CB1100SFyIMPORTANT SAFETY NOTICE Iniestes «strong possibility of severe personal injury or death itinstrctions are not followed. CAUTION: Indicates a possibility of equipment damage if instructions are not followed. NoTE Gives helpful information. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. itis 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. Pleaso understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected, TYPE CODE ‘© Throughout this manual, the following abbreviations are used to identify individual model. cope AREA TYPE cove AREA TYPE EUROPEAN DIRECT SALES E UK. (Austria, Netherlands, Spain, Switzerland, ED | Portugal, Belgium, Canary ilands, Hungary, F FRANCE ‘Sweden, Finland, Denmark, Norway} =HOW TO USE THIS MANUAL This service manual describes the service procedures for the CB1100SF. Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak oper- ating condition, CONTENTS | GENERAL INFORMATION a FRAME/BODY PANELS/EXHAUST SYSTEM. MAINTENANCE Performing the first scheduled maintenance is vary 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 components 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. ENGINE AND DRIVE TRAIN If you don’t know the source of the trouble, go to section 22 Troubleshooting. ‘ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN ‘THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA 2 o a g = 3 LUBRICATION SYSTEM a FUEL SY: (Programmed Fuel Injection) COOLING SYSTEM El ENGINE REMOVAL/INSTALLATION | 7 | Lconpeneociiies; | oe. ‘CLUTCH/GEARSHIFT LINKAGE En ALTERNATOR/STARTER CLUTCH Ea | CRANKCASE/PISTON/CYLINDER Em CRANKSHAFT/TRANSMISSION/ BALANCER FRONT WHEEL/SUSPENSION/ Ea STEERING REAR WHEEL/SUSPENSION E r ra HYDRAULIC BRAKE i 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 MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED. BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS, ELECTRICAL HONDA MOTOR CO, LTD. | SERVICE PUBLICATION OFFICE BATTERY/CHARGING SYSTEM Ea IGNITION SYSTEM Ha LIGHTS/METERS/SWITCHES Ea IMMOBILIZER SYSTEM (HISS) Ea WIRING DIAGRAM En ‘TROUBLESHOOTING Ea Date of ecuer June, 190 HONDA MOTOR CO.,LTD.SYMBOLS ‘The symbols used throughout this manual show specific service procedures. If supplementary information is required Pertaining to these symbols, it would be explained specifically in the text without the use of the symbol. |” rez te partite one stem Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1: 1). g SD =vereonineans nance ter cid { = a | arcttpes grincts 2 " | Use molybdenum disulfide grease (contai equivalent) Example: Molykote® BR-2 plus manufactured by Dow Corning, U. S. A, ‘Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan. Say __Us0 multi-purpose grease Lithium based multi-purpose grease NLGI # 2 or equivalent. ig more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n paste, manufactured by Dow Corning, U. S.A. Honda Moly 60(U. S.A. only) Rocol ASP manufactured by Rocol Limited, U. K. Rocol Paste manufactured by Sumico Lubricant, Japan t || Use molybdenum disulfide peste (containing more than 40 % molybdenum disulfide, NLGI #2 or Use silicone grease, |, Apply seatant. hese | Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified { fees ST emma warrie | | Use Fork or Suspension Fluid.1. GENERAL INFORMATION GENERAL SAFETY 11 TooLs 1-18 SERVICE RULES 1-2 LUBRICATION & SEAL POINTS. +20 | MODEL IDENTIFICATION 13. CABLE & HARNESS ROUTING 124 SPECIFICATIONS 1-4 EMISSION CONTROL SYSTEMS 1-36 TORQUE VALUES 1-13 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, Gag The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area GASOLINE Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is sotred Gasoline is extremely flammable and is explosive under ‘certain conditions. KEEP OUT OF REACH OF CHILDREN. Gog Used engine oil may cause skin cancer if repeatodly left in ‘contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap ‘and water as soon as possible after handling used oil. KEEP (OUT OF REACH OF CHILDREN. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. 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 QUT OF REACH OF CHILDREN. HOT COMPONENTS og 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. 1-1GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned. rr ‘* 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 glyco!) can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF (CHILDREN, Do not 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. CAUTION: Using coolant with silicate inhibitors may cause premature water of water pump seals or brockage of radiator ‘passages. Using tap water may cause engine damage. SERVICE RULES BATTERY HYDROGEN GAS & ELECTROLYTE OOS ‘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 protec: tive clothing and a face shield. ‘Melectrolyte gets on your skin, flush with water. Welectrolyte gets in your eyes, flush with water for at Jeast 15 minutes and call a physician immediately. + Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and 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 diagonally in incremental steps unless a particular sequence is specified. 6.Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly 7.After reassembly, check all parts for proper installation and operation. 8 Route al electrical wires as show on pages 1-24 through 1-35, Cable and Harness Routing,MODEL IDENTIFICATION (1) The frame serial number is stamped on tho right side of the steering head. GENERAL INFORMATION ENGINE SERIAL NUMBER (2), The engine serial number is stamped on the right side of the upper crankcase. BODY IDENTIFICATION NUMBER, COLOR LABEL, Nii ottle body identification number is stamped on the intake side of the throttle body as shown, (@) The color label is attached as shown. When ordering color-coded parts, always specify the designated color code. 1-3GENERAL INFORMATION SPECIFICATIONS GENERAL = rem SPECIFICATIONS DIMENSIONS | Overall length 2,145 mm (84.4 in} Overall width 750 mm (23.5 in) Overall height 41.115 mm (43,9 in} Wheelbase 1/500 mm (58.1 in} Seat height 795 mm (31.3 in) Footpeg height 383mm (15.1 in) Ground clearance 4140 mm (5.5 in) Dry weight 222 kq (489 Ibs} Curb weight 254 kg (660 Ibs) 188 kg (415 Ibs) FRAME Diamond Front suspension Telescopic fork Front wheel travel 108 mm {4.3 in} Rear suspension Swingarm Roar whee! travel 140 mm (5.5 in) Rear damper Nitrogen gas filled damper Front tire size 120/70 2R17 (S8W) /Radial Rear tire size 180/55 2R17 (73W) Radial Tire brand Bridgestone Front: 8757 RADIAL G/Rear: BTS7R RADIAL F Michelin Front: MACADAM 0X G /Rear: MACADAM 90X M Front brake Hydraulic double disc brake with 3 pots caliper Rear broke Hydraulic single disc brake with 3 pots caliper Coster angle 255° Trail length 402mm (4 Fuel tank capacity ie 2265.8 US gal, 48 Imp gal) ENGINE Bore and stroke 79.0 * 68.0 mm (3.11 2.28 in) Displacement Compression ratio Valve train Intake valve opens {ats closes —} (0.04in) lift Exhaust valve opens closes Lubrication system il pump type Cooling system Air filtration Crankshaft type Engine dry weight Cylinder arrangement 41,137 em* (69.4 cu-in) 11031 Chain drive and DOHC 15° BTDC 35° ABDC. 40° BBDC 10" ATOC Forced pressure and wet sump Trochoid/double rotor Liquid cooled Paper filter Unit type 82.8 kq (182.5 lbs) Four cylinder, inline 30° inclinded from verticaly~ GENERAL (Cont'd) ITEM. CARBURETION | Type ___| Throttle bore DRIVETRAIN | Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio ___| Geoarshitt patton ELECTRICAL — | Ignition system | Starting system Charging system Regulatorirectier | GENERAL INFORMATION ‘SPECIFICATIONS PGNI-FI (Programmed Fuel Injection) 42 mm (1.7 in) Multi-plate, wet Cable operated type Constant mesh, 5-speed 1.571 (88/56) 2.529(43/17) 2.769(36/13) 1.938 (31/16) 1.556 (28/18) 1.316 (25/19) 1.167 (28/24) Left foot oparated roturn system, 1-N-23-45 CComputer-controlad digital transistorized with electric advance Electric starter motor Triple phase output alternator SCR shorteditriple phase, full wave rectification Batte 1-5GENERAL INFORMATION Unit: ‘STANDARD 1 (in) ‘SERVICE LIMIT — LUBRICATION SYSTEM ITEM Engine oll capacity, ‘At draining ‘Atdisassembly toil filter change Recommended engine oil Oil pressure at oil pressure switch 380 (40 US qt, 331mp qi) [460 (4.9US qt, 4.0 Imp qt [3.90(41 US gt,3.4impqt) J HONDA 4-stroke oil or equivalent motor oll API service classification SE, SF or SG Viscosity: SAE 10W-40___ 4490 kPa (6.0 kaf/om®, 71 psi) at 5,400 min” (rpm)/(80 °C/176 °F) Oirpump rotor | Feed pump | Tip clearance 0.15 (0.006) max. [0.2070.008) Body clearance | 0.15~-0.21 (0.006~0.008) 0.35 (0.014) Side clearance | 0.04 ~0.09 (0.002~0.004) 170.12 (0.005) | Cooler ipclearanco 0.15 0.008)max. 10.201(0.008 pume | Sodysieernen | 018-021 0008—Gane 0.35 (0.014) Side clearance 10,040.08 (0.002 0.004) (0.12 (0.005) [7 FUEL SYSTEM (Programmed Fuel Injection) -—_ ese TEM: ‘SPECIFICATIONS Base throttle valve for synchronization Idle speed ‘Throttle grip free play | Intake air temperature sensor resistance (at 20°Ci68*F) “Throti body identification number coaiA Starter valve vacuum difference t 20mmHg om No.3 1=4kQ ‘Cam pulse generator peak voltage (at 20 °C68 °F) | Ignition pulse generator peak voltage lat 20 °C/68 *F)_ ‘Manifold absolute pressi Fuel pressure atidle Fuel pump flow (at 12 V) tide Engine coolant temperature sensor resistance [at 20°C68 F) 262 Fuel injector resistence (at 20 °Ci6k = 1300-14449 PAIR id valve resistance (at 20 °C/68 *F) 20-24 0.7 minimum 0.7 minimum 200-250 mm Hg 294 kPa (3.0 kgficm?, 43 psi). 220 em (7.4 US oz , 7.7 Imp oz) minimur/10 secondsGENERAL INFORMATION (~ COOLING SYSTEM. TEM SPECIFICATIONS Coolant capacity Radiator and engine 320 (84US qt, 28impq Reserve tank 0.58 (0.5 US qt,0.4imp qv) Radiator cap relief pressure F0B=137 KPa (1.11.4 kom? , 1620 pail Thermostat [Begin to open 80 84°C (176 183°F) Fully ope! 95°C (203°) = E Valve tft 8mm (0.3in) minimum i Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion protection inhibitors Standard coolant concentration ‘50% mixture with soft water ;~ CYLINDER HEAD/VALVES stan Ain TEM STANDARD ‘SERVICE LIMIT Cylinder compression 1,276 KPa (18.0 kgffem®, 185 pai) at 350 min*(¢pm) Cylinder head warpage _| 0.100.004) Valve, Valve clearance [IN [0.16 = 0.03 (0.006 = 0.001) valvequide | Ex 22 + 0.03 (0,008 + 0.001), Valve stem 0.0. iN 4.975 4.990 0 1965) —~—~S—«.865 (0.1955) EX 4.960—4.975 (0.1953~-0.1958) (0.1949) Vaive guide 10. ow 5.000 6.012 (0.1969 0.1973), | s.040 (0:1984) EX 6.000 5.0120.1969 0.1973) 5.040 (0.1984) Siem-to-guide clearance IN 0.010 0.037 (0.0004—0.0015), = ex 025 0.052 (0.0010—0.0020) Valve guide projection iN 16.3165 (0.64-0.65) ——— _above cylinder head EX___| 16.3166 (0.64-0.65) n Vaive seat width TINIEX | 0,901.10 (0.035 0.043) 15 (0.08) Valve spring | Inner INIEX | 37.4(0.47) [36.4 (1 freelength [Outer IWEX | 40.6(1.60) 386(1 Valve lifter | Valve lifter ©. INEX_ | 26.978 25.998 (1.0228 ~1.0233) 25,97 (1.022) L Vaive lifter bore LD. INEX_ | 26.010 26.026 (1.0240 —1.0246) 26.04 (1.025) Camshaft’ Cam lobe height TIN 091.512) 38.02 (1.4971 [ex uno OilclearanceGENERAL INFORMATION ~ CLUTCH/GEARSHIFT LINKAGE ITEM. Unit: mm tin ‘STANDARD SERVICE LIMIT ‘Warpage ‘uteh lever free play 10—20 (873/16) ‘Clutch spring free lengih : 57.4(2.26) 5621221) Clutch dise thickness Blue color [36 (0.14) z Brown color 350.14) ch plate warpag “{0.30,0.012) Clutch outer guide 10. (031 (1.1036) _| ai [on 34.965 (1.3766) Mainshaft 0.0. at clutch outer guide I z 27.870 (1.1012) Shiftiork, | Fork 12.021 (0.4724 12.03 (0.474) forkshatt | 5.93600 (0.233 ~0.236) 5910.23), Fork shaft 0.0. 11.957 — 11.968 (0.4707 — 0.4712), [11.85 (0.470) Ea Unit: me (in ALTERNATOR/STARTER CLUTCH tem fin} ITEM ‘STANDARD ‘SERVICE LIMIT ‘Siarter driven gear boss 0. 51.699 — 61.716 (2.0364~2.0361) “51684 (2.0348) Unie: men (in | CRANKCASE/PISTON/CYLINDER temen ITEM STANDARD SERVICE LIMIT 795000 79.015(3.1102—3.1708) | _79.10(8.114) LT 10 0.004) 10 (0.004), 05 (0.002) “Piston, piston rings —_|-“IN" mark facing toward the intake side 78.970 ~78. (3.1090~3.1098) 78.90 (3.106) 15 mm (0.6 in) from bottom of skirt Cylinder-to-piston clearance (0.010 ~0.045 (0.0004~0.0078), ‘Connecting rod small and LD. ‘Connecting rod-to-piston pin clearence Crankpin oil clearance 19,030 — 19.051 (0.7492~0.7500) (0.030—0.057 (0.0012 0.0022) _ (0.030 0.052 (0,0012— 0.0020), 19.002 ~ 18.008 (0.7481—0.74 79.03 (0.748) Piston pin 0. 18,90419.000 (0.7478—0.7480) 18.984 (0.7474) ‘ston-to-piston pin clearance 10.002 =0.014 (0.0001 - 0.0006) — |Top (0.030 0.068 (0.0012 0.0026} 0.08 (0.003 |__groove clearance Second (0.015 0.045 (0.0006 0.0018) 0.06 (0.002 Piston ring end gap | Top -0.20-0.35 (0.008 -0.014) 05 (0.02 Second (0400.55 (0.016 0.022) 0710.03), Lo Oil side rail) | 0.2~0.8 [0.01—0.03) 1.0 (0.04) (061 (0.7504) | 10.062 (0.0024) |GENERAL INFORMATION Gear-to-bushing M5. i Clutch outer guide Countershait 0.0. | C2. igto-shatt | Ma clearance co. clearance C2. a [esiar otis (0.025 0.075 (0.0010 0.0030), MainshattO.D. | Ma 27,967 27.980 {1.1011 1.1016) 27,980~27.993 (11018 1.1021) [27.987 (1.1007) — [— CRANKSHAFT/TRANSMISSION/BALANCER —— ve gate TEM STANDARD SERVICE LIMIT rankshatt 0105 0.70 0.002—-0.008) (03010072) | = (0.300.012) — |__| "Main journal of learance {01047 0.036 (0.0007 0.0074) 0.045 (0.0018), Transmission | Gear LD. Ma, 31,000—31.025 (1.2206 — 1.2218) 31.04 (1.222) cr 26,000 26.021 (1.0236 — 1.0244) 26.04 (1.025) bes 33,000 33.026 (,7992—1.3002) | 33.04(1.301) | Bushing OD. (Md, MB 30.950 90.975 [1.2185=1.2195) 30,93 (1.718) 2 32,985 32.990 [ '32.9311.296) a Ca, distance collar 32.950 22.975 [1.2072—1.2082 22.93 (1.296) Bushing LD. ra 27.985 28.006 (1.1018 11026) 28.02(1.103) c2 29,985 30,006 (1.1805 — 1.1813) 30.02 1.182), 0.11 (0.004) (0.11 (0.004) 27.870 (1.1012), -29.967—29.980 (1.1798 1.1803) 0,006 = 0.039 (0.0002 - 0.0016}, 0,005 0.039 (0.0002 0.0015), 27.957 (1.1007) 0.08 (0.003) 0.08 (0.003)GENERAL INFORMATION Unit: mm (in ie i lal Minimur ie ead dep ——— STANDARD SERVICE LIMIT Coldtire pressure | Driveonly_ Driver and passenger ‘Ade runout Wheel rim runout 260 KPa BO kalem, 36 pall ‘250 kPa (2.50 kaf/em#, 36 psi) | Fork ‘Spring diroction “Tube runo. Recommended fork fluid [Fluid level Fluid capacity ‘Steering head bearing pre-load [Spring fre length "32035 (12.62) h the tapered end facing down wi Fork fluid 164 (6.5) “446 = 2.6 em? (16.1 + 0.08 US oz, __| 15.7 + 0.09 Imp oz) 1015 N(1.0— 1.5 kgf [- REAR WHEEL/SUSPENSION Lote mm tn VTEM STANDARD SERVICE LIMIT Minimum tire tread depth Ti 2.0 (0.08) Coldtire pressure [-Driveronly e 200 kPa (2.80 katem®, a2 pa) = Driver and passenger 290 kPa (2.90 kato, 42 psi = Ale runout saa 0:20,(0.008) Wheel rim runout rs a z 2.0(0.08)- 2.00.08) Drive chain ‘Slack DIDSEEV-TTOLE 25351014) 50 (2.0) ‘Shock absorber ‘Spring adjuster standard position | 3rd groove 1-10GENERAL INFORMATION Unit [— HYDRAULIC BRAKE 7 ae TEM STANDARD SERVICE LMT Front ‘Specified brake fluid [bora im Brake dae tiekness 48 (0.18) 35 (010) Brake disc runout a = 0.30 (0.012) Master cylinder LD. ¥2.700— 12.743 (0.6000 —0.6017) 12.76 (0.502) ‘Master piston O.D. | 12.667 12.684 (0.4983 — 0.4994) 12.65 (0.498) | Secondary master cylinder LO. 14,000 — 14.043 (0.5512—0.5529) 14.086 (0.5533) ‘Secondary master piston 0.0. 13.957 ~ 13.964 (0.5495 0.5506) 13.945 (0.5490) Caliper eylinder | Right 27.000 —27.050 (1.0630 1.0650) [27.060 (1.0654) 10. £22,660 22.700 (0.8917 — 0.8937) 22.710 (0.8941) I 0 25.400 25,450 (1.0000 1.0020) 25,460 (1.0024) Left 25,400 25,450 (1.0000 1.0020) | 25.480 1.0024) 22.650 22.700 (0.8817 0.8937) 22.710 (0.8941) iB 22.650 22.700 (0.8817 0.8837) 22.710 (0.8941) Caliper piston | Right | 26.916 ~ 26.968 (1.0887 — 1.0617) 26,910 (1.0584) 00. 22.585 ~ 22.618 (0.8892 0.8805) 22.560 (0.8882) 25,316 ~ 25.368 (0.9868 0.9887) 25,310 (0.9965) | Left 25.318 25.368 (0.9968 0.9987) 25.310 (0.9965) [22.585 — 22.618 (0.8892 - 0.8905) _ 22.560 (0.8882) | 7 22.585 ~ 22.618 (0.8892 1 | 22.560 (0.8882) Rear Specified brake fluid Dora Brake pedal height 165 (2.6) Brake disc thickness Brake disc runout ‘Master cylinder |.0. Master piston 0.0. [5.0 (0.20) 17,460 — 17.503 {0.6874—0.6891) 17.417 ~17.4aé (0.6857 ~0.6868) 4.0 (0.16) [70.30 (0.012), 17.815 (0.6896) 17.405 (0.6852) Caliper eylinder 1D. Rear [Front Center Rear Caliper piston 0.0. 0 22.650 22.70 Center 25.400 ~25.450 £22,650 — 22.700 {0.8917 0.8937) 22.585 — 22.618 (0.8892—0.8905) 25.318 ~ 25.368 (0.9968 ~ 0.9987) [22.585 — 22.618 (0.8892 —0.8905) 710 (0.8941), 25.460 (1.0024) 22.710 (0.8941), "22.560 (0.8882) | BATTERY/CHARGING SYSTEM M a SPECIFICATIONS (20 °Ci68 F) Gatory | Capac (eee 12V— 10H Current leakage fieceaceas 0.2 mA mex Voltage Fully charged 130-132 | teovcisee) [Needs charging | Charan cot | Normal | 09A5-10h | Quick 1-11GENERAL INFORMATION [— IGNITION SYSTEM —— TEM SPECIFICATIONS Spark plug rr CREEHVX—9(NGK) “Spark plug gap — {0.80=0.90 mm (0.031 —0.036 in) ignition coil peak voltage | 100 minimum ignition pulse gonerator peak voltage 0.7V minimum ignition ming ("E” mark) 12° BTOC ate Unit: mm fn) [— ELECTRIC STARTER ; ITEM | STANDARD SERVICE LIMIT Starter motor brush length (azo—7a0 1047-053) 451018) ;—~ LIGHTS/METERS/SWITCHES ITEM SPECIFICATIONS, Bulbs [Headlight (HiiLo} [- i2V—605sW Position light bot cece Brake’tal light vet Front turn signal light 28 1W—21W x2 OO Rear turn signal light 1V=21W x2 a ‘Tinstrument light Td =| ‘Turn signal indicator L ri High beam indi { ‘Neutral indicator e 12V=1.7 1 he Immobilizer indicator I " Fuse Main fuse OT S nes f PGM-Fl fuse tT at __ [Sub fuse 5 1 Tachometer poak voltage ras i OSV minimum — = Thermo sensor resistance 30°C 475—56.8k2 L ae 120°C 149-173kQ Fan motor | Start to close (ON - (20 switch ‘Stop to open 93—97 °C (199-207 °F) 1-12GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE eTEeS rive Nom (kgm Ib) FASTENER TNFE! [Nam (kgm, tt) 5 mmhex bolt and nut 5 (05,36) 5mm screw 410.4,29) {6 mm hex bolt and rut 10(1.0,7) 6 mm screw 910.9,65) ‘8mm hex bolt and rut 2222/16) 6 mm flange bolt (8 mm head) 9(0.9,65) 10 mm hex bolt and nut 34(35 25) {6 mm flange bolt (10 mm head) 12(1.2,9) 12 mm hex bolt and nut 54(6.5, 40) and nut ‘8mm flange bolt and nut 26 (2.7, 20) 10 mm flange bolt and nut 39 (40,28) + Torque specifications listed below are for important fasteners. + Others should be tigntoned to standard torque values listed above. NOTES: 1. Apply sealant tothe threads 2. Apply alocking agent to the threads. 3. Apply groaso to the threads. 4. Stake, 5. Apply ol tothe threads and flange surface. 5. Apply clean engine ol tothe O-ring 7. Usnut 8. ALOC bolt replace with a new one. 9. CTbott ENGINE - THREAD TORQUE rem DIA. (mm) Nem (kgf, tbest) | REMARKS MAINTENANCE: | Spark plug 4 w | a2.9 Timing hole cap 1 45 18(18,13) | NOTES LUBRICATION SYSTEM: Oil drain bolt Jou 14 23 (3.0, 22) Oil filter boss 1 20 18(1.8,13) —-NOTEZ Oil pump assembly flange bolt 1 6 13(1.3,9) NOTES Oil pump driven sprocket bolt 1 6 15(15,11) | NOTE2 Oil strainer nut 1 6 12(1.2,9) NOTE? Oilfiter cartridge 1 20 10(4.0,7) Notes Oil pressure switch )4 Pre 12(1.2,9) NoTE1 Oil pressure switch wire terminal scrow jon 4 2(0.2,1.4) Cilpipe mounting bolt 2 6 12(1.2,9) NoTe2 FUEL SYSTEM (Programmed Fuel Injection): ECT (Engine Coolant Temperature)ithermo sensor 1 2 23(23,17) | NOTE Knock sensor 1 2 318.2, 23) Throttle body insulator band serow 8 5 Seo page 1-18 Throttle cable bracket mounting bolt Z 5 310.35, 2.6) Fuel pipe mounting nut 2 6 10(1.0,7) NOTE? Yellow paint Fuel pipe setting bolt | 2 8 222,16) | Yellow paint Pressure regulator lock nut 1 | 2728/20) Yellow paint Starter valve synchronization plate screw 4 3 | 110.08/0.7) Starter vaive lock nut 4 10 210.18, 1.3) Vacuum joint plug socket bolt for synchronization 4 5 | 3003.22 ‘COOLING SYSTEM: Water pump cover bolt si 6 13113, 9) NOTES 1-13GENERAL INFORMATION _S_—a_aE—aea—E—E—— ENGINE (Cont'd) ‘wea | TonUE rn or | aie | wma) ROMMS ENGINE MOUNTING: | Srv cpocter covert 2s rn2.9 Dive spectet spc ok ie | eta cwtnbeR neaoivaives ingen caver ot 6 8 | tono.n Bronte fone bo 8 8 thai | noreze ‘Camshaft holder flange bolt 1 | 6 12(1.2,9) NOTES Oyinder head sealing bot 7 | we ata.2) | NOTED Qincorneaa Sc 2| 3 wore. Shiner heed mounting botnet | % | erase | nores Cam sprocket bolt hus 7 | 20 (2.0, 14) NOTE 2 Gam chitendener ap ee ett one one er mourn bo pfs tno Cam chain guide A mounting bolt eo 6 12(1.2,9) Gyincerheldstalbon rts stor) — | @ | 8 | Sempage tas exit ve over args ok tg] SESS Compuiegerwater cover Seat ris ee cx Touceanshr ace iach etre rs ws | wrnse.09 | noreas Clutch spring bolvwasher | 6 12 (12,9) | Right crankcase cover SH bolt = 6 12(1.2,9) Fanta corr eter Dt Tf beef ama | Shit renter csr ni foam | wore ‘Shift drum stopper pivot bolt oct 6 12(1.2,9) hers ana iis Bean aTenwaTOn/STARTER LUTE: | toot cover Hoot wo | 2.9 frat e sn tke | 8 | stearae Pet arg 1 ie | restos. | wores Str mourn crt! bot | ma. Bit onary ean DR gi] 8 the.) | nore cratucastsronrevne omar on 1 | o.a9 Stn ino ot) » | 3 | Sas vores an wis ‘ma 7mm ett 7 18(1.8, 13) | mm ¢ | 3 wne.a Connasing 2) freaiay | nores Comer anne fone bal + | | doaolan | Nores tower anne sag at 20mm 1 | Beolan | Nores cnn 1 2 | Rasta | notes CRANKSHAFT/IRANSMISSIONALANCER vnahatorg stp tone ot 2 | ons en2.9 | nore2 Shiu cpt fans bot 2) 8 tnain Nove? Btlncar ot hdr target zi 3 zee.m Balancer shaft pinch bolt + 6 12(1.2,9) | 1-14GENERAL INFORMATION ENGINE (Cont'd) T 1 - THREAD TORQUE rem er | onion | mitt ty | REMARKS IGnion system: | | \gnition pulse generator cover SH bolt aed tica 12(1.2,9) NOTE | | See page 1-20 Ignition pulse generator rotor special bolt 1 10 59(60,43) | NOTES LUGHT/METERS/SWITCHES: | Neutral switch a}| i 12(1.2,9) Throttle body insulator clamp: Exhaust pipe stud bolt: 12.4 1mm (05 + 0.04in) 38.5~39.0 mm (1.62—1.54 in) 1-15GENERAL INFORMATION FRAME rem, FRAME BODY PANELS/EXHAUST SYSTEM: Side stand pivot bolt Side stand pivot lock nut Main stand mounting bolt ‘Main stand spring hook Bank sensor Exhaust pipe joint nut Muffler band bolt Muffler bracket bolt Seat rail mounting bolt FUEL SYSTEM (Programmed Fuel Injection): Fuel tube sealing nut (throttle body side) Fuel tube banjo bolt (fuel tank side) Service check bolt Fuel pump mounting nut Fuel filler cap bolt 0; sensor Bank angle sensor mounting screw COOLING SYSTEM: Cooling fen nut Fan motor nut ENGINE MOUNTING: Side stand bracket bolt Engine hanger nut (rear/upper) Engine hanger nut (rear/lower) Engine hanger bolt Engine hanger adjusting bolt Engine hanger adjusting bolt lock nut (CLUTCH/GEARSHIFT LINKAGE: Gearshift pedal bolt FRONT WHEEL/SUSPENSION/STEERIN Handlebar stopper bolt Handlebar weight mounting screw Steering stem nut Top thread A. Top thread 8 Fork top bridge pinch bolt Fork bottom bridge pinch bolt Front axle bolt Front axle holder bolt Front brake disc mounting bolt Fork cap Fork socket bolt Fork damper lock nut THREAD DIA. (mm) 10 2 2 190 2 2 24 26 10 “ 7 10 TORQUE Nem (kgf-m, Ibf ft) 10(1.0,7) 28 (3.0,22) 545.5, 40) 26 (2.7, 20) 22 (2.2, 16) 21(2.1, 18) 18(1.8, 13) 26 (2.7, 20) 44 (4.5, 33) 22(2.2, 16) 2212.2, 16) 15(1.5, 11) 12(1.2,9) 2(0.2, 1.4) 25(2.5, 18) 2(0.2,1.4) 3(0.27, 2.0) 5 (05,36) 54 (55,40) 64 (65,47) 64 (65,47) 40 (4.1, 30) 1111.1,8) 545.5, 40) 10(1.0,7) 252.6, 19) 1011.0,7) 103 (10.8, 76) 26 (2.7, 20) 23(2.3,17) 49 (6.0, 36) 59 (6.0, 43) 22(22, 16) 20(2.0, 14) 23 (23,17) 20(2.0, 14) 20(2.0, 14) 1+ See page 13-33 | REMARKS. Noes NOTES NoTEa NOTE 2 1-16GENERAL INFORMATION FRAME (Cont'd) — ] tuncan | ToRaue bat ory DIA. (mm) Nem (kgf-m, Ibf-ft) FEM. EAR WHEEL/SUSPENSION Rear axlenct : ® 18 (120,87) NOTE? faa rake ise mounting bo 5 3 23.3) Notes Driven procter rin Boho @ 108 110,80) | NOTE? Reor shock bsorber mourtng nut 2 po) to 23,3) | NOTE? Swingarm pivot nat {oot 8 (85 \53) | NOTE? Foote hlde socket bl poz jo wo 3140.23) Drivechain ser bot 2 8 3103.65) | nores HYDRAULIC BRAKE Frontbake master onder holder bolt 2 6 2112.9) Fontbake master efinde ap see 2 ‘ 1018.1 Brat ever pvt bo Tna[w 6 101,07) | Brake lever pat ut 1 6 eios,as) Brake ever sduster ' 5 | tan. 29) Front broke sch screw 1 ‘ 1012-08) Right ton orate caliper mounting bot 2 8 51132,23) Notes {of trot rat caliper pvt ba 1 é 31132,23) | NOTES Letom rake caliper bol second master 1 é 26(27,20) | NOTEE Caliperbody 8 bot 3 é 32033128) | NOTES Front bake calipers pin (nai) a | 2123.17) | Note? Fontbake caliper side pn sub) Blea 3113.8) | NOTE Pad in Boaftro 10 18(13,13) Brake caliper bleed é @ (08,43) Second master cylinder mounting bolt horetooakers 31 (3.2, 23) NoTES ‘Second master cylinder push rod nut Ioo-a} 8 18.(1.8, 13) Second master eying connector Zoafire 8 "(10.7 Rer masa eyinder meurting Bot azitico 8 220218 Roe mesterevinderesercr oursing bol 1 8 02/8) Rear master cylinder push rod nut Nou-of 8 18 (1.8, 13) Roar meso inder hos jin sre 1 ‘ 1045.1) noTe2 Bratahose oi bat n |. 3438, 25) Brats pie int 2 | mi7,12) | Nores Brats ibe 23 wayne zo 8 ‘aii2.9) | Brake hose clamp bolt 2 6 12(1.2,9) Data valve mouring bot 2 5 r2n2.3) PCV (roporioal Contel Valve) mouningtat | 2 5 2202.3 Fgh fort bake nose clamp bs i 5 202.8) IGHuTiOn S¥STE: iantion cil mounting nu ‘ 5 18118, 2) ignition ea mounting nat 2 3 roi. | LIGHTS/METERS/SWITCHES: | Talltrake ight mounting bot doef 8 7007.53) Root signal nit mourting nt 2 | | Sis'se ‘Combination meter mounting bolt ee 4 2 (0.2, 1.4) Fen moter switch ‘ 6 t(18,13) | NoTEs Ign switch mounting bol 2 ° 228.18) Side stand switch mounting bot fooocinchess 6 w0110,7) | 1-17GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available, 2. Alternative tool 3. Newly provided tool. 4. Newly designed too} DESCRIPTION Fuel pressure gauge il pressure gauge set il pressure gauge attachment Clutch center holder Flywheel holder Flywheel puller Attachment, 32 * 35 mm Attachment, 37 x 40. mm. Attachment, 42 * 47 mm Attachment, 62 < 65 mm ‘Attachment, 62 < 68mm ‘Attachment, 22 24mm, Driver, 40 mm 1.0. Attachment, 30 mm LD. Pilot, 17 mm Pilot, 20 mm, Pilot, 38 mm. Pilot, 28 mm Bearing remover shaft Boaring remover head, 20 mm Driver Valve spring compressor Valve seat cutter ‘Seat cutter, 29 mm (45° EX) ‘Seat cutter, 33 mm (45° IN) Flat cutter, 29 mm (32° EX} Flat cutter, 33 mm (32° IN) Interior cutter, 30 mm (60° EX) Interior cutter, 34 mm (60° IN) Cuttor holder, 5 mm ‘Snap ring pliers, Steering stem socket Valve guide driver, 5 mm Attachment, 28 30 mm Needle bearing remover Ball race remover set Driver attachment, A Driver attachment, 8 —Driver shaft assembly Bearing remover, A —Bearing remover, B ‘Assembly bese ‘Steering stem driver Driver shaft Oil seal driver Slider weight Driver attachment handle Valve spring compressor attachment Driver shaft Valve guide reamer Oil filter wrench 1-18 ‘TOOL NUMBER (07406-0040002 07506-3000000 07510-4220100 07724-0050002 07725-04000 07733-0020001 07746-0010100 (0746-0010200 (07746-0010300 07746-0010400, 07746-0010500 07746-0010800 0746-0030100 0746.0030300 0746.0040400 07746-0040500 07746-0040800 07746-0041100 (07746-0050100 (07746-05060 (07749-0010000 07757-01000 07780-0010300 0780-0010800 0780.0013400 (07780.0012900 (07780-00140 (0780.0014700 0781-0010400 07914-SA50001 (07916-3710101 07942-MA60000 07946-1870100 (07946-KAS000 (07946-KM30001, (07946-KM90100 (07946-KM90200 (07948-KM90300 (07946-KM80401 07946-KM90500 07946-KM90600 07946-00000 (07946-MJ00100 (07947-KA40200 (07947-KAS0100 (07949-3710001 (07959-KM30101 (07964-MB00200 (07964-MA60001 O7HAA.PS70100 REMARKS | NoTes NOTE1 NOTE NOTE 2: 07914-3230001 13,14 1“ 13,14 13,14 913,14 9,18 13 14 13 13 13 14 13 13 14 2GENERAL INFORMATION DESCRIPTION ‘TOOL NUMBER ] REMARKS: ] REF. SEC. Peak voltage adaptor | o7HG-0020100 - NOTE2: 517,19 Imtio diagnostic tester {model 625) Needle bearing remover, 28 mm o7HiMc-MR70100 14 Tappet hole protector O7HMG-MR70002 8 Drive chain tool sot O7HMH-MR10103 3 Compression gauge attachment | O7RML-Myso100 8 Lock nut wrench | o7va.matoroo 7 Test pin box o7wez-0010100 | NOTES 5 ECU tost harness | o7wez-mecoioo | NOTES 5 Testharness 2 O7XMZMBNOt0O | NOTES | 20 1-19GENERAL INFORMATION LUBRICATION & SEAL POINTS y~ ENGINE T Location | MATERIAL REMARKS CCrankcase mating surface Liquid sealant (Three | ar rad THDST | Bond 12078 of equiv alent) 10 15mm (0.4-0.8 in) igang vita | | Ignition pulse generator cover bolt threads (marked | Coating width: 6.5 + 1 mm rar cea eta | onot apply sealant io the thread head 34 mm (0.1~0.2 ap ‘Thermo unit threads Knock sensor threads | 1-20GENERAL INFORMATION ;~ ENGINE (Cont'd) Locarion MATERIAL REMARKS Cylinder head semi-circular cutout "Sealant ‘Camshaft lobes/journals Valve lifter outer sliding surface ‘Valve stem (valve guide sliding surface) Piston pin sliding surface Main journal besring surface Connecting rod bearing surface Crankshaft journals 1M3,C4, C5 shifter gear (shift fork grooves) Clutch outer/primary driven gear sliding surface ‘Clutch outer guide sliding surface Starter reduction gear outer surface Primary drive gear and sub gear sliding surface f APPLY AREA « Carries ale: Piston ring sliding area Main journal 9 mm bolt threads and seating surface (atter removing anti-rust oil additive) Cylinder head special bolt (after removing anti-rust oil additive) Oil strainer packing Oil filter cartridge threads and O-ring Flywheel bolt threads and seating surface Starter one-way clutch sliding surface Connecting rod nut threads Clutch joint piece sliding surface Clutch lifter rod surface Clutch center lock nut threads Clutch dise surface Each gear teeth and rotating surface Each bearing Each O-ring (Other rotating area and sliding surface fide grease Engine oil Molybdenum disul fide oil (2 mixture of 1/2 engine oil and 172 molybdenum disul- 1-21GENERAL INFORMATION ENGINE (Cont'd) LOCATION “Timing hole cap threads Balancer damper rubber fitting area il seal ips Cylinder head sealing bolt threads Gylinder head cover breather joint threads Lower crankoase sealing bolt threads Starter one-way clutch outer bolt threads, il pump driven sprocket bolt threads Oil pipe mounting bolt threads Oil filter boss threads Shift drum set plate bolt threads Shift drum center bolt threads Mainshaft bearing set plate bolt threads Cam sprocket bolt threads Cylinder hoad cover breather plate bolt threads 1-22 | Multi-purpose grease a Coating width: 6.5 + 1 mmGENERAL INFORMATION FRAME T LOCATION MATERIAL REMARKS. Rear wheel dust seal lips Front wheal dust seal lips Multi-purpose arease Rear wheel side collar inner surface Footpeg sliding area Passenger footpeg sliding area Rear brake pedal pivot sliding area ‘Tarottle pipe sliding area Seat catch hook Ae [eet i Steering head bearing sliding surface ‘Multi-purpose grease Steering head dust seal lips (Shell Alvania EP2 or ‘Swingarm pivot bearing equivalent) ‘Swingarm pivot dust seal lips Shock absorber needle bearing ‘Shock absorber dust seal lips | Loft front brake caliper pivot bearing sliding surface Left front brake caliper pivot ol seal sliding surfaco Left fork needle bearing sliding surfaco Left fork dust seal sliding surface Side stand pivot surface Molybdenum disul- Main stand pivot surface fide grease Throttle pipe cable sliding surface ‘Shock absorber spring adjuster cam surface —ielybdenum paste ‘Steering stem top thread Engine oil ‘Throttle cable casing inner Brake pipe joint threads Throttle cable A, 8 casing inner Cable lubricant Choke cable casing inner Clutch cable casing inner | Z Brake master cylinder cups DOT 4 brake fluid Brake caliper piston seals Brake caliper dust seals 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 st de Brake caliper slide pin threads Locking agent Rear master cylinder hose joint screw threads Fork sockot bolt threads Driven sprocket stud bolt threads Handle grip rubber inside Fork cap O-ring Fork ol seal lips Silicone grease 1-23GENERAL INFORMATION CABLE & HARNESS ROUTING COMBINATION METER 9 (NATURAL} CONNECTOR LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH te 6P (BLACK) CONNECTOR wyromizen a | (NATURAL) CONNECTOR COMBINATION METER 9P- (BLACK) CONNECTOR LEFT HANDLEBAR SWITCH 6P (BLUE) CONNECTOR, POSITION LIGHT 2P. (NATURAL| CONNECTOR Ss RIGHT TURN SIGNAL CONNECTOR LEFT TURN SIGNAL, CONNECTOR HEADLIGHT SOCKET HORN WIRE 1-24GENERAL INFORMATION COMBINATION METER WIRE ‘THROTTLE CABLES CLUTCH CABLE RIGHT TURN LEFT TURN SIGNAL WIRE SIGNAL WIRE LEFT HANDLEBAR RIGHT HANDLEBAR] SWITCH WIRE ‘SWITCH WIRE IMMOBILIZER WIRE IGNITION swiTCH WIRE 1-25GENERAL INFORMATION CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE OIL COOLER HOSE FRONT BRAKE HOSE ‘THROTTLE CABLES OIL COOLER HOSE 1-26GENERAL INFORMATION ‘THROTTLE CABLES PAIR CONTROL SOLENOID VALVE / CRANKCASE BREATHER TUBE s \ / No. 2S IGNITION COIL fe - SS = No, IGNITION Z \ coin } = i ie aC . IATSENSOR f y THROTTLE { ‘ SENSOR MAP SENSOR A___— ot pressure 7 SWITCH ECTSENSOR ~~ “knock SENSOR ' Y J | AA\ Is (RS } 7 Aa) ™™ ignmon purse GENERATOR With ALTERNATOR Wit e __/\ / o\ A CAM PULSE GENERATOR wane { Q {| / \ ENGINE SUB STARTER MOTOR CABLE / \ ee / VEHICLE SPEED SENSOR ‘STARTER MOTOR GROUND CABLE 1-27GENERAL INFORMATION No. 2/8 IGNITION COIL MAIN WIRE HARNESS PAIR CONTROL SOLENOID VALVEg? (NATURAL) conwecron \ / CLUTCH CABLE STARTER MOTOR CABLE FAN MOTOR SWITCH WIRE ALTERNATOR WIRE SIDE STAND SWITCH WIRE 1-28GENERAL INFORMATION No. 1/4 IGNITION COIL FUEL TANK OVERFLOW TUBE aR RES UE FUEL TANK AIR VENT TUBE RADIATOR OVERFLOW TUBE \ OIL COOLER BRAKE LIGHT SWITCH WIRE | }OLER HOSE: 0, SENSOR WIRE SIPHON TUBE UPPER RADIATOR HOSE IGNITION PULSE GENERATOR WIRE 1-29GENERAL INFORMATION MAP SENSOR. ECT SENSOR \ KNOCK SENSOR, 1-30GENERAL INFORMATIONGENERAL INFORMATION FUEL CUTRELAY BANK ANGLE SENSOR (ENGINE STOP SENSOR} ENGINE STOP RELAY MAIN FUSE HOLDER MAIN WIRE HARNESS ‘TURN SIGNAL RELAY FUSE BOX STARTER RELAY SWITCH 1-32GENERAL INFORMATION MAIN WIRE HARNESS REGULATOR/RECTIFIER PROPORTIONAL CONTROL VALVE RESERVOIR HOSE BRAKE LIGHT SWITCH WIRE 1-33GENERAL INFORMATION PROPORTIONAL CONTROL VALVE 1-34GENERAL INFORMATION FRONT MASTER CYLINDER, DER SECONDARY MASTER CYLINI é é 5 E 5 IRIE Zh lyre: is SSS eS |AKE CALIPER 1-35GENERAL INFORMATION or 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. 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 <0 FresHAR a BLOW-Y GAS 1-36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 idle speed adjustment with the throttle stop screw. The exhaust emission control system is seperate from the crankcase emission control system, ‘The exhaust emission control system consists of a secondary air supply system which introduces filtered aie 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) control valve, This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable emount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevent reverse air flow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid valve is controlled by the PGM-I unit, and the fresh air passage is openediclosed according the running condition [ECTIATITPIMAP sensor and engine revolution) No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended, AIR CLEANER HOUSING PAIR CONTROL VALVE _- THROTTLE BODY PAIR CHECK VALVE EXHAUST PORT 1-37GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM ‘TEMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing thereof: (1) The removal or rendering in operative 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 of while itis in use; (2) the use of the vehicle after such device or element of {design has been removed or rendered inoperative by any person, AMONG THOSE ACTS PRESUMED TO CONSTITUTE TEMPERING 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 perts other then those specified by the manufacturer. 1-38MEMO,FRAME/BODY PANELS/EXHAUST SYSTEM. BODY PANEL LOCATIONS SEAT REAR GRAB RAIL RADIATOR GRILL SIDE GRILL 2-02. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS 20 FRONT FENDER 25 SERVICE INFORMATION 24 REAR FENDER 25 TROUBLESHOOTING 24 ‘SEAT RAIL 28 Ea SEAT 22 MUFFLER/EXHAUST PIPE 2-10 REAR COWL 22 FOOTPEG 2-16 | RADIATOR GRILL 24 SERVICE INFORMATION GENERAL WARNING + Gasoline is extremely flammable and is explosive under certain conditions. 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, * 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 pipe clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly. ‘ Always inspect the exhaust system for leaks after installation. TORQUE VALUES Bank sensor 22Nem (2.2 kgm, 16 IbE A) Exhaust pipe joint nut 21.Nem (2.1 kgm, 15 bE) Muffier band bolt 18 Nm (1.8 kgm, 13 DFR) Murer bracket bolt 28 Nem (2.7 kgm , 20 bt) Seat rail mounting bolt 44.N-m (45 kgm 33 IDF) TROUBLESHOOTING Excessive exhaust noise * Broken exhaust system * Exhaust gas leak Poor performance Jeformed exhaust system ‘* Exhaust gas leak ‘Clogged mufflerFRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Unlock the seat using the ignition key. Fomove the seat backward, INSTALLATION Align the seat hooks with the frame brackets and install the seat Push the rear end of the seat and lock it. REAR COWL REMOVAL Remove the seat (see above). Remove the rear grab rail mounting bolt rubber plugs. Remove the mounting bolts and rear grab ral Remove the two trim clips under the rear cow. TRIM CLIPS:FRAME/BODY PANELS/EXHAUST SYSTEM Remove the four rear cow! mounting special bolts. SPECIAL BOLT Remove the rear cowl backward. INSTALLATION Installation is in the reverse order of removal REAR COWLFRAME/BODY PANELS/EXHAUST SYSTEM RADIATOR GRILL REMOVAL Remove the six radiator grillside grill mounting ‘special bolts. Remove the radiator grill forward Remove the side grill mounting bolt and mounting rubber, then remove the side gril F INSTALLATION Installation i in the reverse order of removal. RIGHT SIDE GRILL —_*@7 LEFT SIDE GRILL 2-4FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER ' FRONT FENDER REMOVAL Romove the front fender mounting special bolts. Remove the front fender forward, INSTALLATION Installation isin the reverse order of removal. REAR FENDER ENGINE STOP SENSOR REMOVAL RELAYS MAIN FUSE CASE Remove the following: Rear cowl (page 2-2) ~ Battery (page 16-5) —Fuel cutoff relay —Engine stop relay | ~ Starter relay switch Unhook the retaining tab and remove the fuse box. Unhook the retaining tab and remove the main fuse Disconnect the rear brake light switch connector and engine stop sensor connector. Remove tho retaining band and ECM (Engine Control Module), then disconnect the multiFRAME/BODY PANELS/EXHAUST SYSTEM Disconnect theiseal ica ia ‘TAILIBRAKE LIGHT ‘SEAT LOCK CABLE CONNECTOR Disconnect the tailbrake light connector and rear turn signal connectors. Remove the rear fender mounting special bolts. Remove the rear fender mounting bolts, nuts and collars,FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION ENGINE STOP SENSOR \\ MAIN FUSE CASE SEAT LOCK CABLE Sean iotinet sor ot . a \ | Fuseaox Fo \ | / stapter revay Switch REAR FENDER BATTERY NOTE: While installing the rear fender, route the wire harness property (page 1-24), Install and tighten the front side mounting special bolts securely. Install the rear mounting collar, bolt and nut. Tighten the nuts while holding the bolts Install the removed parts in the reverse order of removal Note Route the wires properly (page 1-24).FRAME/BODY PANELS/EXHAUST SYSTEM SEAT RAIL REMOVAL Remove the rear fender (page 2-5). Remove the rear brake hose clamp bolt. Remove the PCV (Proportional Control Valve) mounting bolts, Remove the rear brake reservoir mounting bolt. connector. Remove the bolts and regulator/rectfier Remove the turn bracket. jgnal relay from the Romove the seat rail mounting bolts, nuts and seat railFRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION TURN SIGNAL RELAY SEATRAIL 44.Nom (4.5 kgm , 33 Ib) BRAKE RESERVOIR 44 Nom (4.5 kgm , 33 lb-ft) Install the seat rail and tighten the mounting bolts to the specified torque. TORQUE: 44 N-m (4.5 kgf, 33 bff) Install the turn signal relay onto the seat rail bracket.FRAME/BODY PANELS/EXHAUST SYSTEM Install the regulator/rectifier, tighten the bolts. Connect the regulator/rectfier 6P (Black} connector, Install and tighten the PCV (Proportional Control Valve) mounting bolts. Install and tighten the rear brake hose clamp bolt Ingtall and tighten the rear brake reservoir tank ‘mounting bot, Install the removed parts in the reverse order of removal. Janae MUFFLER/EXHAUST PIPE REMOVAL Gag Do not service the exhaust system while itis hot. Loosen the exhaust pipe/muffler band bolts. Loosen the muffler front mounting nut. 2-10FRAME/BODY PANELS/EXHAUST SYSTEM Remove the muffler rear mounting bolinut, then remove the muffler. Remove the muffler gasket. Remove the following: oes FUEL TANK Seat (page 2-2) Radiator grill page 2-4) Remove the fuel tank mounting bolts. Support the rear end of the fuel tank using @ equipped tool (extension). Disconnect the O, sensor 4P (Gray) connector. (0, SENSOR CONNECTORFRAME/BODY PANELS/EXHAUST SYSTEM Unfasten the tube/wire band. Release the O, sensor wire from the wire clamp, ee | waster sockeToLT | connector. Remove the radiator upper mounting socket bolt ‘and washer | | Remove the radiator from the upper and lower brackets by moving it to the right, then move the radiator/oil cooler forward as an assembly. Remove the exhaust pipe joint nuts. JOINT NUTS: 2-12FRAME/BODY PANELS/EXHAUST SYSTEM Remove the following: —Exhaust pipe mounting bolt/nut Washer ~Collar Exhaust pipe Exhaust pipe gaskets [EXHAUST PIPE INSTALLATION LEFT MUFFLER 26 N.m (2.7 kgm , 20 IbF ft RIGHT MUFFLER, 26 Nem (2.7 kgf-m , 20 bf) 18.Nem (1.8 kgf , 13 IF) i - \\ 21 Nh (2.1 kgf, 18 IbF ft) \ EXHAUST PIPE / ©, SENSOR GUARD Install the new exhaust pipe gaskets onto the [ ‘exhaust ports of the cylinder head. NoTe Always replace the exhaust pipe gaskets with new.FRAME/BODY PANELS/EXHAUST SYSTEM Install the exhaust pipe, temporarily install the ‘exhaust pipe joint nuts and mounting bolt NOTE Install the mounting collars, washer, bolt and nut property, First tighten the exhaust pipe joint nuts to the specified torque. TORQUE: 21 Nem (2.1 kgfm 15 IbF-) Tighten the exhaust pipe mounting bolt/nut. Install the reditoriil cooler assembly aligning the REE radiator grommets with the upper and lower un brackets Install the washer and radiator mounting socket akiet=" sooxer pour bolt, then tighten the socket bot x | Connect the fan motor sub-harness 2P (Natural) 29 re as connector. Ba IN 2P (NATURAL) CONNECTOR 2-14FRAME/BODY PANELS/EXHAUST SYSTEM Route the O; sensor wire and clamp it with a wire clamp. Fasten the O; sensor wire and fuel tank breather tube end overflow tube with a wire band. Connect the O: sensor 4P (Gray) connector. /OENSOA CONNECTION Remove the fuel tank support tool and close the ane fuel tank. Install and tighten the fuel tank mounting bolts! washers. Install the following: Seat (page 2-2) Radiator grill (page 2-4) Install the new gasket into the muffler. Install he mufflers, At muffler installation, align the grommet of the muffler with the hook of the muffler bracket as shown,FRAME/BODY PANELS/EXHAUST SYSTEM FOOTPEG [Feaoma ‘Temporarily install the muffler mounting boltinut, Tighten the muffler bracket nut to the specified torque. TORQUE: 26 Non (2.7 kgfim , 20 bff) Tighten the muffler mounting boltinut to the specified torque. TORQUE: 26 Nom (2.7 kgf-m , 20 Ibf-t) Tighten the muffler band bolts alternately, then tighten to the specified torque. TORQUE: 18N-m (1.8kgfm , 13 IbFft) REMOVAL Release the retaining clip end from the V-cut groove. Pull out the clip from the footpeg joint pin hole. Remove the washer, joint pin and return spring, than remove the footpeg. FOOTPEGFRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION ‘CAUTION: Do not reuse the retaining clip. Install the footpeg onto the holder, then install the return spring, joint pin and washer. Push the new retaining clip into the joint pin hole. Turn the retaining clip with the joint pin, then hook the clip end into the V-cut groove of the footpeg holder. JOINT PIN RETURN SPRING WASHER FOOTPEG 2-17MEMO,3. MAINTENANCE ‘SERVICE INFORMATION 34 DRIVE CHAIN 3-20 MAINTENANCE SCHEDULE 33 DRIVE CHAIN SLIDER 3:24 FUEL LINE 3-4 BRAKE FLUID 3-25 THROTTLE OPERATION 34 BRAKE PAD WEAR 3-25 El CHOKE OPERATION 35 BRAKE SYSTEM 3:26 AIR CLEANER 35 BRAKE LIGHT SWITCH 3-27 SPARK PLUG 37 HEADLIGHT AIM 3-28 VALVE CLEARANCE 3-11 CLUTCH SYSTEM 3-28 ENGINE OIL/OIL FILTER 3-15 SIDE STAND 3.29 ENGINE IDLE SPEED 3-18 SUSPENSION 3-29 RADIATOR COOLANT 3-18 NUTS, BOLTS, FASTENERS 3:30 COOLING SYSTEM 3-19 WHEELS/TIRES 3:31 SECONDARY AIR SUPPLY SYSTEM 3-19 STEERING HEAD BEARINGS 3:31 | SERVICE INFORMATION GENERAL oo * Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. ‘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 may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area, ‘Place the motorcycle on a level ground before starting any work, ‘SPECIFICATIONS a Unit: mm (in) ITEM ‘SPECIFICATIONS Throtile grip free play 2-6(6= Wa) | Spark plug (CREEHVX—9 (NGK}) [Spark plug gap (0.80--0.90 (0.031 0.035) = Valve clearance |_IN_ — | 0.16 = 0.03 (0.006 + 0.003) mE eX (0.22 + 0.03 0.009 + 0.001) 3-1MAINTENANCE MAINTENANCE rem. Engine oll capacity | At draining | Recommended engine oil Engine idle speed filter change SPECIFICATIONS | set(@ous qt 33imp ay 39841 US Qt, 3.4 imp at) HONDA 4-stroke oil or equivalent motor oil API service classification SE, SF or SG Viscosity: SAE 10W 40 4,100 + 100 min" (rpm) [Drive chain slack Recommended brake fluid Tire ‘Bridgestor Michelin Tiresirpressure _Driveronly 2635 mm (1.0~1.4in) [bora sisal 120770 2R17 (58W)/Radial [180/55 ZR17_(73W)/Radiat BTS7F RADIAL G BTS7R RADIAL F |_MACADAM 90x G MACADAM 90X M. zt 250 KPa (2.50 kgticm®, 36 psi) 290 kPa (2.90 kgflcm , 42 psi) Minimum tire tread depth Driver and passenger 250 kPa (2.50 kafiem?, 36 psi) 290 kPa (2.90 kaficm?, 42 psi) 1.5. mm (0.06 in) 2.0 mm (0.08 in) TORQUE VALUES Timing hole cap Spark plug Cylinder head cover bolt drain bolt filter cartridge Rear axle nut Drive sprocket special bolt Driven sprocket nut Rear master cylinder push rod nut TOOLS. Oil fier wrench Drive chain tool set, 18N-m (1.8 kofm , 13 bff) 12Nem (1.2 kgm , 9 bff) 10N-m (1.0 kgm , 7 IDFA) 29N-m(3.0 kgm, 22 IDF) 40 Nem (1.0 kgf , 7 IDE) 118 Nem (12.0 kgm , 87 IDEA) 54 Nem (5.5 kgm, 40 IbFft) 108 Nem (11.0 kgm , 80 IDI) 18N-m (1.8 kgf-m , 13 IF) Apply grease to the threads Apply clean engine oil to the O-ring Usnut O7HAA-PJ70100 o7HMH-MR10103MAINTENANCE SCHEDULE MAINTENANCE SSK Portorm the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. [:Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The following items require some mechanical knowled, ‘more technical information and tools. Consult . Certain items (particularly those marked * and **) may require uthorized HONDA dé iS FREQUENCY | WHICHEV =} ODOMETER READING (NOTE 1) | re ER COMES (5,000 km 78|24 [30] 36. REFER ae pel X00 mr 72] 16|20| 247 ToPAGE L ante _ al Months 18 =| FuELUNE 3 4 THAGTTLE OPERATION aoa # CHOKE OPERATION sus * [AIR CLEANER NOTE SPARK PLUG VALVE CLEARANCE = ci ENGINE OIL as EA HO ENGINE OIL FILTER pra cheval ENGINE IDE SPEED Pe z NOTES i * te “+ | SECONDARY alR SUPPLYSYSTEM - cal, 1 RIVE CHAIN EVERY 1,000 DRIVE CHAINSLIDER e I — BRAKE FLUID ce | TTR RAKE PAD WEAR i “BRAKE SYSTEM 1 | BRAKE LIGHT SwiTCH 1 i 3 [HEADLIGHT Ai ct 1 co = a i ret {fe Me *| WHEELSTinES zi i 1+ STEERING HEAD BEARINGS Chere + Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data and is mechanically qualified. 4 Inthe interest of safety, we recommend these items be serviced only by an authored HONDA desler. NOTES: 1. Athigher odometer reading, repeat at the frequency interval established here 2. Service more frequently if the motorcycle is ridden in unusually wet or dusty areas. 3, Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill 3-3MAINTENANCE FUEL LINE THROTTLE OPERATION 3-4 ‘Support the rear end of the fuel tank (page 2-11) Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. Install the fuel tank in the reverse order of removal. Check for smooth throttle grip full opening and ‘automatic full closing in all steering posi Check the throttle cables and replace them if they are deteriorated, kinked or damaged, Lubricate the throttle cables, if throttle operation is, not smooth. Measure the free play at the throttle grip flange. FREE PLAY: 2~6 mm (1/16~ 1/4 in} Throtle grip fee play can be adjusted at either end of the throttle cable. > AO 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 adjust Remove the air cleaner housing (page 5-60), ‘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.MAINTENANCE CHOKE OPERATION This motorcycle is equipped with a bypass air volume control choke system, controlled by the starter valve, ‘The starter valve opens a bypass air circuit when the choke knob under the left side of the main frame is pulled ON. Choke lever operation Check for smooth operation of the choke knob, Lubricate the choke cable if the operation is not smooth Starter valve lover operation Open and support the rear end of the fuel tank (page 2-11) 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 knob setto fully OFF. Roplace the choke cable if the free play is out of specification. Install the removed parts in the reverse order of removal. AIR CLEANER Disconnect the fuel pumpireserve sensor 3P (Black)MAINTENANCE Romove the fuel tank rear mounting bolts. r FUEL TANK Pull out the fuel tank front bracket rubbers from the frame. Remove the fuel tank mounting collar, temporarily install a fue! tank mounting bolts. ‘Support the front end of the fuel tank using a suitable support as shown,MAINTENANCE Disconnect the IAT (Intake Ar Te connector. ature) sensor Remove the screws and air cleaner housing cover, Remove and discard the air cleaner element in accordance with the maintenance schedule (page 33), Also replace the air cleaner element any time it is excessively dirty or damage, Install the removed parts in the reverse order of removal. SPARK PLUG SIDEGRILL | REMOVAL cAUTION: Be careful not to damage the oll cooler and radiator fins. Remove the radiator gril'side grill mounting bolts and then remove both side gril. Deore he fan mtr su nes P Net —— Remove the radeter mouning soctet bot and | \ | wae CONNECTOR 2P (NATURAL) 3-7MAINTENANCE Remove the radiator from the upper and lower brackets by moving it to the right, then move the radiator/oil cooler forward as an assembly. Disconnect the spark plug caps. Nore: 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 plug using a equipped spark plug wrench or an equivalent, Inspect or replace as described in the maintenance schedule. INSPECTION Check the following and replace if necessary (recommended spark plug: page 3-1) * Insulator for damage * Electrodes for wear ‘© Burning condition, coloration. If the electrodes is contaminated with accumulated objects or dirt, clean the electrode using the spark plug cleaner. CAUTION: © This motoreycle’s spark plug equipped with platinum type electrodes. Do not use wire brush to clean the electrodes. ‘= The plug cleaner should be used with the air pressure of less than 6 kgf/cm (85 psi) and for less than 20 seconds. ioe INSULATOR _ HERES ELECTRODE——_ UPPER BRACKETAlwaysuse specified spark plugs on this motorcycle Replace the plug if the center electrode is rounded {as shown in the illustration, SPECIFIED SPARK PLUG: CRBEHVX~9 [NGK) Check the gap between the ca electrodes with a wire type feeler gauge. and side CAUTION: To prevent damaging the platinum coating of the center electrodes, use a wire type feeler gauge to ‘check the spark plug gap. Moke sure that the 1.0 mm (0.04 in) plug gauge does not insert between the gap. If the gauge can be inserted into the gap, replace the plug with a new one, CAUTION: Do not adjust tho spark plug gap. If the gap is out of specification, replace with a new one. Reinstall the spark plug in the cylinder head and hhand tighten, then torque to specification, TORQUE: 12.N-m(1.2kgfm, 9 IbFft) Iusing the new plug, install as follows: Install and hand tighten the new spark plug, then tighten it about 1/2 turn after the sealing washer contacts the seat of the plug hole. Install the spark plug caps. MAINTENANCE ROUNDED ELECTRODEMAINTENANCE Install the radistor/oil cooler assembly onto the upper bracket Install the radiator lower bracket boss to the Y radiator lowor bracket. LOWER BRACKET Install the washer and radiator upper mounting socket bolt, then tighten the socket bolt. Connect the fan motor sub-harness 2P (Natural) connector. WASHER SOCKET BOLT iA ‘OR Install the both side grill, then tighten the radiator agrillside grill mounting bolts securely. / 3-10MAINTENANCE VALVE CLEARANCE INSPECTION NOTE. Inspect and adjust the valve clearance while the engine is cold (below 36 *C/95 °F) Remove the cylinder head caver (page 8-5) 4 Remove the cam chain tensioner lifter sealing bolt s and sealing washer. SEALING WASHER Turn the cam chain tensioner lifter shaft fully and secure it using the mechanic's tensioner stopper tool (page 8-6), Remove the timing hole cap and O-ring, ‘Turn the crankshaft clockwise, align the ‘T" mark ‘on the ignition pulse generator rotor with the index. ings: mark on the ignition pulse generator rotor cover.MAINTENANCE ‘The timing marks (“IN and “EX") on the cam sprockets must be flush with the cylinder head surface and facing outward as shown, If the timing marks on the cam sprocket facing inward, turn the crankshaft clockwise one full turn (360°) and realign the timing marks with the cylinder head surface so they are facing outward. Insert the feeler gauge between the valve lifter and the cam lobe. ‘Record the Check the valve clearance for the No. 1 and No. 3 Clearance or each cylinder intake valves using a feeler gauge. reference inshim VALVE CLEARANCE: selectionit WN: 0.16 + 0,03 mm (0.006 + 0.001 in) adjustment is required No, SINTAKE VALVES No, 1 INTAKE VALVES ‘Turn the crankshaft clockwise 1/2 turn (180", align the index line on the ignition pulse generator rotor so that its facing up as shown, Record the Check the valve clearance for the No. 2 and No. 4 clearance for each cylinder exhaust valves using a feeler gauge. valve for reference inshim VALVE CLEARANCE: selection it EX: 0.22 + 0.03 mm (0.009 +: 0.001 in) adjustment is required. No. 4ExHAUST VALVES ‘No.2 EXHAUST VALVES | 3-12MAINTENANCE Record the clearance for each valve for selection if adjustment is required. Record the clearance for each valve for selection it adjustment is required. Turn the crankshaft clockwise 1/2 turn (180), align the “T” mark on the ignition pulse generator rotor with the index mark on the ignition pulse generator rotor cover, Check the valve clearance for the No. 2 and No. 4 cylinder intake valves using feeler gauge. VALVE CLEARANCE: IN: 0.16 + 0.03 mm (0.006 + 0.001 in} Turn the crankshaft clockwise 1/2 turn (180°), align the index line on the ignition pulse generator rotor so that itis facing up as shown, Check the valve clearance for the No, 1 and No. 3 cylinder exhaust valves using a feeler gauge. VALVE CLEARANCE: EX; 0.22 1 0.03 mm (0.009 + 0.001 in) No. aiNTane VALVES No. 2INTAKE VALVES | /\MAINTENANCE ADJUSTMENT Remove the camshaft (page 8-7) Remove the valve lifters and shims. NOTE: ‘* 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 with compressed air, ‘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. B-c)+D ‘A; New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness NOTE Make sure of the correct shim thickness by (™ ‘measuring the shim by micrometer. ey) ‘+ Reface the valve seat if carbon deposit result in a = caloulated dimension of over 2.800 mm. | 180mm 1.825mm —1.85mm sare e | 3-14MAINTENANCE Intell the newly selected shim on the valve SGRPEn OE ‘Apply molybdenum disulfide oil to the valve lifters. Install the valve lifters into the valve lifter holes. AK —6) (I NoTE: Install the shims and valve lifters in their original locations, Install the camshatt (page 8-23). Rotate the camshafts by rotating the crankshaft clockwise several times. Recheck the valve clearance. BOLT ‘CAM CHAIN TENSIONER LIFTER Remove the cam chain tensioner stopper tool Install the new sealing washer and cam chain tensioner lifter sealing bolt Tighten the bolt securely. Install the removed parts in the reverse order of removal. ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION Start the engine end lett idle for 2 3 minutes. Turn off the engine and support the motorcycle on its contor stand. Remove the oil level dipstick wipe it clean, Reinstall the oll level dipstick, but do not serew it. Remove the oil level dipstick and check the oil level If the levol is below the lower mark on the dipstick, fill the crankease with recommended oil UPPER LEVEL MARK LOWER LEVEL MARK 3-15MAINTENANCE Remove the oil filer cap, Fill the recommended engine oll up to the upper level mark. RECOMMENDED ENGINE OIL: HONDA 4-stroke oil or equivalent motor oil API service classification: SE, SF or SG Viscosity: 10W—40 NOTE ae eee | Other viscosities shown in the chart may be used ‘when the average temperature in your riding area | is within the indicated range. | Reinstall the filler cap and dipstick ENGINE OIL & FILTER CHANGE oo Wf the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed are. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Werm up the engine. NOTE Change the engine oil with the engine warm and the motorcycle on level ground to assure complete draining, Stop the engine and remove the oil filler cap and drain bolt Drain the oil 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 oil on a daily basis, it is stil ‘advisable to thoroughly wash your hands with soap and water as soon as possible after handling Wa. used oil OIL DRAINBOLTISEALNG WASHER | 3-16