHAFT····························································11-13 ALTERNATOR/STARTER CLUTCH ························ 10-3
CYLINDER COMPRESSION···········································7-6 BATTERY/CHARGING SYSTEM ···························· 15-3
CYLINDER HEAD ASSEMBLY·····································7-17 CLUTCH/GEARSHIFT LINKAGE······························· 9-3
CYLINDER HEAD COVER/CAMSHAFT REMOVAL ······7-6 CRANKCASE/TRANSMISSION/CRANKSHAFT ···· 11-3
CYLINDER HEAD DISASSEMBLY·······························7-10 CYLINDER HEAD/VALVES ······································· 7-3
CYLINDER HEAD INSTALLATION ······························7-18 CYLINDER/PISTON ··················································· 8-3
CYLINDER HEAD REMOVAL·········································7-9 ELECTRIC STARTER ··············································· 17-3
CYLINDER HEAD/VALVES SPECIFICATIONS ··············1-8 ENGINE REMOVAL/INSTALLATION ······················· 6-3
CYLINDER/PISTON INSTALLATION·····························8-7 FRAME/BODY PANELS/EXHAUST SYSTEM·········· 2-2
CYLINDER/PISTON REMOVAL ·····································8-4 FRONT WHEEL/SUSPENSION/STEERING············ 12-3 21
CYLINDER/PISTON SPECIFICATIONS··························1-8 FUEL SYSTEM ·························································· 5-3
DRIVE CHAIN ·······························································3-14 HYDRAULIC BRAKE ··············································· 14-3
D

DRIVE CHAIN SLIDER··················································3-17 IGNITION SYSTEM················································· 16-3

ELECTRIC STARTER SPECIFICATIONS······················1-10 LIGHT/SWITCHES··················································· 18-3
E

EMISSION CONTROL SYSTEMS (BR TYPE) ·············1-24 LUBRICATION SYSTEM··········································· 4-3

EMISSION CONTROL SYSTEMS (U type)·················1-24 MAINTENANCE ························································ 3-2
ENGINE & FRAME TORQUE VALUES ·······················1-11 REAR WHEEL/BRAKE/SUSPENSION ···················· 13-3
ENGINE IDLE SPEED ···················································3-13 SERVICE RULES ···························································· 1-2
ENGINE INSTALLATION ···············································6-8 SHOCK ABSORBER/LINKAGE·································· 13-16
ENGINE OIL··································································3-11 SIDE COVERS································································ 2-3
ENGINE OIL CENTRIFUGAL FILTER···························3-13 SIDE STAND ································································ 3-21
ENGINE OIL STRAINER SCREEN ·······························3-12 SKID PLATE ··································································· 2-5
ENGINE REMOVAL························································6-4 SPARK ARRESTER ······················································ 3-22
ENGINE STOP BUTTON··············································18-5 SPARK PLUG ································································· 3-7
EXHAUST PIPE/MUFFLER ············································2-6 STANDARD TORQUE VALUES ·································· 1-11
FLYWHEEL INSTALLATION········································10-9 STARTER BUTTON ····················································· 18-6
F

FLYWHEEL REMOVAL ················································10-6 STARTER CLUTCH ······················································ 10-7

FORK···········································································12-13 STARTER MOTOR (’07 model)··································· 17-6
FRONT FENDER·····························································2-4 STARTER MOTOR (After ’07) ··································· 17-12
FRONT WHEEL ····························································12-9 STARTER RELAY SWITCH········································ 17-19

21-1
INDEX
STEERING HEAD BEARINGS ····································· 3-24 CLUTCH/GEARSHIFT LINKAGE ······························· 9-4
STEERING STEM ······················································ 12-21 CRANKCASE/TRANSMISSION/CRANKSHAFT····· 11-6
SUSPENSION······························································ 3-22 CYLINDER HEAD/VALVES········································ 7-5
SWINGARM······························································· 13-21 CYLINDER/PISTON ··················································· 8-3
SYSTEM COMPONENTS ELECTRIC STARTER ··············································· 17-4
ALTERNATOR/STARTER CLUTCH ························ 10-2 ENGINE DOES NOT START OR
CLUTCH/GEARSHIFT LINKAGE······························· 9-2 IS HARD TO START ················································ 20-2
CRANKCASE/TRANSMISSION/ ENGINE LACKS POWER········································· 20-3
CRANKSHAFT························································· 11-2 FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 2-2
CYLINDER HEAD/VALVES ······································· 7-2 FRONT WHEEL/SUSPENSION/STEERING ············ 12-5
CYLINDER/PISTON··················································· 8-2 FUEL SYSTEM ·························································· 5-5
ENGINE REMOVAL/INSTALLATION ······················· 6-2 HYDRAULIC BRAKE················································ 14-4
FRONT WHEEL/SUSPENSION/STEERING ··········· 12-2 IGNITION SYSTEM ················································· 16-4
FUEL SYSTEM ·························································· 5-2 LUBRICATION SYSTEM ··········································· 4-3
HYDRAULIC BRAKE ··············································· 14-2 POOR HANDLING ··················································· 20-6
REAR WHEEL/BRAKE/SUSPENSION ···················· 13-2 POOR PERFORMANCE AT HIGH SPEED··············· 20-6
SYSTEM DIAGRAM POOR PERFORMANCE AT LOW
BATTERY/CHARGING SYSTEM ···························· 15-2 AND IDLE SPEED ···················································· 20-5
ELECTRIC STARTER··············································· 17-2 REAR WHEEL/BRAKE/SUSPENSION····················· 13-5
IGNITION SYSTEM················································· 16-2 VALVE CLEARANCE ······················································ 3-8
V

THROTTLE OPERATION ··············································· 3-5 VALVE GUIDE REPLACEMENT ·································· 7-13

T

TRANSMISSION ························································· 11-8 VALVE SEAT INSPECTION/REFACING ······················ 7-14

TROUBLESHOOTING WHEELS/TIRES···························································· 3-23
W

BATTERY/CHARGING SYSTEM ···························· 15-5 WIRING DIAGRAM ······················································ 19-2

21-2