1998-2001HOW TO USE THIS MANUAL This service manual describes the service procedures for the VFRBOOFI Follow the Maintenance Schedule (Section 3) recom- ‘mendations to ensure that the vehicle is in peak oper- ating condition and the emission levels are within the standards set by the U.S. Environmental Profection ‘Agency and California Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that ‘occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removaljinstalla tion of components that may be required to perform service described in the following sections. Section 4 through 19 describe parts of the motorcy- cle, 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 illus: tration, service information and troubleshooting for the section, The subsequent pages give detailed pro- codure, If you are not femiliar with this motorcycle, read Technical Features in section 21 If you don't know the source of the trouble, go to sec- tion 22 Troubleshooting. ‘ALL INFORMATION, ILLUSTRATIONS, DIREC- 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 OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED. WITHOUT WRITTEN PERMISSION. THIS MAN- UAL 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 CONTENTS GENERAL INFORMATION E I FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM (FUEL SYSTEM {Programmed Fuel Injection) COOLING SYSTEM Ey ENGINE REMOVAL/INSTALLATION eB CYLINDER HEAD/VALVES | CLUTCH GEARSHIFT LINKAGE CRANKCASE/PISTON/CYLINDER i E CRANKSHAFT/TRANSMISSION E 12 FRONT WHEEL/SUSPENSION/ STEERING EE REAR WHEEL/SUSPENSION ENGINE AND DRIVE TRAIN CHASSIS HYDRAULIC BRAKE z z g 5 ELECTRIC STARTER/STARTER CLUTCH fis SS, @ - LIGHTS/METERS/SWITCHES E ED WIRING DIAGRAM By TECHNICAL FEATURES - EI | TROUBLESHOOTING eg INDEX ~ Date of lesue: January, 1998SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required per- taining to these symbols, it would be explained specifically in the text without the use of the symbols. Ss Replace the part(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. a 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 Sie 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) ie Example: Molyxote® 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 ie Use silicone grease. ym powivaocing agent Use # mide suength locking agent unless otherwise spect. sm Apply sealant, é Use DOT 4 brake uid. Use the resommenide brake fud unless otherwise spectied aq Use Fork or Suspension Fluid1. GENERAL INFORMATION i GENERAL SAFETY 1-1 LUBRICATION & SEAL POINTS 4-20 SERVICE RULES 1-2 CABLE & HARNESS ROUTING = EE MODEL IDENTIFICATION 13. EMISSION CONTROL SYSTEMS 144 SPECIFICATIONS 1-4 EMISSION CONTROL INFORMATION TORQUE VALUES 114 LABELS 147 TooLs 1.18 GENERAL SAFETY CARBON MONOXIDE USED ENGINE OIL 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 and may lead to death, Ged wong ony come Hiya repeeedy Wh Se i rt ete nateogh It att nttatalencrontiv sesh your hands por piney repeenupbe rnp inser od ae oes Sur OF neaw OF oonen Run the engine in an open area or with an exhaust evac: uation system in an enclosed area, GASOLINE Work in 2 well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is, stored = Gasoline is extremely flammable and is explosive under certain conditions. KEEP QUT OF REACH OF CHILDREN. HOT COMPONENTS = Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. Inhaled asbestos fibers have been found to cause respi- ratory disease and cancer. 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.GENERA FORMATION ‘COOLANT Under some condition, the ethylene glycol in engine coolant is combustible and its lame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned. =a Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame. + Coolant (ethylene glycol) can cause some skin irrita- tion and is poisonous if swallowed. KEEP OUT OF ‘REACH OF CHILDREN. + Donot remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. + Keep hands and clothing away from the cooling fan, as it starts automatically. SERVICE RULES BATTERY HYDROGEN GAS & ELECTROLYTE = 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. — Ifelectrolyte gets on your skin, flush with water. — 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 ‘ilk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN, 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA’s design specifications may cause damage to the 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 diago- nally in incremental steps unless a particuler sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. 8, Route all electrical wires as show on pages 1-24 through 1-43, Cable and Harness RoutingGENERAL INFORMATION MODEL IDENTIFICATION (1) The frame serie! number is stamped on the right side of the steering head. ENGINE SERIAL NUMBER. (2) The engine serial number is stamped on the (3) The Vehicle Identification Number (VIN) is located lower left side of the cylinder block. cn left side of the frame on the Safety Certification Label COLOR LABEL, ee NUMBER, (4) The throttle body identification number is (5) The color label is attached as shown. When stamped on the front side of the throttle body as, ordering color-coded parts, always specify the shown. designated color code.GENERAL INFORMATION. SPECIFICATIONS > GENERAL mem SPECIFICATIONS DIMENSIONS | Overall length 2,100 mm (82.7 in) Overall width 735 mm (28. in) Overall height 1.190 mm (46.9 in) Wheelbase 1,440 mm (86.7 in} | Seat height £805 mm (31.7 in) Footpeg height Ground clearance Dry weight 49 statos/Cananda type California type Curb weight 49 states/Cananda type California type ‘Maximum weight capacity 351 mm (13.8 in) 430 mm (8.1 in} 208 kg (459 Ibs) 210 kg (463 Ibs) 234 kg (516 Ibs) 236 kg (620 Ibs) Reer damper Front tire size Rear tire size Tire brand Bridgestone Dunlop Metzeler Front brake Rear brake Caster angle Trail length Fuel tank capacity 49 states, 409 kg (902 Ibs) Canands type 413 kg (910 Ibs) California type 411 kg (908 lbs) FRAME Frame type Diamond Front suspension Telescopic fork Front wheel travel 120 mm (4.7 in) Rear suspension ‘Swingarm Reer whee! travel 120 mm (4,7 in) Nitrogen gas filled damper 120/70 ZR 17 (68) Radial 180/55 ZR 17 (73W) Radial Front: BT57F Radial J/Rear: BTS7R Radial J Front: D204FK/Rear: D204K Front: MEZ4/Rear: MEZA Hydraulic double disc brake with 3 pots caliper Hydraulic single disc brake with 3 pots caliper 25.5° 95 mm (8.7 in | 21.0 liter (5.55 US gal, 4.62 Imp gall Bore and stroke Displacement Compression ratio. ENGINE Lubrication system Oil pump type. Cooling system Air filtration Crankshaft type Engine dry weight, Firing ord Cylinder arrangement Valve train Intake valve opens — at 1 mm closes — Exhaust valve opens — closes — 72.0 x 48.0 mm (2.83 x 1.89 in) 781 cc (47.6 cu-in) 16:1 Cam gear driven DOHC, 4 valves per cylinder 10° BTDC (49 states/Canada type) 8° BTDC (California type) 35° ABDC 35* BBDC 10° ATDC (49 states/Canada type) =5° ATDC (California type) Forced pressure and wet sump Trochoid/double rotor Liquid cooled Oiled paper filter Unit type, 3 main journals 74 kg (163 Ibs) No. 1 180°-No. 3-270°~ No. 2~ 180° 90°v No. 4-90" -No. 1GENERAL INFORMATION ———— eSeSSSSSSSSSSSSOSSE TE Oe ee~-™ - GENERAL (cont’d) rem SPECIFICATIONS CARBURETION | Type PGM-FI (Programmed Fuel Injection) Throttle bore 36 mm (1.4 in) [DRIVETRAIN | Clutch system ‘Mutti-plate, wet Clutch operating system Hydraulic operated type Transmission Constant mesh, 6-spead Primary reduction 1,939 (64/33) Final reduction 2.529 (43/17) Goar ratio ast | 2.846 (37/13) 2nd | 2.082 (33/16) 3rd 1.831 (31/19) 4th | 1.333 (28/21) th | 1.159 (30/26) 6th | 1.035 (29/28) Gearshift pattern | Left foot operated return system, 1-N-2-3- 4-5-6 ELECTRICAL Ignition system ‘Computer-controlied digital ransistorized with electric advance Starting system Charging system Regulator/rectifier Lighting system Electric starter motor Triple phase output alternator SCR shorteditriple phase, full wave rec BatteryGENERAL INFORMATION > LUBRICATION SYSTEM Seem rreM STANDARD SERVICE LMT Engine oil capacity [Ataraining 28 liter (3.1 US at, 2.6 Imp at) — iz disassembly 3.8 liter (4.0 US qt, 3.3 Imp qt) — | ___[avoititerehenge | 8.1 tor 83 US 27 Impat — Recommended engine oll HONDA GN éstroke all or equivalent motor al | | APlservice classification Sears = | |=) —— Viscosity SAE TOW. Gir preesre ot ol prosure sich 490 KPa (5.0 kg, 77 pa ot — 6,000 rpmi(80°C/176°F) Oil pume rotor | Feed pump | Tip dearanee 0415 (0.006) max 0.20 (6.008) Body clearance 0.45 - 022 (0.008 = 0.005) 035(0.014) Side clesranco 002-007 0001-0003) 10,6008) Coster pump | Tip learance 015 (0.06) max 0.20 (0.008) Body clearance 015-022 (0,006 = 0.008) 035 0.014) Side clerance 0102-007 (0.001 0.003) [0:0 0.000 > FUEL SYSTEM (Programmed Fuel Injection) $$ TEM ‘SPECIFICATIONS | Throitie body identification 49 states/Canada type GO30A | number California type 60308 Starter valve vacuum difference 20 mmHg | Base throttle valve for synchronization - No.1 Idle speed 49 states/Canada type 1,200 100 rpm California type 1,300 £ 100 rpm, | Throttle grip free play 2= 6mm (1/12 - 1/4 in) Intake air temperature sensor resistance (at 20°C/68°F) 1-4ko Engine coolant temperature sensor resistance (at 20°C/68"F) 23-26k0 Cam pulse generator resistance (at 20°C/68°F) 400-600 2 | Fuel injector resistance (at 20:C/68°F) 13.0 14.4 KO -| Bypass solenoid valve resistance (at 20°C/68°F) 28-320 PAIR solenoid valve resistance (at 20°C/68°F) 20-240 Purge control solenoid valve resistance (at 20°C/68°F) 30-340 | Cam pulse generator peak voltage (at 20°C/68°F) 0.7,V minimum | Tonition pulse generator peak voltage (at 20°C/68°F) (0.7 V minimum | Manifold absolute pressure at idle 200 - 250 mmHg Fuel pressure at idle 250 kPa (2.85 kat/em’, 36 psi) Fuel pump flow (at 12V) 180 0c (5.0 US 07, 5.3 Imp 02) minimum/10 secondsGENERAL INFORMATION + COOLING SYSTEM mem SPECIFICATIONS Coolant capacity Radiator and engine 276 er 2.9 US at 24 Imp a Reserve tank 0.45 liter (0.5 US at. 0.4 Imp at) Faciator cap relef pressure - 108 ~ 137 kPa (1.1-1.4 Kotler’, 16 -20 psi) Thermostat Begin to open 80 - 84°C (176 - 18957) Fully open ~ 95°C (20371 Vale lift Sram 03in) minimum —————*d + CYLINDER HEAD/VALVES Unitrin) Tem STANDARD SERVICE LIMIT Cylinder compression 1 981-1373 kPa 100-140 kotion®, | 142 ~ 199 psip at 300 rpm —_ Cylinder head warpage — 0.10 0.008) Valve, Valve clearance 0.18. 0.03 (0.006 = 0.007) — valve guide LEX | 030+ 0.03 (0.012 + 0.001) i ‘Valve stem O.D. LIN 4.475 ~ 4.490 (0.1762 ~ 0.1768) | 4.468 (0.1758) EX _| 4.465 - 4.480 (0.1759 -0.1768) 14.455 (0.1788) | Valve guide 1. IN| 4500-4512 (0.1772 0.1778) 4540(0.1787)_| EX | 4.500 4.512 (0.1772 -0.1776) | 4540 0.1787) | ‘Stem-to-guide clearance IN| 0.010 0,037 0.0004 -0.0015) — EX | 0.020-0.047(0.0008-0.0019) _| Valve guide projection above | IN| 17 (0.7) cylinder head x Ten Valve seat width TWEX | 09- 1.1 (0035 - 0.083) 15 (0.08) Valve spring | Inner INEX | 3851156) 376 11.48) free length Outer INEX | 425 (167) 405 (159) | Valve lifter Valve lifter 0.D. IN/EX | 25,978 - 25.993 (1.0228 - 1.0233) 25.97 (1.022) [Valve lifter bore I.D. IN/EX | 26.010 - 26.026 (1.0240 - 1.0246) 26.04 (1.025) Camshaft Cam lobe height IN 36.24 ~ 36.48 (1.427 — 1.436) ~ | 36.21 (1.426) (49 states/Canada type) EX 36,08 - 36.32 (1.420 - 1.430) 36.05 (1.419) [Cam lobe height IN| 35.34 - 35.58 (7.391 - 1.400) 35.31 (1.390) (California type) EX | 35.18 — 35.42 (1.385 - 1.394) 36.15 (1.384) | Journal 0.0. 24.989 — 24.980 (0.9826 - 0.9835) Runout — 0.05 (0.002) Oil clearance |_.0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)GENERAL INFORMATION — cLurcH Unit: men lin) Tem STANDARD SERVICE LIT Recommended clutch fuid DOT brake id — ~ Ctch master evlinder Cylinder 14.000 - 14.069 (0.519 —08829) 14.06 (0.554 [Piston 0.0. _ | 13.957 - 13.984 (0.5496 - 0.5506) 13.94 (0.549) Clutch outer guide LD. _ 24.995 ~ 25,012 (0.9841 - 0.9847) 25.08 (0.987) Clutch spring free length 46.5 (7.80) : 26.68 | Clutch disc thickness 2.92 ~ 3.08 (0.115 - 0.121) 2.5 (0.10) ~ Clutch plate warpage — - 0.30 (0.012) Unit: mn 7. CRANKCASE/PISTON/CYLINDER TEM STANDARD SERVICE LIMIT Gyinder LD. : (72.000 - 72.015 (2.8946 - 2.8969) 721012899) | Out ofround — 0.10 (0.008) Taper — 0.100.004 Werpage (0.10 (0.004) Piston, Piston mark direction "IN" mark ocng toward the ntale side | — Pistonrings Piston OD. 71975 72.008 28957-28048) | ‘7480289 Piston 0.D. measurement point 18 mm (0.7 in) from bottom of skit | — Piston pin bore LD 17.002 - 17,06 (0.5694 ~ 0.696) 77.02 (0870) | Piston pin 0.D. 16.994 ~ 17.000 (0.6691 - 0.6693) 16.98 (0.669) Fiston-to-rston pin clearance 01002 0.014 (0.0001 0.006) 04 (0.002) Fisionringtoring | Top 0.030 0.065 (0.0072 0.0026) a1 (0008) | groove clearance | Second | 0015 0.650 (0.0008 0.0020) 0.100.008 Piston ring ond gap | Top 020-030 (0008-0012) 05 0.02 ‘Second 0.30 ~ 0.45 (0.012 - 0.018) 7 0.6 (0.02) | _[[oit ice rai | 020-070 0.008 -0.028) 29 (0.08 hinderso-iston clearance 1.015 - 0.050 (0.0008 0.0020) — Connecting rod stall end LD. 1.076 17.036 (0.6599 0.5706) rosa aro) Connecting rod-te-piston pn Clearance 1016 -0.040 (0.0008 0.0016) — Crankpin oil clearance 0.030 — 0.052 (0.0012 - 0.0020) (0.08 (0.003)GENERAL INFORMATION > CRANKSHAFT/TRANSMISSION, Yan in TEM STANDARD SERVICE UM Crankahakt | Sidecleranco 0.10 0200004 0.012 [ew oor8) Runout 0.030.000, Main our ol slerance 1028 0.01 (00008 -a.0T6 0.08 0.021 Transmission | Geer. M5, MB 2.000 - 28024 (1.1024 1.1082) 2204 1.00 | ci 26.007 2028 (1.0239~ 0247 7506 (1.975) ce 31.000 91.016 (1.2005 ~1.2211) 103.222) roc | 3.000 = 2.096 71.2005 1.2016) 94 220 Bushing 0. | MS, MB 27969-27880 (1.1067 11018) | 2744100) c2 | 30.970 - 30.995 (1.2193 - 1.2203) [30.95 (1.219) cc 30.950 99875 (1.2185 — 12195) sosa(i218) | Bushing. | MS 24.965 25.006 (09897 - 0.9645) 25.09(0.985) cz 2.000 = 28.024 .1028 =. 1022) 20.106) Gear-to-bushing | M5, M6 0.020 - 0.062 (0.0008 - 0.0024) — dleorance Tce 0.005 = 0.046 (0.0008 =0.00%8 | ca.0 0250.75 (09010-00080) — | Mainshaft 0.0. | M5 "24.959 - 24.980 (0.9826 - 0.9835) 24.95 (0.982) Courteretat | C2 27 967 77.800 (1.1011- 1.1036) 27961.) Bushingionnam [WE 005-0047 (00002 -000%—) | | clearance c2 0.020 - 0.054 (0.0008 - 0.0021) — Shift fork, fork | Shift fork Fork LD. 14.000 - 14.021 (0.5512 - 0.5520) 14.03 (0.552) shat | Caw Wickness | 64-650 (0259-02961 6.0 (0252 Fork shaft 0.0. 18.973 ~ 13.984 (0.5501 — 0.5506) 13,965 (0.5498),GENERAL INFORMATION [- FRONT WHEEL/SUSPENSION/STEERING Unt me fn} ire STANDARD SERVICE LIMIT 1.5 (0.06) ~ Cold tire pressure | Up to 90 kg (200 Ib] load 250 kPa (2.50 kaf/em?, 36 psi) — Up to maximum weight copesty 250 KPa (2.50 ker 36 psi) — Axle runout — 0.20 0.008) Wheel rim runout | Radial — 2.0 (0.08) Axial [ —— 2.0 (0.08) a Fok Spring ee levath 327 SOT 3750 (1476) Spring direction With the tapered end facing down — Tube runout 10.20 (0.008) Pre-oad adjuster standard position | 8mm (0. i fom top suase offorkcap | —— VV Recommended fork fluid Pro Honda Suspension Fluid SS-8 —_— Fiuid evel 130 6.1) — Fluie capacity 457 = 2505 (1554008 US 02, —_ 16.1 0.08 Imp oa Steering head bearing pre-load 1.0 ~ 1.5 kgf (2.2 - 3.3 Ibf) — nin) ;- REAR WHEEL/SUSPENSION TEM STANDARD SERVICE Limit Minimum tire tread depth — 2.0 (0.08) Cold tire pressure | Up to 90 kg (200 Ib) load 290 kPa (2.90 kgt/cm?, 42 psi) — | Up to maximum weight capacity 290 kPa (2.90 kaflem?, 42 psi) — SS Axle runout I — 020 0.008) Wheel rim runout | Radial t 2010.08) ‘Axial 2.0 (0.08) | Drive chain | Siofink DID OVA? ~108LE RK | HFOZ3 - 108LE — | Slack [20-30 (09-12) 502.0) Shock absorber | Preioad adjuster stendard postion | 2nd groove — Rebound damping adjuster standard | 1-1/2 tums fom full hard _ positionGENERAL INFORMATION (— HYDRAULIC BRAKE Lnit-mmn inh TM STANDARD SERVICE UNATT | Front | Specified brake fluid bors | Brake die thickness 45 (0.1) 3510.18 Brake aise runout — 0.300.012) [ Master evinder LD. 12.700 12.043 (05000-05017) 72:76 (0502), Master piston 0.. 12.657 12.684 (0.4963 —0.4994) 72.65 (0.498) Secondary master cylinder LD 12.700 12.043 (0.5000 - 0.5017) 12.76 (0.502) Secondary master piston O.D. [12.657 ~ 12.684 (0.4983 0.4998) 12.65 (0.498), Caliper cylinder LO. | Right | Upper | 27.000~27.060 (7.0630 ~ 1.0850) 77.080 (7.0658) | Middle | 22.650~ 22.700 0.8917 ~0.6937) 22.710/0.6981) Lower | 25.400 25.450 (7.0000 = 1.0020) 25.460 (7.0028) Left Upper | 25.400 - 25.450 (1.00¢ 25.460 (1.0024) | Middle | 22.650 22.700 0.8917 — 22.710 0.8941) | Lower | 22.650 22.700 (0.8917 - 22.710 (0.8941) Caliper piston OD. | Right | Upper | 26.916 26.968 (1.0597 - 1.0617) 26.910 (1.0594) | | Middle | 22.585 - 22.618 (0.8892 - 0.8905) 22.560 (0.8882) | [Lower | 25.318 - 25.368 (0.968 - 0.9987) 25.310 (0.9965) Te [Upper | 25.318 26.368 (0.9968 0.9987) 25.310 0.9965) Middle 22.585 ~ 22.618 (0.8892 - 0.8905) 22.560 (0.8882) | [Tower | 22.585 - 22.618 (0.8892 - 0.8905) 22.560 (0.8882) Rear Specified brake fluid bors | — Brake pedal height 675 (266) 7 — | Brake disc thickness 6.0 (0.24) 5.0 (0.20) Broke dise runout — 0.30 0.012) | Master cylinder LD. 17.480 17.503 (06874-06891) | 17.515 0.6896) Master piston O.D. - ‘17.417 — 17.444 (0.6857 — 0.6868) 17.405 (0.6852) | Caliper cylinder. Front | 22.650~ 22.700 (0.8917 -0.8837) 72.710 0.8941) | Center 27.000 - 27.050 (1.0630 - 1.0650) 27.060 (1.0654) Rear | 22.650 22.700 (08917 - 0.8937) 22.71010.8941) Caliper piston 0.D. Front 22.585 ~ 22.618 (0.8892 ~ 0.8905) | 22.560 (0.8882) Center | 26.916 - 26.968 (1.0597 - 1.0617) 26.910 (1.0594) Rear | 22.585 ~ 22.618 (0.8802 - 0.8905) [22.560 (0.8882)GENERAL INFORMATION ;- CHARGING SYSTEM/ALTERNATOR TEM SPECIFICATIONS [Batey ‘| Capacity 12V= 10h Current leakage - 1.2 mA max. Voltage (20°C/68°F) | Fully charged 130-132 Needs charging Below 123V Charging current | Normal 126-10 fou BOATOh Alternator Capacity 0.47 KN/5,000 rom Charging col resistance 20°06) o1-108 Regulator/rectfier regulated voltage 14.0 14.8 V/5,000 rpm ;- IGNITION SYSTEM ITEM SPECIFICATIONS Spark plug NGK CROEH-9 DENSO U27FERS Spark plug gap (0.8- 0.9 mm (0.03 - 0.06 in) [ Ignition coil peak voltage Ignition pulse generator peak voltage 100 V minimum 0.7 V minimum Ignition timing ("F* mark) 19 statesiCanada ty 15° BTDC atidle California typo 10° BTDC a | ELECTRIC STARTER/STARTER CLUTCH wt men fn rreM STANDARD SERVICE LIMIT Starter motor brush length 12.0 - 13.0 (0.47-0.51)_ 4.5 (0.18) Starter driven goar 0. 15.657 ~ 45,673 (1.7975 17961) #846 (1.797)GENERAL INFORMATION Front tum signalrunning light ;- LIGHTS/METERS/SWITCHES eM SPECIFICATIONS Bulbs [Headlight ito) 1aV- «645 Wad Brakorallight 12V-205 Wx2 12V- 215 Wx2 Rear turn signal light 12V-21Wx2 License light 12V-8W. Instrument light 12-17 Wx5 Turn signal indicator igh beam indicator jeutral indicator Oil pressure indicator PGM-FI malfunction indicator ‘Stop to open. Fuse ‘Main fuse [A 8 EN Sub fuse 20Ax2,10AX6 Coolant temperature sensor resistance (at 50°C/122°F) 68-720 Fan motor | Start to close (ON) — 98 — 102°C (208 - 216°F) switch 93 97°C (199 - 207F)GENERAL INFORMATION TORQUE VALUES TORQUE |__ToRQUE FASTENER TYPE Nem (kgf-m, Ibf ft) FASTENER TYPE Nem (kgfm, IbFft) mm hex bolt and nut 5(05,36) | Smmscrew 404,29) 6 mm hex bolt and nut 10(1.0,7) | & mm screw 9109, 65) ‘8 mm hex bolt and nut 22(2.2,16) 6 mmflange bolt (@ mm head 9109.65) 10mm hex bolt and nut 34(35,25) small flange) — 12mm hex bolt and nut 54 55, 40) O @ 6 mm flange bolt (10 mm head: 12112,9) large flange) and nut > | CO) dam | OY 8 mm flange bolt and nut 28 (2.7, 20) | 10mm flange bolt and nut 39 (40, 29) + Torque specifications listed below ore for important fasteners + Others should be tightened to standord toraue values listed above NOTES: 1. Apply sealant to the threads. 2: Apply locking agent tothe threads. 3. Apply grease tothe threads. 4. Stake 5: Apply il tothe threads and flange surface 6. Apply clean engine ollto the Oving. 7. Unt 8. ALOC bolt: replace with @ new one. © cT bat i ENGINE vty | THREAD TORQUE rem ory DIA. (mm) Nem (kgf-m, Ibfft) REMARKS | MAINTENANCE: Spark plug 4 w | 2.9) | Timing hole cap 1 45 18 (18,13) NOTES LUBRICATION S¥STE! | oiterain bot 1 2 29 (30, 22) Oil pump assembly flange belt 2 6 12(12.9) | NOTES Oil pump driven sprocket bol 1 6 | 1118.13) NOTE? Oil fitercortidge 1 20 10110,7) | NOTES. Oil pressure switch 1 Pre 121129) | NOTE PGMCFI (Programmed Fue! Injection Engine coolant temperature (ECT) sensor 1 2 23123, 1) Insulator band screw 4 5 — See page 1-15 Fuel pressure regulator mounting nut 1 2 29 (30, 22) Fuel injector holder mounting bolt 4 6 10(10,7) Fuel pipe mounting nut 2 2 2212.2, 16) COOLING SYSTEM: Water pump cover bolt 2 6 13(13,9) | NoTES CYLINDER HEAD/VALVES: Cylinder head cover bolt 8 6 10(10.7) Breather plate flange bolt ‘ 6 12(12.9) | NoTE2,9 PAIR reed valve cover flange bolt va 8 3218278) | Nore Camshaft holder flange bolt | 6 | 12112,9) | Notes Cylinder head mounting bolt | 2 9 | atias.39 | NoTES Cylinder head sealing bolt ja 18 32(33,24) | NOTE2 Cylinder head stud bolt |e 8 ———" | See page 1-15 Gear train mounting bokwasher Le 6 | ae)— ENGINE (cont’d) GENERAL INFORMATION THREAD TORQUE ‘ret LOT) pia. ime) | rem tkgtm, tarry REMARKS CLUTCH: | [. Clutch center lock nut | 2 12713094) | NOTE 4,5 Clutch slave cylinder bleeder 8 909,65) | GEARSHIFT LINKAGE Drive sprocket cover rubber mounting bolt 2 6 12(12,9) | NOTE2,9 Drive sprocket special bolt 1 | 10 515.2, 38) Shift drum center socket bolt 1 8 73(23,17) | NOTE2 Shift drum stopper pivot bolt 1 6 12(1.2,9) Gearshift return spring pin 1 8 23(23, 17) (CRANKCASE/PISTON/CYLINDER: Crankease bolt, 10 mm 5 wo 394.0, 29) 9mm 8 9 See page 11-12 | NOTES 7mm 3 7 18118, 13) Lower crankcase sealing bolt i 20 29(30,22) | NoTE2 Connecting rod nus 8 8 3313425) | NOTES | CHARGING SYSTEM/ALTERNATOR: | Flywheel flange bolt ba 10 103 (10.5, 76) | NOTES Stator mounting tore bolt loa 6 12(1.2,9) Aerator wit lr sockt bolt 4 3 has) IGNITION SYSTEM: | Ignition pulse generator SH bolt 2 6 12112,9) | ELECTRIC STARTER/STARTER CLUTCH: lanition pulse generator rotor/orimary drive gear bolt. =| 1 10 103105, 76) | NOTES LIGHTS/METERS/SWITCHES: Neutral switeh 1 10 1202.9) it filter bors: Exhaust pipe stud bolt 215405 mm 77.0- 180mm (0.85 + 0.02 in) a (087 £0.71 in) Insulator clamp (cylinder head side): 10+ 1mm (0.4+ 0.04 in) Insulator clamp (throttle body side}: | T= 1mm (0.30.04 in) |GENERAL INFORMATION [- FRAME Vary | THREADDIA. | TORQUE rem OTH ev) Nen koi, ery | REMARKS FRAME BODY PANELS /EXHAUST SYSTEM: Side stend pivot bot 1 10 1011.0. Side stand pivot lock aut 1 10 29 (30,22) Side stand bracket bolt 2 10 39 (4.0, 29) Side stend switch mounting bolt 1 6 10110,7 | NoTEe Main stand mounting bolt 1 10 54 (55,40) | NOTES oar grip socket bolt 4 8 34 (3.5, 25) Exhaust pipe joint special aut 8 6 12(1.2,9) Muffler bracket bolt 1 a 21 (2.1, 15) Upper cow stay mounting flange nut 2 8 32(33,28) | NOTE7 Upper cowl screw 2 5 400.18, 1.) Side cowl serew 70 5 1(0.15,1.1) Inner half cow! serow 4 5 140.18, 1.41) Meter panel screw | 2 5 100.15, 1.1) Rear cow! screw 4 5 440.15, 1.3), Seat rail spacial bolt 2 10 48(65,39) Seat ral flange nut \ 2 10 44(65, 33) Bank sensor 2 8 22 (22,16) Pillon step flange bolt 4 8 32 (3.3, 24) PGM-l (Programmed Fuel Injection! Fuel tube bolt (uel tank side) 1 2 22(2.2,16) | Yellow paint Fuel tube sealing nut A (throttle body side) 1 2 22 (2.2, 16) Fuel pump mounting flange nut 6 6 12(12,9) | See page 5-49 Fuel filer cop socket bolt 3 4 2001813) | COOLING sySTEM: Cooling fan motor nut 1 6 2.50.25, 1.8) | Note2 Fan motor switch 1 16 18(18, 13) | Note 1 ENGINE MOUNTING Engine hanger nut (front) 1 2 54(55, 40) —-See page 77 Engine hanger flange bolt (middle/rear) 4 10 445,33) Shock absorber lower bracket flange cap nut (upper) 1 10 39 (40,29) Shock absorber lower bracket flange nut (lower) 1 10 42(43,31) | NOTET cure: | Clutch master cylinder holder bolt 2 6 12(12,9) Clutch master cylinder cap screw 2 4 10.15, 3.1) Cluten lever pivot bolt 1 6 110.1,0.7) Gluten lever pivat nut fa 6 6108, 43) Clutch lever adjuster 1 5 410.4, 2) Cine eae 4 : feet (GEARSHIFT LINKAGE: | Gearshift pedal flange bolt 1 6 10K, | FRONT WHEEL/SUSPENSION/STEERING: Hendlebar pincn bolt 2 8 28 (2.7, 20) Handlebar woignt mounting serow 2 6 70(1.0,7) | NOTES Steering stem nut 1 2 103 (108, 76) —/-See page 19:31 Top thread A 1 26 — 4 Top thread 8 1 26 — J Fork top bridge pinch bolt 2 8 232317) Fork bottom bridge pinch bolt 2 10 49 (50,36) Front axie bolt 1 14 53 (60, 43) Front axle holder bolt 4 8 2212.2, 16) Front brake dise mounting bolt 2 6 20(20,14 | Notes Forkcap 2 37 2312.3, 17) Fork socket bolt 2 2 2020.14 | Note2 Fork damper lock nut 2 10 202.0,14GENERAL INFORMATION | FRAME (cont'd) | THREADDIA. | ‘TOROUE | TEM ory (eam) | Nem (kgm, bet) REMARKS | REAR WHEEL/SUSPENSION: | Rear axle nut 1 35 20 (208, 148) | NOTE Final driven sprocket nut 8 8 34(35,25) Rear whee! nut ‘ 2 | r08i11.0,80) | Roar brake dise mounting nut ‘ a | 36035,25) | Note? Roar brake torque rod 2 10 34(35,25) | NOTE2 Swingarm pivot aut 1 8 93 (85,69) | NOTET Drive chain siger bolt ‘ 6 9(03,65) | NOTES Bearing holder pinch bolt 1 16 78075, 58) Air guide mounting bolt 2 6 9109,65) | NOTES Rear shock sbsorber upper bracket nut 1 10 42(43,31) | NOTET Rear shock absorber mounting nut 2 10 42(83,31) | NOTET Shock Hak nut (frame side) 1 10 59 (60,43) | NOTET Shock link nut (shock arm plate side) 1 0 42(43,31) | NOTET Shock arm plate nut (swingarm sido) 1 10 42(¢3,31) | NOTET HYDRAULIC BRAKE: Front brake master cylinder holder bolt 2 6 12112,9) Front brake master eylinder cap screw 2 ‘ 1810.18, 1.1) Brake lever pivot bolt 1 6 T0407) Brake lever pivot aut 1 6 610643) | Brake lever adjuster 1 5 4(0.4, 2.9) | Front brake switch screw 1 | 4 1.2(0.12,0.8) | Aight front brake caliper mounting bolt 2 8 312,23) | NOTES Lett front brake caliper pivot bolt 1 8 31002,29 | Notes Lett front brake caliper bolt (second master joint) 1 8 210a2,29 | NOTES Caliper body 8 bolt 9 8 32 (3.3, 24) NOTE 8 Front brake caliper slide pin (min) 3 2 231231) | noTe2 Front brake caliper slide pin (sub) 3 8 731139) | NOTE2 Pad pin 3 0 18(18, 13) Brake caliper bleeder 6 8 6 (08, 43) Second master cylinder push rod nut 1 8 18(1.8, 13) Second master cylinder connector 2 6 30(1.0,7) Rear master cylinder mounting bolt 2 8 321129) Rear master oylindar reservoir mounting bolt 1 6 1212.9) Rear master cylinder push rod nut 1 8 38118, 1 Rear master cylinder hose joint screw 1 4 140.15, 1.1) | NOTE2 Brake hose oil bolt 2 10 24 (25, 25) Brake pipe joint 8 10 17(17,12) | NOTES Brake pipe 2/3 way joint 2 5 12(13,9) Brake hose clamp bolt 2 8 | 029) Delay valve mounting bolt 2 6 1212.9) PCV (Proportional Control Valve) mounting bolt 2 6 2029) | Right front Brake hose clamp bolt 1 6 | raze | Rear brake caliper mounting bolt 2 8 | 3143.2, 23) NOTE 8 LIGHTS/METERS SWITCHES: Ignition switeh mounting one-way bolt 2 8 26 (27,20) awaGENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available in U.S.A. 2. Not available in U.S.A, 3. Alternative tool 4. Newly designed tool, DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Oil pressure gauge attachment 07406 - 0030000 | NOTE1 a Fuel pressure gauge 07406 - 0040002 5 Oil pressure gauge 07508 - 3000000 NOTE1 4 Clutch canter holder 07724 ~ 0050002 8 Universal holder (07725 - 0030000 18 Flywheel holder 077250040000 | NOTE 1 10 Rotor puller (07733 - 0020001 NOTE 3: 07933 - 3960000 10 | Attachment, 32 x 35mm. 0746 - 0010100 4 ‘Attachment, 37 x 40 mm, 0746 - 0010200 4 ‘Attachment, 42 x 47 mm 0746 - 0010300 13,14 ‘Attachment, 62 x 85 mm, 0746 - 0010400, 14 Attachment, 62 x 68 mm 07746 - 0010500 4 ‘Attachment, 24 x 26 mm 0746 - 0010700 “ Driver B 0746 - 0030100 2 Attachment, 25 mm (IN) 07746 - 0030200 2 Pilot, 17 mm 07746 - 0040400 4 Pilot, 20 mm 07746 - 0040500 4 Pilot, 40 mm 07746 0040900 “ Pilot, 28 mm 07746 0041100 4 Bearing remover shaft 07746 - 0050100 3 Bearing remover head, 20 mm. 07746 - 0050800 13 Driver 07749-0010000 13,14 | Valve spring compressor 07757 -0010000 8 Valve seat cutter | Note 1 8 Seat cutter, 29 mm (45° IN) 0780 - 0010300 ‘Seat cutter, 27.5 mm (45° EX) 0780 - 0010200 Flat cutter, 30 mm (32° IN) 077@0-0072200 Flat cutter, 27 mm (32° EX) (07780 - 0013300 Interior cutter, 30 mm (60° IN/EX) | 07780 - 0014000 Cutter holder, 4.5 mm, 0781 - 0010600 ‘Snap ring pliers 07914-SA50001 | NOTE 3: 07914 -3230001 8 Steering stem socket 07916 - 3710101 NOTE 3: 3 07916 - 3710100 (U.S.A. only) Bearing remover set 07936 - 3710001 ry — Remover handle 07936 - 3710100 — Remover set 07936 - 3710600 — Remover weight 07741 - 0010201 NOTE 3, 07936 - 3710200 07936 - 371020A (U.S.A. only) Driver shaft 07946 - KA50000 13 Ball race remover set o7946-Kmg0001 | NOTE 3: 1B — Driver attachment, A 07946-KMs0100 —_| Can be used with the following = Driver attachment, B o7946-KMs0200 | combination: — Driver shaft assembly 07946-KM90300 |: O7VMF - MAT0100 = Bearing remover, A 07946-KMg0401 | O7VMF- MATO200 — Bearing remover, B 07946-KMs0500 | O7VMF - Kz30200 — Assembly base 07946 -KMs0600 | O7VMF- MATO300 O7VMF - MATO400 07947 ~ KABO100 | 07965 - MA60000 07346 - MES0200 Steering stem driver (07946 - MB00000 13 Driver shaft 07946 ~ MJ00100, 4 Slider weight 07947—KASO100 3 Oil seal driver 07847 -KFOO100 13 Valve spring compressor attachment __ 07859 - KM30101 8GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS | _ REF. SEC. Pin driver ‘O7GMD—KT80100 | NOTES: 1 07949 - 3710001 Oil iter wrench O7HAA~ P7010 34 Peak voltage adaptor o7HGJ 0020100 | NOTE 4: 8.17 Peak voltage tester (USA oniy) Needle bearing remover o7HMC ~MR70100 1“ Valve guide driver O7HM - MLo0101 8 Bushing driver attachment o7HMF - MMg0300 | 4 Tappet hole protector O7HMG-MA70002_ NOTE 2 | 8 Valve guide reamer, 45 mm O7HMH—MLo0101 NOTE 3: 8 O7HMH ~ MLOOTOA (U.S.A. only] Drive chain tool set OTHMH=MR10103.—- NOTE 3: 3 O7HMH ~ MR10108 (U.S.A. only) Socket wrench, 46 mm (07JMA.~ MINB0100 4 Needle bearing remover set o7LMC- Kv30100 1“ Compression gauge attachment O7RMJ-MY50100-| NOTE 1 8 Oil pressure gauge joint adaptor «ORM MW40100_| NOTE 2 4 Test pin box o7wez-o010100 | NOTE 4 5 ECU test harness o7wwiz—MBGo100_| NOTE 4 5GENERAL INFORMATION LUBRICATION & SEAL POINTS r ENGINE Location MATERIAL REMARKS Crankease mating surface 5-15 mm (0.40.6 in) 0.8 in) Oil pressure switch threads Do not apply to the thread head 3~ 4 mm (0.1-0.2in} [i | H |b Alternator grommet Ignition puise generator grommet Aan Liquid sealant (Three Bond 12078 or equivalent) 5 Eg eee Y i} ef es surface surfaceGENERAL INFORMATION y ENGINE (cont'd) LOCATION MATERIAL REMARKS Cylinder head semi-circular cutout Sealant ‘Camshaft lobes/journals Molybdenum disulfide Valve lifter outer sliding surface oil (a mixture of 1/2 Valve stem (valve guide sliding surface) engine oil and 1/2, Piston pin bore molybdenum disulfide Main journal bearing surface grease) Connecting rod bearing surface Connecting rod small end bore Cam gear sliding surface Second cam gear sliding surface Clutch outer sliding surface Primary drive gear sliding surface Maia, C5, C8 shifter gear (shift fork grooves) Cylinder head 9 mm bolt threads and seating surface | Engine oil Piston surface Piston ring surface Clutch center lock nut threads Clutch friction dise lining surface Connecting rod bolt/nut threads Main journal 9 mm bolt threads and seating surface Flywheel bolt threads lanition pulse generator rotor bolt threads, Oil filter cartridge threads and mating surface Each bearing Eech gear Each O-ring Other rotating area and sliding surface Timing hole cap threads ‘Mukti-purpose grease Each oil seal lips Cylinder head 18 mm sealing bolt threads Locking agent Gearshift cover bolt threads Sa Drive sprocket cover rubber bolt threads 4 Coating width: 6.5 1 mm Cylinder head cover breather plate bolt threads Oil filter boss threads Oil pump driven sprocket bolt threads Lower crankcase 20 mm sealing bolt threads Mainshaft bearing set plate bolt threads Shift drum bearing sot plate bolt threads 4 Shift drum center bolt threads |GENERAL INFORMATION > FRAME Location MATERIAL REMARKS Steering head bearing sliding surface Multi-purpose grease Steering head dust seal ips ‘Swingarm pivot needle bearing ‘Swingarm pivot dust seal lips Front wheel dust seal lips Left fork needle bearing sliding sutace Left fork dust seel sliding surface ‘Shock absorber needle bearing Shock link needle bearing ‘Shock link dust seal i ‘Swingarm shock link plate pivot needle bearing ‘Swingarm shock link plate pivot dust seal lips Rear wheel hub bearing holder dust seal lips Driven flange O-ring sliding surface Dust seal holder dust seal lips Driven flange needle bearing Footpeg pivot sliding area Pillion footpeg pivot sliding area Pillion footpeg spring inside Side stand pivot sliding surface Main stand pivot sliding surface Throttle pipe sliding area Rear brake pedal sliding surface Seat catch hook Shock absorber spring adjuster cam surface Molybdenum paste Steoring stom top thread Engine oil Throttle cable A and B casing inner Choke cable casing inner Brake pipe joint threads Brake master cylinder cups DOT 4 brake fluid Brake caliper piston seals Brake caliper dust seals, Silicone grease Front brake lever pivot and piston tips ‘Second master cylinder boot inside and push rod tips Rear master cylinder boot inside and push rod tips Brake caliper slide pin surface Roar brake torque rod bolt threads Locking agent Fork socket bolt threads Brake caliper slide pin threads Thermo switch threads and O-ring Sealant ss ry AJL, Et = sf Ly [5GENERAL INFORMATION ——_—— OOSEEAaE——— 7 FRAME (cont'd) LocaTion MATERIAL REMARKS Handle grip rubber inside Honda Bond A or | Honde Hand Grip Cement (U.S.A, only) Fork cap O-ring ro Honde Suspension | Fork oll seal ips Fluid S58 | 1.92GENERAL INFORMATION COMBINATION METER 10P (GRAY) CONNECTOR COMBINATION METER 10? (BLUE) CONNECTOR ENGINE STOP RELAY HEADLIGHT RELAY (Lo! ‘TURN SIGNAL RELAY. CABLE & HARNESS ROUTING + , S S HEADLIGHT RELAY (Hi) ——— ain WIRE HARNESS ‘THROTTLE CABLES HORN WIREGENERAL INFORMATIONGENERAL INFORMATION uad/1V9 LNOUS L337 W3QNIIAD HaLSVW AUYNOD3S, 3SOH HOLNT9 3SOH SVHA ¥3N31 USQNITAD HALS¥IN HOLM19 acGENERAL INFORMATION YIM HOSNAS SUNLVH3dWAL HY N3dO ¥JQNMAD HALSWWW 34vHS INL BATVA ATIC 3SOH 3yW¥a Y3AI7 497GENERAL INFORMATION PAIR TUBE NO, 1 IGNITION COIL NO, 3 IGNITION COIL FUEL TANK OVERFLOW TUBE RADIATOR OVERFLOW TUBE NO. 2 IGNITION COIL FUEL TANK AIR VENT. TUBE ENGINE SUB-HARNESS ‘THROTTLE BODY SUB-HARNESS CONNECTOR CONNECTOR RADIATOR SUB-HARNESS. CONNECTOR: 4 J 0GENERAL INFORMATION 3ANL LNA UlV NVI 13nd SEN. MOTAHSAO ¥NWA 13Nd 3eIM BOLVNUSLTY 3YIM HOLIMS ONVIS 30S 3S0H HOLNI9 TIaV9 HOLOW YALVIS 14190GENERAL INFORMATION FUEL RETURN TUBE //* FUEL TUBE FUEL PUMP WIRE ‘UE LEVEL SENSOR CONNECTOR UEL TANK AIR VENT TUBE g E 2 = ‘OR CABLE STARTER MOTGENERAL INFORMATIONGENERAL INFORMATION. 3SOH WOLWIgVH HaddN YIM HOLWYINAD 3SINd NOLIN! 2 SUIM UOLWHIND 3SINd WO gan. aaang uiv HOLVIaVE ‘SSINYVH 3UIM NIVGENERAL INFORMATION SATA GIONSIOS: SNVINI uIY aTaVINVA Ban. WANoWA- a waanvHo WNNoWA BATVA AVM3NO - 7 NOSNaS 3UNSSaud ALNTOSAY GTOSINYI, SEF be YOSNAS FTLLOUHL 3ANL WNNOWA W3ONMIAD € “ON WOVYHdVIG BAVLNI uy TEVA QQGENERAL INFORMATION HOLIMS 3HNSS3UE 710 3aNL SSvdAa YIM HOLWHANaD aSINd WO SS3NYVH-ANS 3NIONT 3SOH NOLWIave waddn- an. g3378 uly HOLWIave 3ENLLNSA uIV NL TINS 1.24GENERAL INFORMATION SS3NUVH-ENS 3NIONS BuIM HOLIMS WHLNNGENERAL INFORMATION YOLDANNOD 4O3HO 30INNIS YOLDINNOD (HOW TA) azz. S@V9 SALISOd ANALLVE ‘SSINUVH 3UIM NIV HOLIMS AVI UaLUWES: xoa asn3 OLDANNOD (AVYD) dz WOSNAS JUNSSIUd JULIWOUE SUIM 911d MuvdS € “ON 3UIM 971d WHS LON, Av ay Ln9 Tana AVTIY dOLS NIN SV9 AALVOAN ANALLVE,MAIN FUSE 8 GENERAL INFORMATION BATTERY NEGATIVE CABLE STARTER RELAY SWITCH REAR BRAKE LIGHT SWITCH CONNECTORS ENGINE STOP RELAY BATTERY POSITIVE CABLE FUEL CUT RELAY BAROMETRIC PRESSURE SENSOR,GENERAL INFORMATIONGENERAL INFORMATION (y30NMAd HaLsvW vay WOU) 3SOH 3yv¥8 INN 193410 (nod WoUs) 3S0H 3¥v¥a JNM OAUSS 1.329GENERAL INFORMATION, UIISINYD dvAa INV TIN OL) 3aNL L “ON BATA GIONS10S TOHLNOD 39uNd d¥Aa 'adAL VINYOsIVO ° y =GENERAL INFORMATIONGENERAL INFORMATIONGENERAL INFORMATION NIWA GIONSTOS TOULNOD 3OHNe dVAT Ban. oN ANIOP AVS 3ANL WANOWA HIONITAD € “ON 38M WANOWA HIGNITAD ¥ ON 3an. son SRNL WANOWA UIGNITAD Z ON 3BNLWANOWA NIGNITAD | ON 1A2GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency, California Air Resources Board (CARB) and Transport Cenada require manufactur- ers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated. {and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Limited Warranty for Honda Motoreycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect. 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 Honda Motor Co., Ltd. utilizes lean injection settings as well as other systems, to reduce carbon monoxide and hydrocarbons, CRANKCASE EMISSION CONTROL SYSTEM. ‘The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body. AIR CLEANER HOUSING THROTTLE BODY oo <<: FRESH AIR, ——’ Gm blow ay cas 1_AAGENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) ‘The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except to the idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase amission 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 by the function of the PAIR (Pulse secondary air injection) contral valve. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocar- bons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevents reverse air flow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid valve is controlled by the ECM, and the fresh air passage is openediclosed according the running condition (ECTIIAT/TPS/MAP sensor and engine revolution). No adjustments to the secondary air supply system should be made, although periodic inspection of the components is rec- ‘ommended. AIR CLEANER HOUSING I PAIR CONTROL VALVE EXHAUST PORT 1ABRGENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with California Air Resources Board evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the tengine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body, |\| evar puRGe conTROL SOLENOID VALVE EVAP CANISTER, THROTTLE BODY <= FRESH AIR em FUEL VAPOR NOISE EMISSION CONTROL SYSTEM ‘TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing there- of: (1) The removal or rendering inoperative by any person, other than for 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 the vehicle after such device or element of design hes been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 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 than those specified by the manufacturer. 4AREMISSION CONTROL INFORMATION LABELS ‘An Emission Control Information Label is located on the storage compartment as shown. ‘Tha seat must be removed to read it. It gives base tune-up specifications. ‘VACUUM HOSE ROUTING DIAGRAM LABEL (CALIFORNIA TYPE ONLY) The Vacuum Hose Routing Diagram Label is on the air cleaner housing cover as shown. The fuel tank must be opened to read it, Refer to page 3-4 for fuel tank opening, VACUUM HOSE ROUTING LABEL GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL (vacuum Hose ROUTING DIAGRAM EaFRAME/BODY PANELS/EXHAUST SYSTEM. BODY PANEL LOCATIONS UPPER COWL REAR GRIP FRONT FENDER, REAR FENDER SIDE COWL UPPER COWL COVER REARVIEW MIRROR METER PANEL:2. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS 2-0 REAR COWL 23 SERVICE INFORMATION 2-1 SIDE COWL 26 TROUBLESHOOTING 2-1 UPPER COWL 27 TRIM CLIPS 2:2 FRONT FENDER 212 2 SEAT STOPPER 2.2 SEAT RAIL/REAR FENDER 242 SEAT 2-3 MUFFLER/EXHAUST PIPE 2419 SERVICE INFORMATION GENERAL Gasoline is extremely flammable and is explosive under certain condition. KEEP OUT OF REACH OF CHILDREN. + Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. + 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. This section covers removal and installation of the body panels and exhaust system, Refer to section 5 for fuel tank removaliinstallation. ‘Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. ‘When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust clamps first, then tighton the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat prop- ely + Always inspect the exhaust system for leaks efter installation. TORQUE VALUES Sido stand pivot bolt 10 Nem (1.0 kgm, 7 tb) ‘Sida stand pivot lock nut 29 Nem (3.0 kgf, 22 Ff) Side stand bracket bolt 39 Nem (4.0 kghm, 29 IDF) Side stand switch mounting bolt TON (1.0 kgfm, 7 IDF) ALOC bott Main stand mounting bolt 54 Nem (85 kgfm, 40 bf ft) ALOC bolt Rear grip socket bolt 34 Nem (3.5 kgf, 25 loft) Exnaust pipe joint special nut 12 Nem (1.2 kgm, 8 bf) ‘Mutfler bracket bolt 21 Nem (2.1 kgm, 15 loft) Upper cow! stay mounting flange nut 32.Nem (33 kgfm, 24 Ibfft) _U-rut Upper cow! screw 1 Nem (0.18 kgm, 1.1 lb Side cowl serew 11Nem (0.15 kgm, 1.1 left) Inner half cow! screw 11Nem (0.18 kgfm, 1.1 bet) Meter panel screw 11Nem (0.18 kgm, 1.1 IbFft) Rear cowl screw 1 Nem (0.15 kgm, 1.1 lof) Seat rail special bolt 39 Nem (4.0 kgf, 28 lbFft Seat rail flange nut 39 Nem (4.0 kgm, 28 Ibe Bank sensor 22 Nem (2.2 kgf, 16 Ibf ft) Fillion step flange bolt 32 Nem (33 kam, 24 IbFf) TROUBLESHOOTING Excessive exhaust noise Poor performance + Broken exhaust system + Deformed exhaust system + Exhaust gas leak + Exhaust gas leak + Clogged mufflerFRAME/BODY PANELS/EXHAUST SYSTEM. TRIM CLIPS REMOVAL Push the center of the trim clip in Remove the trim clip. INSTALLATION Raise the center pin by pushing the retaining tabs back. Install the trim clip. Push the center pin until the pin flush with the outer casing, SEAT STOPPER REMOVAL/INSTALLATION Remove the setting bolts and washers. Remove the seat stopper by releasing the tabs from the rear cowl Install the seat stopper in the reverse order of removal, SETTING BOLT WASHER, » SEAT STOPPERFRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Unlock the helmet holder using the ignition key. Pull the seat lock lever down, Remove the seat backward while releasing the front ‘end of the seat hooks from the fuel tank INSTALLATION Install the seat while aligning its hooks, with the fuel tank. Push the seat forward, lock it securely. REAR COWL REMOVAL Remove the rear grip mounting bolts, washers and both rear grips. Disconnect the tailfbrake light connectors and turn signal connectors, SEAT vs lieninowney REAR GRIPS ‘TURN SIGNAL CONNECTORS BRAKE/TAIL LIGHT CONNECTORSFRAME/BODY PANELS/EXHAUST SYSTEM. Remove the rear cowl setting bolts, washers and spacers. Remove the rear cowl mounting screws. Remove the rear cowl backward. INSTALLATION 11Nem (0.15 kgfim, 1.1 IbFfE) Install the rear cowl while aligning its bosses with the ‘grommet on the rear fender. SETTING BOLT SPACER REAR COWL BossesFRAME/BODY PANELS/EXHAUST SYSTEM Install the rear cow! mounting screws. SCREWS Install the spacers, collars and setting bolts, NOTE: Note the direction of the spacers. Tighten the setting bolts. Tighten the mounting screws to the specified torque. TORQUE: 1 Nim (0.15 kgfim, 1.1 IbFt) 3—4 SETTING BOLT Cannes he tur signal connectors and brake ight ‘TURN SIGNAL CONNECTORS Install the rear grips, washers and socket bolts, then ° tighten the socket bolts to the specified torque t ¢ TORQUE: 34 Nim (3.5 kgf'm, 25 Ibftt) REAR GRIPSFRAME/BODY PANELS/EXHAUST SYSTEM SIDE COWL REMOVAL Remove the trim clips between the right and left side cowls. Remove the trim clips and setting screws between the right and left side cowls and inner half cowl. Remove the special screws and cowl setting screws, then remove the side cow Remove the two trim clips and inner half cowl. SCREWS, INNER HALF cowl IFINSTALLATION RIGHT SIDE COWL Installation is in the reverse order of removal. NOTE: ‘Align the tabs of the inner half cow! with the upper cowl UPPER COWL REARVIEW MIRROR REMOVAL Remove the rearview mirror pivot boot. Remove the following Bolts — Rearview mirror —Mirror plate — Rubber cushion FRAME/BODY PANELS/EXHAUST SYSTEM 11 Nkm (0.18 kgm, 1.1 IbFft) LEFT SIDE COWL ns =) LIN ode 2-7FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN REPLACEMENT Remove the screw/washer and upper cowl cover. SCREW UPPER COWL COVER Remove the windscreen mounting screws. Remove the windscreen upward. Nor: At installation, install the windscreen bosses into the upper cow! grooves. UPPER COWL REMOVAL UPPER COWL Remove the following: — Side cowis and inner half cow! (page 2-6) — Rearview mirror (page 2-7) and windscreen Remove the two trim clips. Remove the upper cow! mounting screws. SCREWS Release the upper cowl from the rearview mirror bracket and pull the upper cowl forward. Disconnect the headlight sockets and turn signal sockets Remove the upper cowl. 2-8Remove the trim clips and meter panel. Remove the air tomperature sensor from the right inner panel (page 19-10). Release the main wire harness from the left inner panel. Remove the trim clips and both inner panels, Remove the headlight unit from the upper cowl (page 19:7) UPPER COWL INSTALLATION Nem (0.18 kgf, 1.1 IDF) WINDSCREEN REARVIEW MIRROR INNER PANEL UPPER COWL, FRAME/BODY PANELS/EXHAUST SYSTEM METER PANEL aI CLIPS ‘TRIM CLIPS TRIM CLIPS | INNER PANELS UPPER COWL COVER 2-9FRAME/BODY PANELS/EXHAUST SYSTEM Install the inner panels and secure it with two trim TRIM CLIPS TI curs | clips. Install the main wire harness to the left inner panel JD Install the alr temperature sensor onto the right inner panel (page 19-12). INNER PANELS Intl the mer panel and secur it wih two tim WETER PANEL rin cups ~ Install the headlight unit (page 19-5). Connect the headlight sockets and turn signel sockets, sockets YS Install the Upper cow! aligning the bosses on the [UPPER COWL hoadlight unit with the rubber grommets on the upper cowl stay. Bosses GROMMETS 2-10Align the upper cow! bosses with the meter panel grooves. 2w mirror hole on the upper cowl with ipper cow! stay. Install and tighten the upper cowl mounting screws to the specified torque. TORQUE: 1 Nem (0.15 kgftm, 1.1 Ibftt) Install the two trim clips. Install the following: — Windscreen (page 2-7) — Inner half cow! and side cows (page 2-7) REARVIEW MIRROR INSTALLATION Install the rubber seats and rearview mirror plate. NOTE: + Install the rubber cushions with their identification mark ("R" or "L") facing + Install the mirror plate wi forward and upward. its arrow marks facing Install the rearview mirror and tighten the bolts securely. FRAME/BODY PANELS/EXHAUST SYSTEM UPPER COWL UPPER COWL SCREWS TRIM CLIPS. RUBBER —pLare REARVIEW MIRROR ~ | } BOLTS LEFT SIDE SHOWN (“L” IN) REARVIEW MIRROR pare RUBBER ] RIGHT SIDE SHOWN ("R” IN} 2-11FRAME/BODY PANELS/EXHAUST SYSTEM Install the upper cow! cover aligning it bosses with the grooves in the meter panel. Install and tighten the screw/washer. FRONT FENDER REMOVAL Remove the four front fender mounting special screws and reflector. Remove the front fender forward, INSTALLATION Installation is in the reverse order of removal SEAT RAIL/REAR FENDER REMOVAL Romove the following — Rear cowl (page 2-5) — Fuel tank (page 5-50) — Battery (page 165) —ECM (page 5-74) Remove the brake hose clamp socket bolt from the inside of the battery compartment, Remove the fuel tank bracket pivot bolt/nut and bracket. Remove the rubber seat A and lift up rubber seat B. scREW SOCKET BOLT] FUEL TANK BRACKET. UPPER COWL COVER REFLECTOR PIVOT BOLT/NUT® 2-12Remove the regulator jrectifier unit (page 16-12). Release the main wire harness from the seat rail and remove from the seat rail/rear fender assembly. Remove the bolts and BARO sonsorifuel cut relay bracket. Remove the wire band. Remove the rear master cylinder reservoir mounting bolt. Release the engine stop relay from the rear fender bosses. Unhook the retaining tab and remove the fuse box. Unhook the retaining tab and remove the main fuse holder. Rolease the starter relay switch from the rear fender boss. Remove the seat lock cable from the seat rail hook. FR ’AME/BODY PANELS/EXHAUST SYSTEM. REGULATORRECTIFIER UNIT MAIN WIRE HARNESS. BARO SENSORFFUEL CUT RELAY BRACKET \ ENGINE STOP RELAY WIRE BAND’ BRAKE RESERVOIR STARTER RELAY SWITCH) MAIN FUSE HOLDER] RFUSE BOX, SEAT LOCK CABLE 2-13FRAME/BODY PANELS/EXHAUST SYSTEM Remove the bolts and left pillion footpeg bracket Romove the muffier bracket mounting boltinut Remove the bolts and right pllion footpeg bracket, Remove the rear fender mounting special bolts, nuts and flange bolts, then remove the seat rail/rear fender assembly, Remove the bolts, wire clamp and rear fendar from the seat rail SEAT RAIL 2-14FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION 31 Nm (3.2 kgm, 24 IDE) SEATRAIL | 44 Nim (4.5 kgm, REAR FENDER. 31 Nim (3.2 kafim, 24 Ibft) 21. Nem (2.1 kgm, 15 IbFft)FRAME/BODY PANELS/EXHAUST SYSTEM Install the rear fender into the seat rail aligning its groove with the seat rail cross bar. Install the wire clamp and tighten the rear fender mounting bolts, SEAT RAIL WIRE CLAMP REAR FENDER. H__WIRE CLAMP _REAR FENDER | Install the seat rail/rear fender assembly onto the BOLT/NUT frame, install the flange bolts, flange nuts and special bolts. NOTE: Route the main wire harness while installing the seat railvrear fender. Tighten the flange nuts and special bolts to the speci- fied torque. TORQUE: 44 N-m (4.5 kgm, 33 Ibfft) Install the right pillion footpeg bracket and tighten the bolts to the specified torque. TORQUE: 32 Nem (3.3 kgf-m, 24 Ib) Install the muffler bracket mounting bolt/nut, tighten ‘the nut to the specified torque. TORQUE: 21 Nom (2.1 kgm, 15 Ibtft) 2-16FRAME/BODY PANELS/EXHAUST SYSTEM Install the left pillion footpeg bracket and tighten the bolts to the specified torque. TORQUE: 31 Nem (3.2 kgfim, 26 Ibfft) If the seat lock lever bracket is removed, install the BOLT SEAT LOCK BRACKET lever aligning its boss with the seat rail hole. ; Tighten the bolt securely. Route and connect the seat lock cable to the lever, Install the seat lock cable to the bracket hook ‘SEAT LOCK CABLE Install the fuse box, main fuse holder and starter STARTER RELAY SWITCH rolay switch. BS i z MAIN FUSE HOLDER]FRAME/BODY PANELS/EXHAUST SYSTEM Route the wire harness, Install the engine stop relay to the rear fender boss, Install the BARO sensor/fuel cut relay bracket and tighten the bolts, Install the wire bang. Install and tighten the rear master cylinder reservoir ‘mounting bolt. Route the wire harness onto the rear fender, then install the regulator/rectifiar unit (page 16-12), Connect the regulator/rectifier unit connectors and secure them with a wire band. Install the rubber seat A onto the fuel tank bracket. NoTe: Note the direction of t rubber seat. Install the fuel tank bracket, then install the pivot bolt from the loft side. Hold the pivot bolt, then tighten the nut. Install and tighten the brake hose clamp socket bolt securely. Install the following: — ECM (page §-74) — Battery (page 16-5) — Fuol tank (page 5-51) — Rear cowl (page 2-5) BARO SENSOR/FUEL CUT RELAY BRACKET 1 \ ENGINE sToP RELAY ET BOLT] 2-18FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER/EXHAUST PIPE REMOVAL = 8 = Do not service the exhaust system while it is not. Remove the side cow! (page 2-7). Loosen the exhaust pipe/muffier clamp bolts. Remove the muffler bracket mounting boltinut, then remove the muffler. Remove the swingarm pivot nut cap, pivot nut and upper heat guard plate mounting bolt. Remove the right footneg holder/heat guard assem biy. Loosen the exhaust pipe clamp bolts.FRAME/BODY PANELS/EXHAUST SYSTEM. Romove the front exhaust pipe joint nuts. JOINT NUTS: Remove the front exhaust pipe. I we Remove the rear exhaust pipe joint nuts and rear exhaust pipes. JOINT NUTS INSTALLATION MUFFLER oo 93 Nem (9.5 kgfim, 69 IbFft) FRONT EXHAUST PIPES \ 12. Nem (1.2 kgm, $ IBF SSS 2-20Install the new exhaust pipe gasket onto the exhaust ports of the rear cylinder head. NOTE: + Always replace the exhaust pipe gaskets and exhaust pipe joint gaskets with now ones. + Prevent falling the gasket, apply grease t exhaust pipe gaskets the Install the rear exhaust pipes, temporarily install the rear exhaust pipe joint nuts but do not tighten them yet. Install the new exhaust pipe gasket onto the exhaust ports of the front cylinder head and exhaust pipe joints. NOTE: + Always replace the exhaust pipe gaskets and exhaust pipe joint gaskets with new ones. Prevent falling the gasket, apply grease to the exhaust pipe gaskets. Route and install the front oxhaust pipe into the center stand. Temporarily install the front exhaust pipe joint nuts but do not tighten them yet. Make sure the exhaust pipe band tabs are seated onto the exhaust pipe flange. Tighten the front exhaust pipe joint nuts to the speci- fied torque. TORQUE: 12 Nem (1.2 kgf, 9 Ibft) FRAME/BODY PANELS/EXHAUST SYSTEM JOINT NUTSFRAME/BODY PANELS/EXHAUST SYSTEM Tighten the rear exhaust pipe joint nuts to the speci JOINT NUTS fied torque, am < TORQUE: 12 Nem (1.2 kgm, 9 bf) Tighten the exhaust pipe joint band bolts. Install the heat guard/right footpeg holder assembly ‘onto the frame, install the swingarm pivot nut and upper heat guard mounting bolt Tighten the swingarm pivot bolt to the specified torque. TORQUE: 93 Nem (9.5 kgf, 69 lbf ft) Install the swingarm pivot cap. Install the new gasket onto the muffler joint Install the muffler. 2-22FRAME/BODY PANELS/EXHAUST SYSTEM Install the muffler bracket mounting bolt/nut, then tighten the nut to the specified torque. TORQUE: 21 Nim (2.1 kgm, 15 Ibft) Tighten the exhaust pipe/muffler clamp bolts. 2-23MEMO.3. MAINTENANCE | SERVICE INFORMATION 3-1 DRIVE CHAIN 317 | MAINTENANCE SCHEDULE 3-3 DRIVE CHAIN SLIDER 3:22 | FUEL LINE 3-4 BRAKE FLUID 3-22 THROTTLE OPERATION 3-5 BRAKE PAD WEAR 3-23 CHOKE OPERATION 3-5 BRAKE SYSTEM 3-23 E | AIR CLEANER 3-6 BRAKE LIGHT SWITCH 3-25 SPARK PLUG 3-7 HEADLIGHT AIM 3:25 | VALVE CLEARANCE 3-9 CLUTCH SYSTEM 3-26 | ENGINE OIL/OIL FILTER 3-12 CLUTCH FLUID 3-26 ENGINE IDLE SPEED 3-14 SIDE STAND 3:27 RADIATOR COOLANT 3-15 SUSPENSION 3:27 COOLING SYSTEM 3-15 NUTS, BOLTS, FASTENERS 3.28 SECONDARY AIR SUPPLY SYSTEM 3-16 WHEELS/TIRES 3-29 EVAPORATIVE EMISSION CONTROL STEERING HEAD BEARINGS 3-30 SYSTEM (CALIFORNIA TYPE ONLY) 3-16 SERVICE INFORMATION GENERAL sxtremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking 19 flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. angine must be running to do some work, make sure the area is well ventilated. Never run the engine in an »xhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may + Place the motorcycle on a level ground before starting any work. SPECIFICATIONS fed 1 ‘SPECIFICATIONS Throttle grip free play 2-6 mm (W12- Wein) Spark plug NGK CROEHS PDENSO | UQ7FERO Spark plug gap 7 0.8— 0.9 mm (0.03 - 0.04 in} Valve clearance IN 0.16 = 0.03 mm (0.006 # 0.001 in) - x 0.30 = 0.03 mm (0.012 + 0.001 in) 3-1MAINTENANCE. eo TEM ‘SPECIFICATIONS Engine oll capacity At draining Atoll filter change 2.9 liter (3.1 US at, 2.6 Imp qt) 3.1 liter (3.3 US qt, 27 Imp qt) Recommended engine oil HONDA GN4 4-stroke oil or equivalent motor oil API service classification SF or SG Viscosity: SAE 10W-40 Engine idle speed [ 49 StatesiCanada type California type 1,200 = 100 rpm 1,300 + 100 rpm Drive chain slack 20-30 mm (0.9 1.2in) Recommended brake fluid DoT 4 120/70 ZR 17 (58W) Radial Tire size [ Front | Rear | 180166 2R 17 (73W) Radial Tire brand Bridgestone | Front BTB7F Radial J Rear BTS7A Radial J Dunlop Front Da04FK | Rear Dz08K Metzeler Front MEZ4 [ Rear _TMEZeA Tire air pressure Driveronly | Front 250 KPa (2.50 kgilem, 36 psi) Rear 280 KPa (2.90 kgflem*, 42 psi) Driverend | Front 250 kPa (2.50 kgf/cm’, 36 psi passenger | Rear 280 kPa (2.90 kaffem, 42 psid “Minimum tire tread depth Front 4.5 mm (0.08 in) [Rear 2.0 mm (0.08 in) TORQUE VALUES Spark plug Timing hole cap Oil drain bolt Oil filter cartridge Cylinder head cover bolt Camshaft holder flange bolt Rear wheel nut Bearing holder pinch bolt TOOLS Oil filter wrench Drive chain tool set, 12.Nem (1.2 kgm, 9 IbF ft) 18 Nem (1.8 kgf, 13 IbFft) 29 Nim (3.0 kgm, 22 IbFt) 10.Nem (1.0 kgm, 7 Ibf) 10.Nem (1.0 kgém, 7 bff) 12. Nm (1.2 kgm, 9 Ib) 108 Nem (11.0 kgm, 80 IDFR) 74.Nim (7.5 kgm, 84 IDF ft) Apply grease to the threads Apply clean engine oil to the O-ring Apply oil to the threads and seating surface O7HAA ~ P70100 O7HMH - MR10103MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. |: Inspect and Clean, Adjust, Lubr te or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate The following items require some mechanical knowledge. Certain items (particularly those marked “and **) may require more technical information and tools. Consult their authorized HONDA dealer. ODOMETER READING (NOTE 1) FREQUENCY - REFER xi000m [06] «| @ | 12) | 20] %| 10 LF itoooim | 1 [6 | 12/18 24 | 20) a6 | PAGE > | FUEL LINE i 1 vp a oy THROTTLE OPERATION lo 1 Tp + | CHOKE OPERATION I a 1 1 35 [arose Wore Torey whe 2 | spark puua [R R R37 @ |= | VALVE CLEARANCE I 1 38 3 /__[ ENGINE OIL ck R R a) 3 @ | ENGINE OIL FILTER R R R R312 5 | +) ENGINE IDLE SPEED reife felsl rye ate | RADIATOR COOLANT —__ NOTE ¢ fa U TR 315 1B [= | Cooune system i 1 1) 38 + | SECONDARY AIR SUPPLY SYSTEM 1 L in 3-16 ~ EVAPORATIVE EMISSION CONTROL | Nore, , | sw DRIVE CHAIN - - EVERY 500 mi (800 km) 1, L a7 DRIVE CHAIN SLIDER, 1 1 1) 322 | BRAKE FLUID NOTE ¢ titfRtr (opal os E |_| BRAKE PAD WEAR Fee repre fe] 20 3 |_| BRAKE sySTEM 1 1 1 1] 323 @ (| BRAKE LIGHT SwiTcH SERA 1 1] 325 @ [+ | HEADLIGHT AIM t t 1) 325 2 |_| cuuTcH system - 1 1 1) 326 |_| c.uten FLuo NOTE @ thrtafe[s [al az = |_| SIDE STAND 1 1) fa] oar 3 || susrension } (tae eon | 2 | «| NUTS, BOLTS, FASTENERS 1 1 I EZ 7] WHEELS TIRES Pr T 1] 329 +*| STEERING HEAD BEARINGS - = t t 1 3:30 * Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data and is mechani cally qualified. ** In the interest of safety, we recommend these items be serviced only by an authorized HONDA dealer. NOTES: 1. At higher odometer reading, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Ci a fornia type only. cal skill. jeplace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechani- 3-3MAINTENANCE FUEL LINE Remove the seat (page 2-3) Ramove the two fuel tank mounting bolts and washers, Lift the fuel tank and temporarily install the either of the mounting bolts Open and support the fuel tank using the equipped tools (pin spanner and extension) Check the fuel lines for deterioration, damage or leak- age. Replace the fuel line if necessary. Also check the fuel line fittings for leakage. Remove the support tools and close the fuel tank. CAUTION: Be careful not to pinch the air vent and overflow tubes. Install and tighten two fuel tank mounting bolts. BOLTSIWASHERS| 3-4MAINTENANCE THROTTLE OPERATION Check for smooth throttle grip full opening and auto- ‘matic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is, ot smooth, 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 adjustment are made with the upper adjuster. Adjust the free play by loosening the lock nut and turning the adjuster. Major adjustments are made with the lower adjuster (on the throttle body. ‘Open and support the fuel tank (page 3-4). Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Recheck the throttle operation, Replace any damaged parts, if necessary. CHOKE OPERATION This motorcycle is equipped with a bypass air vol- ume control choke system, controlled by the starter valve. ‘The starter valve opens a bypass air circuit when the choke lever on the left handlebar switch is turned ON. Choke lever operation Chack for smooth operation of the choke lever. Lubricate the choke cable if the operation is not smooth 3-5MAINTENANCE _—_— eS AIR CLEANER 3-6 Starter valve lever operation [STARTER VALVE LEVER Remove the air cleaner housing (page 5-53). Check for smooth operation of the starter valve lever. There should be no free play. Set the starter valve lever to fully closed so that the lever contacts the throttle stop screw. Check that there is a maximum of 1-2 mm (0.04 - 0.08 in) of free play in the inner choke cable with the choke lover set to fully OFF. Replace the choke cable if the free play is out of spec- ification, Install the removed parts in the reverse order of removal, Open and support the fuel tank using the equipped tools (page 3-4), Remove the vacuum tube from the air intake valve. Remove the screws and air cleaner housing cover. SCREWS, Remove and discard the air cleaner element in accor- i JAIR CLEANER ELEMENT} dance with the maintenance schedule (page 3-3 Also replace the air cleaner element any time it is excessively dirty or damage. Install the removed parts in the reverse order of removal,MAINTENANCE SPARK PLUG REMOVAL Front cylinder: Remove the side cowl and inner half cowl (page 2-6). Remove the oil cooler mounting bolts. Move the oll cooler forward. Remove the spark plug caps. Rear eylinder: (Open and support the fuel tank using the equipped tools (page 3-4). Remove the spark plug caps. NOTE: Clean around the spark plug bases with compressed air before removing, and be sure that no debris is, allowed to enter the combustion chamber. Remove the spark plugs using a equipped spark plug wrench or an equivalent, Inspect or replace as described in the maintenance schedule (page 3-3) SPARK PLUG WRENCH 3-7MAINTENANCE 3-8 INSPECTION Check the following and replace if necessary (recom- mended spark plug: page 3-1) = Insulator for damage — Electrodes for wear — Burning condition, coloration; — dark to light brown indicates good condition. — excessive lightness indicates malfunctioning ignition system or lean mixture. —wet or black sooty deposit indicates over-rich mixture, REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or special plug cleaner. Check the gap between the center and side elec- trodes with a wire-type feoler gauge. If necessary, adjust the gap by bending the side elec- trodes carefully. ‘SPARK PLUG GAP: 0.8 - 0.9 mm (0.03 - 0.04 in} CAUTION: To prevent damage to the cylinder head, hand-tight- ‘en the spark plug before using a wrench to tighten to the specified torque. Reinstall the spark plugs in the cylinder heed and hand tighten, then torque to specification TORQUE: 12 Nem (1.2 kgfm, 9 Ibft) REPLACING A SPARK PLUG Set the plug gap to specification with a wire-type feeler gauge (see above). CAUTION: Do not overtighten th Install and hand tighten the new spark plug, then tighten it about 1/2 tur after the sealing washer con- tacts the seat of the plug hole. Install the spark plug caps. CENTER ELECTRODE INSULATOR SIDE ELECTRODE 08-09mm| (0.03 0.08 iy ‘SPARK PLUG WRENCHVALVE CLEARANCE Record the clear: ‘ance for each valve for refer fence in shim selection if just ‘required. INSPECTION NOTE: Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F) Remove the side cowl and inner half cow! (page 26). Remove the front and rear cylinder head covers (page 8-4) Remove the timing hole cap and O-ring. ‘Turn the crankshaft clockwise, align the “1T” mark on the ignition pulse generator rotor with the index mark on the right crankcase cover. Make sure that the No. 1 piston is at TDC (Top Dead Center) on the compression stroke, Insert the feeler gauge between the valve lifter and the cam lobe. Check the valve clearance for the No. 1 cylinder intake and exhaust valves using a feeler gauge. VALVE CLEARANCE: IN; 0.16 £ 0.03 mm (0.006 « 0.001 in} EX: 0.30 + 0.03 mm (0.012 + 0.001 in) FEELER GAUGE. 3-9MAINTENANCE. No.1 TDC > 180° Turn the crankshaft clockwise 1/2 turn (180°), and align the "3T” mark on the ignition pulse generator rotor with the index mark on the right crankcase cover, Check the vaive clearance for the No. 3 cylinder, ‘Tur the crankshaft clockwise 3/4 turn (270°), and align the “2T” mark on the ignition pulse generator rotor with the index mark on the right crankcase cover. Check the vaive clearance for the No. 2 cylinder. ‘Turn the crankshaft clockwise 1/2 turn (180°), and align the “4T” mark on the ignition pulse generator rotor with the index mark on the right crankcase cover. Check the vaive clearance for the No. 4 cylinder, ADJUSTMENT Remove the camshafts (page 8-9) Remove the valve lifters and shims. Nort + Shim may stick to the inside of the valve lifter. Do not allow the shims to fall into the crankcase. + Mark all valve lifters and shims to ensure correct reassembly in their original locations, + The valve lifter can be easily removed with a valve lapping tool or magnet. + The shims can be easily removed with a tweezers or magnet, Clean the valve shim contact area in the valve lifter VALVE LIFTER with compressed air. 3-10Install the shims ‘and valve lifters in their original locations. ‘Measure the shim thickness and record it. NOTE: Sixty-five different thickness shims are available from the thinnest 1.200 mm thickness shim to the thickest 2.800 mm thickness shim in intervals of 0.025 mm. Calculate the new shim thickness using the equation below. A=(B-C)+D A: Now shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness NOTE: + Make sure of the correct shim thickness by mea: suring the shim by micrometer. + Reface the valve seat if carbon deposit result in a calculated dimension of over 2.800 mm. Install the newly selected shim on the valve retainer. Apply molybdenum disulfide oil to the valve lifters, Install the valve lifters into the valve lifter holes. Install the camshaft (page 8-28) Rotete the camshafts by rotating the crankshaft clock wise several times. Recheck the valve clearancs Install the removed parts in the reverse order of removal Apply grease to the timing hole cap threads, install the timing hole cap. NOTE: Check that the O-ring is in good condition, replace if necessary. MAINTENANCE ‘SHIM 3-11MAINTENANCE Tighten the timing hole cap to the specified torque. TORQUE: 18 Nem (1.8 kgm, 13 Ibfft) ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION Start the engine and let it idle for 2-3 minutes. Stop the engine and wait 3 minutes. Support the motorcycle on its center stand, check the oil level through the inspection window. If the level is below the lower line, remove the oil filler cap and fill the crankcase with recommended oil up to the upper level line. RECOMMENDED ENGINE OIL: HONDA GN4 4-stroke oll or equivalent moter oil API service classification: SF or SG Viscosity: 10-40 NOTE: Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range, Reinstall the oil filler cap. 3-12MAINTENANCE ENGINE OIL & FILTER CHANGE [Ben car x= A warmed-up engine and the oil in it are hot, be careful not to burn yourself. NOTE: + If you plan to replace the oll and filter, remove the side cowl and inner half cow! (page 2-6), + Change the engine oil with the engine warm and the motoreycle on level ground to assure com. plete draining, Remove the oil filler cap, Place a oil drain pan under the engine to catch the oll, then remove the oil drain bolt and sealing washer, Drain the oll completely. CAUTION: 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 daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oll. Remove and discard the oil filter cartridge using the special tool. TOOL: Oil filter wrench, O7HAA- PJ70100 Check that the sealing washer on the drain bolt is in good condition, replace if necessary. Install and tighten the drain bolt. ‘TORQUE: 29 N-m (3.0 kgf'm, 22 Ibf ft) DRAIN BOLT/SEALING WASHER 3-13MAINTENANCE Apply oil to the new oil filter cartridge O-ring Install the new oil filter cartridge and tighten it to the specified torque. TOOL: Oil filter wrench ‘O7HAA - P7010 TORQUE: 10 Nem (1.0 kgfim, 7 Ibf ft) Fill the crankcase with recommended engine oil (FILLER CAP OIL CAPACITY: 2.9 liter (3.1 US qt, 2.6 Imp qt) at draining 3.1 liter (3.3 US qt, 2.7 Imp qt) at oil filter change Install the oi filler cap, Start the engine and let it idle for 2 to 3 minutes, Stop the engine and recheck the oil level Make sure there are no oil leaks. ENGINE IDLE SPEED running to do some work, make sure the area is well ventilated, Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. NOTE: + Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. + The engine must be warm for accurate idle speed inspection and adjustment. Warm up the engine and shift the transmission into neutral Remove the adjusting hole rubber plug, Turn the throttle stop screw through the frame hole as required to obtain the specified idle speed, IDLE SPEED: 49 states/Canada type: 1,200 = 100 1pm California type: 1/300 = 100 rpm THROTTLE STOP SCREW 3-14MAINTENANCE RADIATOR COOLANT “UPPER” LEVEL LINE} COOLING Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the “UPPER” and ‘LOWER’ level lines. W necessary, add recommended coolant. “LOWER” LEVEL LINE Remove the side cow! (page 2-6. Remove the reserve tank filler cap and fill to the “UPPER” level line with 50/50 mixture of distilled ‘water and antifreeze. Reinstall the filler cap. SYSTEM Remove the side cow (page 2-6). Check the radiator air passages for clogging or damage. Straighten bond fins, and remove insects, mud or other obstructions with compressed air or low water pressure, Replace the radiator if the air flow is restricted over more than 20% of the radiating surface. Inspect the radiator hoses for cracks or deterioration, and replace if necessary. Check the tightness of all hose clamps and fasteners. RADIATOR HOSES, 3-15MAINTENANCE. SECONDARY AIR SUPPLY SYSTEM. NOTE: + This model is equipped builtin secondary air sup- ply system. The pulse secondary air supply sys tem is located on the cylinder head cover. + The secondary air supply system introduces fil tered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system. This charged secondary air pro: motes burning of the unburned exhaust geses and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless car- bon dioxide and water, Check the air injection hoses between the PAIR (pulse secondary air injection) control solenoid valve and cylinder head cover for deterioration, damage or loose connections. Make sure that the hoses are not cracked. NOTE: if the hoses show any signs of heat damage, inspect the PAIR check valve in the PAIR reed valve cover for damage. Chack the air suction hose between the air filter and PAIR control solenoid valve for deterioration, dam ‘age or loose connections. Make sure that the hoses ‘are not kinked, pinched or cracked. EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) Check the tubes betweon the fuel tank, EVAP canis. ter, EVAP purge control solenoid valve for deteriora- tion, damage or loose connections, Check the EVAP canister for cracks or other damage. Refer to the VACUUM HOSE ROUTING DIAGRAM LABEL (page 1-47) and CABLE & HARNESS ROUT. ING (page 1-24) for tube connections. CYLINDER HEAD COVER PAIR CHECK VALVE EXHAUST PORT AIR HOSES | EVAP CANISTER, 3-16MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF, place the motorcycle on its center stand and shift the transmission into neu- tral Check the slack in the drive chain lower run midway between the sprockets. CHAIN SLACK: 20 - 30 mm (0.8~ 1.2 in) CAUTION: Excessive chain slack, 50 mm (2.0 in) or more damage the frame. may Lubricate the drive chain with #80 - #90 gear oil or Pro Honda chain lube designed specifically for use with O-ring chains. Wipe off the excess oil or chain ubricant. ADJUSTMENT Loosen the axle bearing holder pinch bolt. Turn the axle bearing holder with the pin spanner BEARING HOLDER] provided in the tool kit until the correct drive chain slack is obtained NOTE: For ease of adjustment, raise the rear wheel using the center stand and turn the wheel in the same direction as the axle bearing holder rotation. [PIN SPANNER] 3-17MAINTENANCE ‘Make sure brake hose guile is positioned prop: erly ater tight ening pinch bolt 3-18 After adjustment, check the drive chain wear indica- tor label attached on the swingarm. If the red zone of the indicator label reaches the out- side diameter of the driven sprocket, replace the rive chain with a new one (page 3-18). Tighten the axle bearing holder pinch bolt to the specified torque. Tora 4 Nem (7.5 kgfim, 54 Ibfft) Recheck the drive chain slack and free wheel rotation, Lubricate the drive chain, CLEANING AND LUBRICATION Clean the chain with non-flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubri- cating Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fit ting links, or otherwise appears unserviceable. Installing @ new chain on badly worn sprockets will ‘cause the new chain to wear quickly. Inspect and replace sprocket as necessary, Lubricate the drive chain with #80 ~ #90 gear oil or Pro Honda chain lube designed specifically for use with O-ring chains. Wipe off the excess oil or chain lubricant. RED ZONE NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT. WIPE AND DRY. LUBRICATE #80 - #90 GEAR OIL OR ~ PRO HONDA CHAIN LUBEMAINTENANCE SPROCKETS INSPECTION Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary. Never use a new drive chain on worn sprockets, Both chain and sprockets must be in good condition, or the new replacement chain will wear rapidly. Check the attaching bolts and nuts on the drive and riven sprockets, If any are loose, torque them. TORQUE: Drive sprocket bolt: 51 Nem (5.2 kgm, 38 Ibf‘t) Driven sprocket nut: 34 N-m (3.5 kgfim, 25 Ibfft) REPLACEMENT This motorcycle uses a drive chain with a staked master link Loosen the drive chain (page 3-17) ‘Assemble the special tool as shown. Tool: Drive chain tool set O7HMH - MR10103 or O7HMH - MR10108. (U.S.A, only) NOTE: ‘When using the special tool, follow the manufacturer's Instruction. DRIVE CHAIN TOOL SET 3-19