Paper Book Part No. 67MBLE1MH HOW TO USE THIS MANUAL This service manual describes the service procedures for the NT 650 V. Follow the Maintenance Schedule (Section 3) recommenda- tions to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set. Performing the first scheduled maintenance is very important, It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of compo- nents that may be required to perform service described in the following sections. Sections 4 through 20 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section, The subsequent pages give detailed procedure. H you don't know the source of the trouble, go to section 22 Troubleshooting, All information, illustrations, directions and speci- fications included in this publication are based on the latest product information available at the time of approval for printing. HONDA MOTOR CO., LTD. reserves the right to make changes at any time without notice and without incurring any obligation whatever, Ao part of this publication may be reproduced without written permission. This manual is written for persons who have acquired basic knowledge of ‘maintenance on Honda Motorcycles, Motor Scooters or ATVS. Contents General Information 1 | Frame/Body Panels/ Exhaust System Maintenance | 3 | £ 3S £ ° 2 a 3 z & ° Lubrication System Og Fuel System Engine Removal/Installation Hd Clutch/Gearshift Linkage [3 | Cylinder Head/Valves mH Cylinder/Piston 114] Crankshaft/Transmission Final Drive Chassis Front Wheel/Suspension/ Steering Rear Wheel/Suspension Hydraulic Brake HONDA MOTOR CO.,LTD SERVICE PUBLICATIONS OFFICE Ignition System Electric Starter Lights/Meters/Switches Wiring Diagram Troubleshooting [carinnrreneson ERY [rom [Se [Resruneesueeenion EE [wowooe [irtensown A ee 19) [vovemmerssucnes BM) Co 2 [roaienseIMPORTANT SAFETY NOTICE strong possibility of severe personal Injury or death It instructions re not followed. CAUTION _Indicates a possibility of equipment damage if instructions are not followed. NOTE Gives helpful information. Datailad descriptions of standard workshop procedures, safaty principles and service operations are not included. It is important to note that this manual contains some warnings and cautions ‘against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possible hazardous consequences of each conceivable way, nor could Honda inves- tigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be Jeopardized by the service method or tools selected,Type Codes ‘Throughout this manual, the following abbreviations are used to identify individual model. Code ‘Area type E UK. FE France SW. Switzerland @ Germany ED European direct sales, WE France: 25 Kw limited 1e Germany: 50 PS limited me Germany: 25 Kw limited TED European direct sales: 25 Kw limited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, DP _| reece prs win now oan sey Use recommended engine oil, unless otherwise specified, Use molybdenum oll solution (mixture of the engine oll and molybdenum grease in a ratio of 1:1). Sam | Use muiti-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NGI F2 oF equivalent ie Example: Molykote® BR-2 plus manufactured by Dow Coming, U.S.A Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide grease (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote Q-n Paste manufactured by Dow Oorning, 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 @ middle 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. Aman) &GENERAL SAFETY 141 SERVICE RULES 4-2 MODEL IDENTIFICATION 1-3 ‘SPECIFICATIONS 1-4 TORQUE VALUES 114 1. General Information TOOLS 1-18 LUBRICATION & SEAL POINTS 1-20 CABLE & HARNESS ROUTING 1-24 EMISSION CONTROL SYSTEMS. 1-30 General Safety Carbon Monoxide If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. poisonous carbon monoxide loss of consciousness and gas that can caus may lead to death. Fun the engine in an open area or with an exhaust eva- uation system in an enclosed area. Gasoline Work in a wall ventilated area. Keep cigarettes, flamas or sparks away from the work area or where gasoline is, stored. rm * Gasoline xtremely flammable and is explosive ne. KEEP OUT OF NACH ‘* Engine and exhaust system parts become very hot and remain hot for some time after the engine insulated gloves or wait until the ‘haust eystem have cooled before parts. Used Engine Oil * Used engine oll may cause skin cancer if repea- tedly left in contact with the skin for prolonged periods. Althoufh # handle used oil on a daily to thoroughly wash your hands with soap and water as soon as possible after handlina used oil. KEEP OUT OF REACH OF CHILDREN. Brake Dust Never use an air hose or dry brush to clean brake assem- blies, Use OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers. on ‘Inhaled asbestos fibers ha respiratory disoase and cance Brake Fluid CAUTION ‘Spilling fluid on painted, plastic or rubber parts will damage them, Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN.GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the engine ethylene glycol does ignite, you will not see any flame, but you can be burned. ‘* Avoid spilling engine coolant on the exhaust sys- ‘tom or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flam + Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed, KEEP OUT OF REACH OF CHILDREN. ‘= Keep out of reach of pets. Some pets are attached to the amell and taste af coolant can die if they drink i ‘* Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scaled you. Itis contacts your skin, wash the affected areas immediately with soap and water. Ifit contacts your eyes, flush them thoroughly with fresh water and get immediate medical attention. If it is swallowed, the victim must be forced to vomit then rinse mouth and throat with fresh water before obtaining medical attention. Because of these dangers, away from the reach of children. Recycle used coolant in an ecologically correct manner. Service Rules Battery Hydrogen Gas & Electrolyte Cos ‘The battery gives of explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space. ‘* 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 wat + If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately . Electrolyte is nolsonous. + If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vege- tale oil and call a physician. KEEP OUT OF REACH OF CHILDREN. 1. Use genuine HONDA or HONDA - recommended parts and lubricants or thelr equivalents. Parts that don't 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 Enolish fasteners. When tightening bolts or nuts, begin with the larger Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. ameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 1-2 Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly After reassembly, check all parts for proper installation and operation. Route all electrical wires as shown on pages 1-24 through 1-29, Cable & Harness routing.GENERAL INFORMATION Model Identification (1) The frame serial number is stamped on the right (2) The engine serial number is stamped on the right side of the steering head. side of the crankcase below the rear cylinder Bs Ae IDENTIFICATION NUMBER (@) The carburetor identification numbers are stamped (4) The color label is attached on the rear fender of the on the intake side of the carburetor body as, under the seat. When ordering color-coded parts, shown. always spectty tne desiyrtated vulur code. 1-3GENERAL INFORMATION Unit: mm (in) Specifications Goneral item ‘Specifications Dimensions ‘Overall lenght 2,215 mm (87.2 in) ‘Overall width 780 mm (30.7 in) ‘Overall height 4,260 mm (49.8 in) Wheelbase 1,475 mm (58.1 in) Seat height 814 mm (32.0 in) Footpeg height Ground clearance Dry weight ‘Curb weight Maximum weight capacity 319 mm (12.6 in) 140 mm (5.5 in) 223 kg (492 Ib) 243 kg (636 Ib) 192 kg (428 Ib) Frame Frame type Front suspension Front wheel travel Rear suspension Rear wheel travel Rear damper Font tre size Roar tre size Tire brand Dunlop Michelin Front brake Rear brake Caster angle Trail langht Fuel tank capacity Fuel tank reserve capacity Twin tube Teleecapie fore 130 mm (6.1 in) Swingarm 122.5 mm (4.8 in) Nitrogen gas filled damper 120/70 ZR17 (58W) 180/70 217 (89W) Front: D20SFN/Rear: D205N Front/Rear: MACADAM 90XB Hydraulic double disc brake Hydraulic single disc brake 28° 50° 120.5 mm (4.74 in) 19.0 liters (6.02 US gal, 4.18 Imp gal) 3.2 liters (0.85 US gal, 0.70 imp gal) Engine ‘Bore and stroke Displacement Compression ratio Valve train Intake valve opens clnees Exhaust valve opens closes Lubrication system il pump type Cooling system Air filtration Crankshaft type Engine dry weight Firing order Gylinder arrangement Cylinder number 79.0 x 66.0 mm (8.11 x 2.60 in) 647 om? (38.5 cu-in) 9.2: 1 Silent, multi-link chain drive and OHC with rocker arm s°BTDC — ane anne — 40° BDC — seatoc — Forced pressure and wet sump Trochoid Liquid cooled Paper filter Unit type, two main journals 66.5 kg (146.6 Ibs) Front - 232° - Rear - 488° - Front Two cylinders, 52° V transverse Front: #2, Rear: #1 F— at 1 mm (u.v4 in) tne Carburetor Carburetor type ‘Throttle bore ‘CV (Constant Velocity) dual carburetor with fuel pump 36.5 mm (1.4 in)GENERAL INFORMATION Unit: mm (in) General (Cont'd) item ‘Specifications Drive Train | Clutch system Muiti-plate, wet Clutch operation system Mechanical type Transmission Constant mesh, 5-speeds Primary reduction 4.763 (67/98) ‘Secondary reduction 0.820 (32/39) Third reduction 1.088 (18/17) Final reduction $090 (34/71), Goarratio 1st 8.000 (38/11) 2nd 41941 (33/17) 3rd 4.500 (80/20) 4th 1.240 (81/25) 5th 1.095 (23/21) Gearshitt pattern Left foot operated retum system, 1-N-2-3-4-5 Electrical | tgnition system Full transistor digital ignition Starting systom Electric starter motor Gharging system Triple phase output alternator Regulator/ectiti SCR shorted/triple phase, full wave rectification Lighting system BatteryGENERAL INFORMATION Unit: mm (in) Lubrication System Nem Standard Service Limit Engine oll capacity ‘After draining 8 (2.52 US. gt, 2.11 Imp at) = ‘After disassembly 3.0 liters (8.15 US. at, 2.64 Imp at) = ‘After oll iter change 2.6 liters (2.73 U.S. @t, 229 Imp at) = Recommended engine oll Honda 4-stroke ol or equivalent |APt service clas Viscosity: SAE 10W-40 motor ol = ification SE, SF oF SG (il pressure at ol pressure switch 441 kPa (4.5 kgl/eme, 64 psi) at = 6,000 min (rpm) (80° C/176" F) ‘ii Pume Tio clearance 0.15 (0.008) 0.20 0,008) Body clearance (0.15 - 0.22 (0.006 - 0.008), 0.85 (0.014) End clearance 10.02 -0.07 (0.00% - 0.003) (0.10 (0.004) Unit: mm (in) [Fuel System tem Specitications Carburetor identification number Except SW type VOKiD. ‘SW type VOKAC. Main jet Front 4125 Rear #125 ‘Slow jot 45, Pilot screw Iniiavfinal opening ‘See page 5-21 Float level 8.2 mm (0.86 in) Base carburetor [for synchronization) ear cylinder (#1) Tale spoed Excopt SW type 4,200 = 100 min-1 (mm) SW type 7,200 = 50 min" (rpm) Gaibureior vavuun ulfererce BF RPa (20 nn Hig 0-7 in Fg) PAIR control valve specified vacuum [320 mm Hg (12.6 in Ha) Throttle grip ree play 2-6 mm (1/12 1/4 in) Fuel pump flow capacity ‘Minimum 600 em® (20.8 US oz, 21.1 Imp oz) per minute at 13 VGENERAL INFORMATION -Coolig System Wem Spevineations Coolant capacity Radiator and engine 1.8 lers (1.80 US gt, 1.58 Imp at) Reserve tank (0.25 liters (0.26 US qt, 0.22 imp at) Radiator cap relief pressure 88 - 127 KPa0.9- 1.9 kat/om®, 13 - 18 psi ‘Thermostat Begin to open 80- 84° 0 (178-188) Fully open ‘Re © (ona) Valve lift {mm (0.3 in) minimum ‘Standard coolant concentration 50 % mixture with soft water Unit: mm (in) Clutch System Item Standard Service Limit ‘Clutch lever free play 10-20 (9/8-8/4) = (Clutch spring free length 42.3 (167) 48.9 (1.73) ‘Clutch dise thickness | A, 2.62-2.78 (0.108-0.107) 2.3 (0.09) 5 2.92-8.08 (0.115-0.121), 2.6 (0.10) © 2.62-2.76 (0.100-0.107), 2.9 (0.08) ‘Clutch plate warpage = 0.300.012) Clutch outer guide Lo. 21.991-22.016 (0,8658-0.8668) 22.09 (0.870) 00. '31,959-01.975 (1.2582-1.2589) 34.92 (1.257) Oil pump drive sprocket I. D. '32.025-2.145 (1,2608-1.2655) 30.15 (1.187) Mainshaft OD. at clutch outer guide 21.967-21.980 (0.8648-0.8654) 21.95 (0.864) Unit: mm (in) -Alternator/Starter Clutch Item Standard Service Limit ‘Starter driven gear bo. '7.000-37,025 (1.4567-1.4577) | __ 97.10 (1.461) 0.0. 57.749-57.768 (22736-22743) | [email protected])GENERAL INFORMATION Unit: mm (in) Cylinder Head/Valves om ‘Standara ‘Service Limit Gylinder compression 1,924 2 196 KPa (13.5 = 2.0 katlome, = 192 = 28 psi) at 400 mi (rpm) Oylinder head warpage = (0:10 (0.004) valve, Valve clearance N (0:13-0.17 (0.005-0.007) = valve quide ex (0.18-0.22 (0.007-0.009) = Valve stem 0.0. IN 5.475-5.490 (0.2156-0.2161) 5.47 (0215) x 6.555-6.570 (0.2580-0.2587) 6.55 (0.258) Valve guide LO. N 5.500-5.512 (0.2165-0.2170) 5.53 (0.218) ex '6.600-6.615 (0,2598-0.2608) 6.66 (0.262) ‘Stem-to-guide clearance N 0.010-0.087 (0.0004-0.0015) 0.07 0.003) =x °0.030-0.060 0.0012-0.0027) 0.11 (0.004) Valve guide projection above N 49.4-19.6 (0.76-0.77) = cylinder head x 17.9-18.1 (0.70-0.71) = Valve seat width INEX (0.90-1.10 (0.035-0.043) 4.5 (0.06) Valve spring free length | Outer IN 42.14 (1.658) 40.58 (1.598) x 42.63 (1.686) 141.25 (1.624) inner 1 6.17 (150M) 30.67 (1.90) x 38.81 (1.765) 37.51 (1.477) ‘Camenatt | Cam lobe height IN 38.189 (1.5035) 98.17 (1.503) x 38.219 (1.5044) 38.19 (1.504) Journal 0.0. 27,959-21,980 (0.8645-0.8054) | 21.95 (0.864) Runout| 0.090-(0.012), (0.08 (0,002) Oil clearance 0.049-0.088 (0.0018-0.0037) 0.11 0.004) Ientitication marks Front, “A: Rear = Rocker arm LD. INE 72.000-12.018 (0.4724-0.4731) | 12.03 (0.474) Rocker arm shaft 0.D, IN/EX 11,966-11,964 (0.4711-0.4718) | 11.96 (0.471), locker arm-to-rocker arm shaft clearance 0.016-0.082 (0.0008-0.0020) 0.07 (0.008) 1-8GENERAL INFORMATION Unit; mm (in) (-Cylinder/Piston tem ‘Standard Service Limit ylinder LD. 79,000 - 79.015 (8.1102 - 8.1108) 79.05 (3.192) ‘Out of round = 0.06 (0.002) Taper = 0.06 (0.002) Warpage = 0.10 (0.004) Piston, Piston mark direation TIN" mark facing toward the intake side = piston rings Piston 0.0. 78.97 - 78.99 (9.109 31.110) 72.92 (3.107) Piston 0.D. measurement point 7-17 mm (0,3-0.7 in) from bottom of skirt = Piston pin bore LD. 20.002 - 20.008 (0.7874 - 0.7877) 20.02 (0.788) Piston pin 0.0. 19.994 - 20.000 (0.7871 - 0.7874) 19.98 (0.787), Piston-to-piston pin clearance (0.002 = 0.014 (0.0001 - 0.0006) 0.03 (0.001) Piston ring-to-ring | Top (0.025 - 0.055 (0.0010 - 0.0022) 0.11 (0.008) groove clearance _| Second (0.015 - 0.046 (0.0006 - 0.0018) 0.10 (0.004) Piston ring end Top. (0.20 0.35 (0.008 - 0.014) 0.7 (0.03) grap Second 0.85 - 0.50 0.014 - 0.020) 0.7 0.03) Oil (side rai) 10,20 - 0.60 0.008 - 0.081) 1.0 (0.04) Piston sing mark | Top mark = Second "RNY mark = Gylinder-to-piston clearance: 0.070 - 0,085 (0.0004 - 0.0014) 0.13 (0.008) {Connecting rod small end LD. 20.016 - 20.084 (0.7880 - 0.7887) 20,04 (0.789) ‘Connecting rod-to-piston pin clearance 0,076 - 0.040 (0.0006 - 0.0016) 0.08 (0.002) 1-9GENERAL INFORMATION Unit: mm (in) [-rankanesTrenamiesion tem standara Service Limit Granta’ [Ste cance 5:0 29(6 0020.00 ose runout = 995,000 Crankin ofclerance Cs DRE OT ATDAD | 0.080.009 Wain joa ol csrance 0025-0081 .co1-0018) | 005 0.002 rransrisson | ari. Ws, M5 67,68,68 | 28000-26071. 102e-1 1032) | 70.08 (.105) Busting 0 wa.ws, cic, c3 | 2795627960 (.1007-1019 | 27.85.00) Busing iD ws 62,68 25.00-25021 (9609-09951) | 25090985) Geartosusning | MAME. 020-o0se,eceee-ce) | 098/000 ctewance 22,09 aisha 3 1 being aaa am eomeoemG | Dass 9am case unata | 18380-19998 0.7996-0779) | 19.9 0 706 aseural | 21957-21900 (0.9048-09560 | 71.94 (0860 Guinea Ob, | Cabustng 2.592 990(0.905-09895) | 2495 0980 ca bushing 24. 059-2490 0580-09005, | 2895 0980) casejourala | 1980-19900 (0.7286-0771) | 10.98 0700 Gare ounal | Toseo-1v awa a re-07er) | 19. 960.78) ee ce oor-oose@aneecocey | 0080.09) Sina ok | For v3 amm-ae sTeosIeg | ame sat aw mires 599-6.00(0000-020) 35 (02 Tons OD Taase-T ane ostos-05i7g | 1290 0508 Shift drum 0.0. (at left side journal) ae 11.966- 11.984 (0.4711-0.4718) 11.94 (0.470) up cive[Ouipu gear. 2408-081 OauGaRIET | _ AIOE in Out gear bushing [0 2,059.20. 90 (9 3n0-0 9447) | 2970(0309) 1D. .00-00.081 (7002-07880) | 20.0 0709) st ive gear sa0.0 {9.76-29000 (07005-07679) | 1997 0785 ear ueing erence a.on-nmo nnn ens) | Pn) Gear buing-o shah clearance 00.058 coe-0. 0028, | 0 (0.088 spat a arr srg elena 350829) S220 Ost rive ger backash 08-0. 0.008: 05 3a 0) Sacks fees between nearer = 20/0009 Unit: mm (in) (-Final Drive tom standard Service imi Recrnanded al ae Typ aro SAE HO = Final veo capoty a caing/dasssenby Edom (5.108 0%, 59 mpaa = Fina ve ear bscsh 06. 0.16 08 0.098 aaean Backs dlfercebetwoan easvarnis = 01010008 Ting esr-sop pin caren o5-08 005-008 e Fal ve grease preload pa Sanme-sigten,17a5em[ = 1-10GENERAL INFORMATION Unit: mm (in) [-Front Wheel/Suspension/Steering m stangara ‘Service Limit Minimum tre tread depth = 1.5 (0.06) Cold tre pressure Up 10 80 kg (200 1b) load 245 kPa (2.60 kgf/cm, 36 psi = Upto maximum weight capacity 285 KPa (2.50 kafem?, 36 psi = ‘Axle runout = (0.200.008) Wheel rim runout Radial = 2.0 (0.08) ‘Axial = 2.0 (0.08) Wheel balance weight = 60.9 (2.1 02) Fork Spring free length 416.9 (16.41) 408.6 (16.09) Tube runout = 10.20 (0.008) Recommonded fork fluid Fork fluid SI Oilievel 1364) = Oil capacity, 480 + 2.5 om? (16.2 + 0.08 US 02, = 16.9 0.09 Imp 02) ‘Steering head bearing preload 1.04 1.46 kot (2.50-9.22 169) = Unit: mm (ind [Rear Wheel/Suspension. tem Standard Service Limit ‘Minimum tre tread depth = 2.0 (0.08) Cold tire pressure Up 10 90 kg (700 Ib) load £284 kPa (2.90 kal/om?, 41 psi) = Upto maximum weight capacity 284 kPa (2.90 kgllem?, 41 psi SI ‘axle runout = 0.20 0.008) Wheel rim runout Radial = 2.0 (0.08) ‘Axial = 2.0 (0.08) Wheel balance weight = 6092.1 02) ‘Shock absorber spring preload adjuster setting ‘4 turns (@ clicks) from lowest position 1-11GENERAL INFORMATION Unit: mm (in) Hydraulic Brake tem Standard Service Limit Front ‘Specified brake fluid Dora = Brake pad wear indicator = To groove Brake disc thickness 45 (0.18) 35 (0.14) Brake dise runout = 0.25 (0.010) Rear ‘Specified brake fluid pots = Brake pad wear indicator = To groove Brake disc thickness 5.0 (0.20) 4.0 (0.16) Brake dise runout = 0.25 (0.010) Master oylinder LD. 4.000 14.043 (0.5512 -0.5528) | 14.085 (0.5533) Master piston O.D. 18.957 - 18.084 (0.6495 -0.5506) | 18.946 (0.5490) Caliper oyinder 1.0. {38.180 - 38.280 (1.503% - 1.5051) 38.24 (1.508) Caliper piston 0.0. 938.006 - 08.148 (1.4962 - 1.5019) 38.09 (1.500) -Battery/Charging System Item Specifications Battery Capacity 12V- Ah Current leakage 1.0™mA max. Voltale 20°C /68°F) | Fully charged 130-192 Needs charging Below 12.3, Charging current Normal OBA/B-10h Quick 40A/ 1h max ‘Alternator Capacity {808 W/ 6,000 min-* (pm) Charging coil resistance (20° C / 68°F) 01-108 Regulator/rectifer regulated voltage 4= 48.V/ 5,000 min (rpm) ‘Ignition System tem Specifications ‘Spark plug NGK DENSO ‘Standard DPRBEA-@ X24EPR-UD For cold climate (below 5° G/61° F) DPRTEA-@ X22EPR-U9 For extended high speed riding DPROEA-@ X2TEPR-US ‘Spark plug gap 0.80 - 0.90 mm (0.081 - 0.035) in {gnition coll primary peak voltage 100 V minimum ignition pulse generator peak voltage (0.7. V minimum Ignition timig “F* mark 95° BTOC ‘Advance ‘Start 10° 71,500 min" (pm) ‘Stop 29° 8,000 min (pm) Full advance 29" 1-12GENERAL INFORMATION Unit: mrn (in) Electric Starter Hom Standard Service Limit ‘Starter motor brush lenght 12.5 (0.49) 6.5 (0.26) -Lights/Meters/Switches tem Specifications Bulbe Headlight (High/low beam) 12. - 60/55 W Position light 12V-4W Braketal ight 12V-21/5 W ‘Turn signal ight 12V-21Wx4 Instrument ight 42V-1.7Wx2 Clock light 12V-1.7W Turn signal indicator 12V-1.7Wx2 High beam indicator 12V-1.7W Neutral indicator 12V-1.7W Oilindicator 12V-1.7W Tose Main ‘OO ‘Sub fuse BAx2, 10Ax2, 15Ax2 Fan motor switch ‘Star to close (ON) ‘98 - 102°C (208 - 216° F) ‘Start to open (OFF) 93 - 97° C (199 - 207° F) Coolant temperature ‘Star to close (ON) 112 - 118° C (259 - 270° F) ‘Start to open (OFF) Below 108° C (252° F) 1-13GENERAL INFORMATION Torque Values Standard Torque Torque Fastener Type Nem (kgf-m, Ibf-ft) N-m (kgf-m, Ibf-ft) 5 mm hex bolt and nut 5(0.5,3.6) | Smmscrew 4(0.4, 2.9) 6 mm hex bolt and nut 10(1.0.7) |.6mmscrew 9 (0.9.6.5) 8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9, 6.5) 40mm hex bolt and nut 0410.5, 25) | ommlange bolt (10mm head) and nut] 12(1.2, 9) +2 mm hex bolt and nut 54 (6.5, 40) | 8 mm fiange bolt and nut 26 (2.7, 20) 10 mm flange bolt and nut 39 (4.0, 29) * Torque specifications listed below are for important fasteners + Others should be tightened to standard torque values listed above. NOTES: 1. Apply grease tothe threads. 2. Apply oil to the threads and seating surface. 3. Apply sealant to the threads. 4. Apply a locking agent tothe threads. 5. Stake 6. CT bol. 7. UBS bolt 8. Lefthand threads. 8. Seif tapping screw. 40. ALOC bolt replace with a new one, 41. Usnut 12, Torxbott. Engine . Thread Di Torque ttem a mm) Nim (kgtem, ioe | Remarks MAINTENANCE: ‘Spark plug 4 12 14 (1.4, 10) Engine oil drain bolt fl 14 29 (8.0, 22) Engine oil filter cartridge 1 20 10 (1.0, 7) Timing hole cap 1 14 10(1.0,7) | NOTE Grankshatt hole cap 1 30 18(.5,11) | NOTET Vaive adjusting serew lock nut 8 7 aaa | Note? LUBRICATION SYSTEM: Oil pressure switch 1 PTV8 12 (1.2, 9) NOTE 3, Oil pressure switch wire terminal screw 1 4 2 (0.2, 1.4) il pump cover bolt 3 6 13(13,9) | NOTES Engine oil fiter boss (stud) 1 20 18(1.8,13) | NOTES COOLING SYSTEM: Water pump cover bolt 2 6 12 (1.2, 9) CLUTCH/GEARSHIFT LINKAGE: Clutch titer plate bolt 4 6 12(1.2,9) Clutch center lock nut 1 18 128 (13.0,94) | NOTE2,5 Primary drive gear bolt 1 12 88 (0.0,65) | NOTE2 Gearshift return spring pin 1 8 232.3, 17) il pump driven sprocket bolt 1 6 45(15,11) | NOTES ALTERNATOR/STARTER CLUTCH: Flywheel bolt 1 12 120(13.0,08 | Note 7,8 ‘Stator mounting socket bolt 4 6 12 (1.2, 9) NOTE 4 Starter one-way clutch hosing socket bolt 6 8 29(3.0,22) | NOTE4, 12 Stator wire holder socket bott 1 6 12(1.2,9) | NOTE4 1-14GENERAL INFORMATION Engine (Cont'd), tem Q'ty Remarks CYLINDER HEAD/VALVES: EVAP air injection reed valve cover bolt 4 5 5(0.5,3.6) NOTE 6 Gylinder head cover bolt 4 6 10(1.0, 7) Cam sprocket bolt 4 7 23 (2.3, 17) NOTE 4 Camshaft holder 8 mm bolt 6 8 232.3, 17) &mmonut 4 8 23 (2.3, 17) (Gann chat tensioner mounting Let 4 ° 10(1.0, 7) Cylinder head & mm bolt 4 8 23 (2.3, 17) NOTE 2 Bmmnut 2 8 232.3, 17) 10 mmnut 8 10 47 (4.8, 35) GRANKCASE/CRANKSHAFT/TRANSMISSION: Crankcase 8 mm bolt 15 a 23 (2.8, 17) Connecting rod bearing cap nut 8 8 33 (8.4, 25) NOTE 2 Output gaar ease halt: Ry 119 mm 2 a arson) | NOTRE a7 8x65mm 1 8 3132.23) | NOTE4.7 8x60mm 1 8 91 (82,23) | NOTE2,7 8x 45mm 1 8 31(8.2,23) | NOTE2,7 Output drive gear bearing lock nut (inner) 1 30 69 (7.051) | NOTE2.5 (outer) 1 64 98 (10.0, 72) | NOTE2,5 Output driven gear bearing lock nut (inner) 1 30 69(7.0,51) | NOTE2,5 {outer) 1 64 98 (10.0, 72) | NOTE2, Output driven gear bearing holder bolt 4 8 313.2, 28) NOTE 2 Output drive gear shaft bolt 1 10 49 (6.0, 36) ELECTRIC STARTER: Starter motor cable nut 1 6 10(1.0, 7) Starter motor cable socket bolt 1 4 5 (0.5, 3.6) LIGHTS/METERS/SWITCHES: Neutral switch 1 10 12(1.2,9) 1-15GENERAL INFORMATION —Frame (Cont'd) ; Thread Dia. 7 {tem arty fm) | nem orto) | Remarks FRAME/BODY PANELS/EXHAUST SYSTEM: Saddle bag adjust bolt lock nut 2 4 50 (6.0, 49) Footpeg bracket bolt 4 8 262.7, 20) Saddle bag lid bar 8 4 20.2, 1.4) Saddle bag lid hinge 16 4 202,144) Saddle bag lid catch 8 4 200.2 1.4) MAINTENANCE: ‘Ar cleaner housing cover screw 10 5 0.4 (1.0.7 Side stand pivot bolt 1 10 40(1.0,7) Side stand pivot lock nut 10 29 (8.0, 22) COOLING SYSTEM: Fan motor nut 3 5 30.3, 2.2) Cooling fan nut 1 5 5005.96) | NoTEs Cooling fan shroud bott 3 8 9(0.3, 65) Radiator filer bolt 2 8 9 (0.3, 6) Thermostat housing cover bolt 2 6 40(1.0,7) Fan motor switch 1 erie 1010.7) | Notes Water pump cover bolt 4 6 1303.9) ENGINE MOUNTING: Front engine mounting bolt 1 10 39 (4.0, 29) Rear engine mounting bolt 2 10 39 (4.0, 29) Engino braokot bolt 6 8 27 (8.0, 20) FINAL DRIVE: Final gear case assembly mounting nut 4 10 64 (6.5, 47) NOTE 7 Final drive oil filler cap 1 30 121.2, 9) Gear case cover bolt: 10 mm 2 40 47 (4.8, 35) NOTE 4 Gear case cover bolt: 8 mm 6 8 25 (2.5, 18) Pinion retainer 1 64 108 (11.0, 80) Fock tab bolt 1 6 40 (1.0.7) shaft nut 1 16 108 (11.0, 80) Dust guard plate bolt 1 6 10 (1.0, 7) NOTE 9 FRONT WHEEL/SUSPENSION/STEERIN Steering stem nut 1 24 103 (10.5, 76) +See page 14-37 Top thread A 1 26 25(2.5, 18) NOTE 2 Top thread B 1 26 = Top bridge pinch bolt 2 a 23 (2.3, 17) Bottom bridge pinch bolt 2 10 39 (4.0, 29) Front axle 1 14 59 (6.0, 43) Front axle pinch bolt 4 a 22 (2.2, 16) Front brake disc bolt 12 8 42 (4.3, 31) NOTE 4 2 37 23 (2.3, 17) 2 8 22 (2.2, 16) NOTE 4 Handlebar upper holder bolt 4 8 27 (2.8, 20) REAR WHEEL/SUSPENSION: Rear axle nut 1 18 88 (9.0,65) | NOTE 11 Rear axle pinch bolt 1 a 26 (2.7, 20) Rear brake disc bolt 6 8 42 (4.3, 31) NOTE 4 Damper holder plate bolt 5 6 202.0, 14) NOTE 10 Final driven flange bolt 5 10 59 (6.0, 43) Rear shock absorber upper mounting nut 1 12 108 (11.0, 80) | NOTE2, 11 Rear shock absorber lower mounting nut 1 10 44 (4.8, 33) NOTE 11, ‘Swingarm right pivot boit 1 23 10(1.0, 7) ‘Swingarm right pivot lock nut 1 23 98 (10.0, 72) ‘Swingarm left pivot bolt 1 23 98 (10.0, 72) Rear brake caliper stopper bolt 1 14 88 (9.0, 65) 1-16GENERAL INFORMATION Frame (Cont'd) tem arty | eee | nm matter) | Remarks HYDRAULIC BRAKE: Front brake caliper mounting bolt 4 8 [email protected],22) | Notes Rear brake caliper mounting bolt 1 8 232817) Rear brake caliper pin bot 1 2 27 28,20) Rear brake caliper bleeder 1 8 6 (06, 4.3) Rear brake pad pin 1 10 180.8, 19) Rear brake pad pin plug 1 1 3(0.3,22) Front brake caliper bleeder 2 10 44 (1.4 10) Brake lever pivot bolt 1 6 1(0:1,0.7) Brake lever pivot nut 1 6 6 (006,43) Front master eyinder holder bolt 2 8 42(1.2,9) Rear master cylinder holder bolt 2 6 12(1.2,9) Rear master cylinder oint lock nut 1 8 18(1.8,13) Rear brake reservol holder bolt 1 8 121.9) Front master eyinder cover screw 2 4 11.07 Front brake light switch screw 7 4 1(0.1,0.7) Brake hose oll bolt 5 10 29 (8.0, 22) Front brake hose guide bott 1 6 42(1.2,9) Rear brake hose guide bolt 2 6 12 (1.2, 9) Rear brake Hose joint screw + 4 2(02,14) | Notes Front brake pipe 2 10 17 (1.7, 12) Apply PZ100 LIGHTS/METERS/SWITCHES: Side stand switeh mounting bolt 1 6 1011.0.) Thermosensor 4 16 18 (18,13) 1-17GENERAL INFORMATION Tools Tool Number Remarks Float level gauge Pressure guage Oil pressure gauge attachment Universal bearing puller Gear holder Flywheel holder Rotor puller Sliding remover weight Valve guide remover, 5.5 mm (IN) Valve guide remover, 6.6 mm (EX) Valve guide driver Attachment, 32 x 35 mm Attachment, 42 x 47 mm Attachment, 52 x99 «un Attachment, 62 x 68 mm Attachment, 24 x 26 mm Inner handle Inner driver, 25 mm Inner driver, 30 mm Pilot, 17 mm| Pilot, 20 mm Pilot, 30 mm Bearing remover shaft Remover head, 20 mm Driver Valve spring compressor Seat cutter, 27.5 mm (45° EX) Seat cutter, 35 mm (45° IN) Flat cutter, 28 mm (32° EX) Flat cutter, 35 mm (32° IN) Interior cutter, 30 mm (60° EX) Interior cutter, 37.5 mm (60° IN) Cutter holder, 5.5 mm (IN) Cutter holder, 6.6 mm (EX) Valve adjusting wrench Lock nur wrencn Retainer wrench Snap ring pliers Snap ring pliers Steering stem socket Lock nut wrench Pinion holder Pinion holder plate = Set collar, 11 x 16 x 50 Puller shaft Bearing puller & driver attachment Remover handle Bearing remover set Valve guide driver attachment, 11.3 mm (IN) Valve guide driver attachment, 12.3 mm (EX) Ball driver attachment Ball race remover Steering stem driver Driver shaft Slider welght Seal driver attachment Driver handle 1-18 07401-0010000 07508-30000 07510-4220100 07631-0010000 07724-0010100 07725-00400 07733-0020001 07741-0010201 07742-0010100 07742-0010200 07743-00200 07746-0010100 07748-01030 07740-0010400 07746-0010500 07748-01070 07748-0030100 07746-03020 07746-0030300 07746-0040400 07746-0040500 07746-0040700 07746-0050100 07746-0050600 07749-00100 07757-0010000 07780-01020 07780-0010400 07780-0012100 07780-01230 07780-00140 07780-0014100 07781-0010101 07781-0010202 (97908-KE90000 (07908-ME90000 (07910-MA10000, (07914-5670101 07914-SA50001 07916-3710101 07916-MB00001 07924-Me40002 07724-ME40110 07924-ME40120, 07931-ME40000 07934-MB00000 07936-3710100, 07936-3710600 07943-MF50100 07943-MF50200 07945-3330300 07946-3710500 07946-MB00000 (07946-Mu00100 (07947-KA50100 07947-KF00100 07949-3710001 oF 07965 - 6920201 12, 13, 14, 15 12,13, 14 12 18 12, 13 13 12 12,18 19,14, 18, 12 14,18 14.15 12,13, 14, 15 10 10 10 10 10 10 10 10 10 3 13 R 16 1“ 2 8 13 18 2 12 10 10 13 14 4 15 14 14 18GENERAL INFORMATION Description Tool Number Remarks Ref. Section Ball race remover 07953-Mu10000 14 Slider weight (07947-KA50100 14 Seal driver attachment 07947-KF00100 14 Drive handle 07949-3710001 16 Ball race remover 07953-MJ10000 4 Driver attachment (07953-MJ10100 14 Driver handle 07953-MJ10200 14 Damper spring compressor (07964-ME90000 12 Disassembly tool 07965-3710101 12 Seal driver attachment 07965-KE80200 | or 07931 - 4630300 13 Valve guide reamer, 5.510 mm (IN) 07984-2000001 40 Valve guide reamer, (EX) 07984-2E20001 10 Bearing driver attachment O7GAD-SD40101 13 Oil filter wrench O7HAA-PJ70100 3,4 Peak voltage adapter (07HGJ-0020100 18 Pinion puller base O7HMC-MM80110 18 Bearing drive attachment O7HMF-Mmg0400 2 Clutch center holder (07JMB-MN50301 8 Pilot screw wrench, D O7KMA-MS60101 5 Holder A O7PAB-0010100 12 1-19GENERAL INFORMATION Lubrication & Seal Points Location Remarks Camshaft lobes/journals Valve stem (valve guide sliding surface) Rocker arm slipper surface Rocker arm shaft outer surface rankstatt crank pin ang Jourtias Glutch outer guide outer surface Transmission gear shift fork groove Transmission collar inner and outer surface Transmission spline collar outer surta Connecting rod small end inner surface Molybdenum disulfide oit (a mixture of 1/2 engine oll and 1/2 molybdenum disulfide grease) Piston outer surface Piston ring outer surface Piston pin outer surface Primary drive gear bolt threads and seating surface Flywheel bolt threads and seating surface Starter one-way clutch sliding lock surface Starter reduction gear shaft outer surface Clutch center lock nut threads Clutch lifter arm-to-right crankcase cover sliding surface Clutch disc outer surface Cylinder wali surface Cylinder stud bolt threads Cylinder 8 x 187 mm bolt threads Valve adjusting screw threads and seating surface Connecting rod bolt/nut threads and seating surface Gylinder head mounting volt an nut seating surhace Oil filter cartridge threads and O-ring Each bearings rolling area Each O-rings Fagina ail Crankshaft hole cap threads ‘Timing hole cap threads Each ail seal lipe Multi-purpose grease Cam sprocket bolt threads Starter one-way clutch housing bolt threads il pump driven sprocket bolt threads Stator wire holder socket bolt threads Gearshift cam plate bolt threads Transmission bearing set plate bolt th Countershaft oil seal set plate bolt threads Cam chain tensioner set plate bolt threads Stator mounting bolt threads ll filter boss crankcase side threads Ignition pulse generator bolt threads Left crankcase cover bolt threads (marked "A“) Locking agent Coating width: LLL 6.5=1mm (0.26 + 0.04 in)GENERAL INFORMATION Engine (Cont'd) Oil pressure switch threads 3-4 mm (019-048) Fan motor switch threads Location Material Remarks Cylinder head cover-to-gasket groove Honda Bond A or ‘equivalent FN Output gear case bolt threads Sealant 1-21GENERAL INFORMATION Engine (Cont'd) Location Right crankcase-to-cover mating surface Remarks Sealant 1-22GENERAL INFORMATION —Frame. Location Material ‘Remarks Final gear case O-rings and oll seal lips Multi-purpose grease Steering head bearing sliding surface Steering head dust seal lips ‘Swingarm pivot dust seal lips ‘Swingarm pivot bearing rolling area Front and rear wheels dust seal lips Each dust seal lips Each oll seal lips ‘Speedometer gear box inside Molybdenum disulfide ‘Speedometer gear and pinion sliding surface grease Throttle pipe inner surface and rolled-up portion Clutch lever pivot bolt sliding surface Main and side stand pivot sliding surface Rear brake pedal pivat sliding surface Gearshift pedal pivot sliding surface Seat lock sliding area Final drive pinion joint spline Spreading 2.0 9 Final drive shaft pline (universal joint side) Spreading 1.0 Final drive shaft oil seal lips Spreading 0.5.9 ‘Output driven gear shaft spline (universal joint side) Spreading 1.09 Universal joint bearings and dust seals Rear wheel hub-to-driven flange mating surface Molybdenum disulfide | Spreading 3.09 min. Rear wheel hub O-ring groove paste Final driven flange spline and O-ring groove Spreading 5.09 Final driven flange-to-final gear case O-ring holder mating surface Thermosensor threads Sealant Final gear case-to-case cover mating surface Steering top threads Engine oil Rear shock absorber upper bolt threads and sli Brake master cylincer inside DOT 4 brake fluid Brake master piston Brake caliper piston seals, Brake lever pivot and piston tips Silicone grease Spreading 0.1 g Brake caliper dust seals. Brake caliper slide pin sliding surtace Spreading 0.4 gin. Brake caliper bracket pin sliding surface Spreading 0.4 9 min, Rear master cylinder push rod rounded surface Spreading 0.1 g Rear master cvlinder boot setting area Spreading 0-1 g Brake cliper slide pin threads Locking agent Brake caliper bracket pin threads Rear brake hose joint screw threads Front fork socket bolt threads Main stand bolt threads Pinion joint nut threads Final gear case cover 10 mm bolt threads Final gear case stud bolt threads (gear case si Front brake caliper mounting bolt threads Rear brake caliper mounting bolt threads Front and rear brake disc bolt threads Handle grip rubber inside Honda Bond A or Spreading 80% min. equivalent Front fork oil seal and dust seal lips Fork fluid — 1-23GENERAL INFORMATION Cable & Harness Routing (2) COMBINATION METER WIRE (1) THROTTLE CABLES (@) GHOKE CABLE (6) SPEEDOMETER CABLE (7) BRAKE HOSE ~ (6) HORN WIRE 1-24GENERAL INFORMATION (1) THROTTLE CABLES (@,CLUTCH CABLE (6) BRAKE HOSE (6) SPEEDOMETER CABLE (@) BRAKE HOSE 1-25GENERAL INFORMATION (1) COOLANT OVERFLOW TUBE (10) STARTING ENRICHMENT VALVE CONTROL CABLES (2) SUB-AIR CLEANER TUBES (@) SECONDARY AIR INTAKE TUBE (@ FUEL TUBES (AIR SUCTION TUBES (#) CRANKCASE BREATHER TUBE (6) FUEL TANK AIR VENT TUBES. (7) AIR VENT TUBE. 1-26GENERAL INFORMATION (1) SPARK PLUG WIRE (@) SUB-AIR CLEANER TUBE (8) FRONT IGNITION COIL (4) SPARK PLUG WIRE SS (6) IGNITION PULSE GENERATOR WIRE (7) STARTER MOTOR CABLE — (6) CLUTCH CABLE (1) STARTING ENRICHMENT VALVE CONTROL CABLES (2) SECONDARY AIR INTAKE TUBES. (9) SUB-AIR CLEANER TUBES (4) PAIR CONTROL VALVE (10) FAN MOTOR VACUUM TUBES SWITCH WIRE (6) SPARK PLUG WIRES (@) AIR SUCTION TUBES (6) ALTERNATOR WIRE (7) NEUTRAL SWITCH/OIL PRESSURE SWITCH WIRE (@) SIDE STAND SWITCH WIRE 1-27GENERAL INFORMATION (1) BATTERY POSITIVE CABLE (@) FUEL TANK AIR VENT TUBES (2) Fuse Box (@) GROUND ae emanate per - aN We = (4) AIR VENT TUBE (6) REAR BRAKE HOSE (6) REAR BRAKE LIGHT SWITCH (1) FUEL FILTER, (@) BATTERY NEGATIVE CABLE (6) NEUTRAL SWITCH/OIL PRES- ‘SURE SWITCH WIRE (6) SIDE STAND SWITCH WIRE 1-28GENERAL INFORMATION (8) FUEL CUT RELAY (1) SADDLE BAG CABLES (@) GROUND & (7) TURN SIGNAL RELA (6) REAR LEFT TURN SIGNAL wire (6) TAIL/SRAKE TURN SIGNAL WIRE (4) REAR RIGHT TURN SIGNAL WIRE (@) REAR BRAKE HOSE 1-29GENERAL INFORMATION Emission Control Systems Source of Emissions ‘The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic. ‘SW, AR Types Honda Motor Co., Ltd. utilized lean carburetor setting as well as other systems, to reduce carbon monoxide and hydrocarbons. The engine equipped witha closed crankcase system which routes crankcase emissions through the er cleaner into the combustion chamber Condensed crankcase vapors are accumulated in a crankcase storage tank and drain tube which must be emptied periodicaly (page 8-3). The drain tube needs to be checked for oil accumulation more frequently ifthe machine has been consistently ridden at high speeds or in rain. (1) AIR. CLEANER, (@) CARBURETOR (2) CRANKCASE BREATHER TUBE a © QLeRESH AIR @8Low-sy Gas. 1-30GENERAL INFORMATION ——————————— Exhaust Emission Control System (Secondary Air Supply System) ‘The exhaust emission contro! system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop control knob. The exhaust emission control system is separate from the crankcase emission control system. The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a consi | | = oe i \ (o| iS) ty aes) ne= i a \) = J J) i (3) O1L PUMP (4) 01 STRAINER, (5) PRESSURE RELIEF VALVE4, Lubrication System ‘SERVICE INFORMATION 44 ENGINE PRESSURE CHECK 4-3 TROUBLESHOOTING 42 OIL PUMP. 44 Service Information GENERAL ‘If the engine must be running to do some work, make sure the area Is well ventilated. Never run the engine in ‘an enclosed area, The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness \d may lead to death. Run the engine in an open area or with an exhaust evacuation system in enclosed * 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 oll on a dally basis, itis still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oll. KEEP OUT OF REACH OF CHILDREN. ‘© The engine must be removed from the frame before servicing the oll pump. ‘+ When removing and installing the oil pump use care not to allow dust of 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. ‘= After the engine has been installed check that there are no oll leaks and that oil pressure is correct. ‘For oll pressure indicator inspection, refer to section 20 of this manual. SPECIFICATIONS. Unit: mm (in) item ‘Standard Service Limit Engine ol ca ‘for draining 2a kere @52 US. ak 2.11 mp a = ‘After cisassombiy 3. ters @.15 US. at, 2.64 Imp at) = ‘After ll fiter orange 2.6 kere 2.79 US. at 2.29 mp at = Recommended engine ol Honda 4-troke olor equivalent, motor i = [API service ciasification SE, SF or SG viscosity: SAE 10W-40 (Oil pressure at oll pressure switch “441 kPa (4.5 kgl/on", 64 psi = £6,000 min* (rpm) (80° C/176" F) ‘Oil pump rotor Tip clearance 10.15 (0.006), 0.20 (0.008) Body clearance (0.15 - 0.22 0,006 - 0.008), 0.95 (0.014) ‘Side clearance (0.02 -0.07 (0.00% - 0.003) 0.10 (0.004)LUBRICATION SYSTEM TORQUE VALUES ll pressure switch Oil pressure switch wire terminal screw il pump cover bolt Engine oil filter boss (stud) TOOLS Ol fitter wrench Oil pressure gauge Oil pressure gauge attachment Troubleshooting Oil level low # Oil consumption = External oil leak ‘+ Worn piston ring or incorrect piston ring installation ‘+ Worn valve guide or seal ‘Ol contamination (White appearance) ‘© From coolant mixing with oil - Faulty water pump mechanical seal - Faulty head gasket = Water leak in crankcase No oil pressure = Oil level too low * Oil pump drive chain or drive sprocket broken ‘= Oil pump damaged (pump shaft) ‘Internal oil leak Low oil pressure ‘© Pressure relief valve stuck open ‘* Clogged oil filter and strainer screen = Oil pump worn or damaged * Internal oil leak * Incorrect oil being used = Oil level tool low High oil pressure ‘© Pressure relief valve stuck closed * Plugged oi titer, gallery, or metering orifice * Incorrect oil being used 12.N-m (1.2 kgt-m, 91bF-M) Apply sealant to U 2.N-m (0.2 kaf-m, 1.4 Ibf-ft) 431N-m (1.3 kgf-m, 9 IDF) CT bolt 18 Nem (1.8 kaf-m, 13 Ibf-ft) Apply a locking agent to the threads threads O7HAA-PJ70100 ‘97506-3000000 07510-4220100 Seized engine ‘= No or low oil pressure ‘* Clogged oll orifice/passage «Internal oll leak ‘* Non-recommended oll used * Deteriorated oil * Faulty oi filter * Worn piston ring (White appearance with water or moisture) = Damaged water pump mechanical seal - Damaged head gasket = il relief nat frequent enough Oil pressure warning indicator does not work * Faulty oil pressure switch © Short circuit in the indicator wire * Low or no oil pressure