1987 CBR1000F Factory Service Manual

HOW TO USE THIS MANUAL CONTENTS
..
Follow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is GENERAL INFORMATION
in peak operating condition and the emission
levels are within the standards set by the U.S. LUBRICATION
-
Environmental Protection Agency and the Cal-
ifornia Air Resources Board. Performing the MAINTENANCE
first scheduled maintenance is very impor-
tant. It compensates for the initial wear that FUEL SYSTEM
-..
occurs during the break-in period.
Sections 1 through 3 apply to the whol~

motorcycle, while sections 4 through 20
describe parts of the motorcycle, grouped ac-
COOLING SYSTEM
ENGINE REMOVAL/INSTALLATION
..
..
cording to locations. w
z CYLINDER HEAD/VALVE
Find the section you want on this page, then C!1
turn to the table of contents on the first page z CYLINDER/PISTON
w
of that section.
Most sections start with an assembly or

system illustration, service information and
CLUTCH
DI
GEARSHIFT LINKAGE/BALANCER
troubleshooting for the section. The subse-
quent pages give detailed procedures. TRANSMISSION/CRANKSHAFT
If you don't know the source of the trouble,
FAIRING/EXHAUST SYSTEM
go to section 21 TROUBLESHOOTING.
~
C/J FRONT WHEEL/SUSPENSION
C/J
ALL INFORMATION, ILLUSTRATIONS, DI- <(
RECTIONS AND SPECIFICATIONS INCLUDED J: REAR WHEEL/SUSPENSION
IN THIS PUBLICATION ARE BASED ON THE u
LATEST PRODUCT INFORMATION AVAIL-
HYDRAULIC BRAKES
ABLE AT THE TIME OF APPROVAL FOR
PRINTING. HONDA MOTOR CO., LTD. RE-
SERVES THE RIGHT TO MAKE CHANGES AT BATTERY /CHARGING SYSTEM
ANY TIME WITHOUT NOTICE AND WITHOUT
...I
INCURRING ANY OBLIGATION WHATEVER. <( IGNITION SYSTEM
NO PART OF THIS PUBLICATION MAY BE RE- u
PRODUCED WITHOUT WRITTEN PERMIS-
SION.
....a:
u
ELECTRIC STARTER
w
...I
w LIGHTS/SWITCHES
HONDA MOTOR CO., LTD.
SERVICE PUBLICATIONS OFFICE
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
Date of Issue: Feb., 1 987

© HONDA MOTOR CO., LTD.
1. GENERAL INFORMATION
GENERAL SAFETY 1-1 TOOLS 1-8
SERVICE RULES 1-1 CABLE & HARNESS ROUTING 1-10
MODEL IDENTIFICATION 1-2 EMISSION CONTROL SYSTEMS 1-15 Ill
SPECIFICATIONS 1-3 EMISSION CONTROL INFORMATION
LABELS 1-18
TORQUE VALUES 1-5
GENERAL SAFETY
IJIH;fr@ld •¥Mfodlfld
If the engine must be running to do some work, make sure the The battery electrolyte contains sulfuric acid. Protect your
area is well-ventilated. Never run the engine in a closed area. eyes, skin and clothing. If case of contact, flush thoroughly
The exhaust contains poisonous carbon monoxide gas that with water and call a doctor if electrolyte gets in your eyes.
may cause loss of consciousness and lead to death.
G11H;W@M
Gi'M!.11&
The battery generates hydrogen gas which can be highly explo-
Gasoline is extremely flammable and is explosive under certain sive. Do not smoke or allow flames or sparks near the battery,
conditions. Do not smoke or allow flames or sparks in your especially while charging it.
working area.
SERVICE RULES
1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA's
design specifications may damage the motorcycle.
2. Use the special tools designed for this product.
3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English
fasteners. The use of incorrect tools and fasteners may damage the motorcycle.
4. Install new gaskets, 0-rings, cotter pins, lock plates, etc. when reassembling.
5. When tightening a series of bolts or nuts, begin with larger-diameter or inner bolts first, and tighten to the specified torque
diagonally in 2 or 3 steps, unless a particular sequence is specified.
6. Clean parts in clearning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
1-1
GENERAL INFORMATION
MODEL IDENTIFICATION
(1 l VEHICLE IDENTIFICATION NUMBER
The vehicle identification number (VIN) is on the left side

of the steering head.
(2) FRAME SERIAL NUMBER (3) ENGINE SERIAL NUMBER

The frame serial number is stamped on the right side of the The engine serial number is stamped on the front of the
steering head. crankcase.
(4) CARBURETOR IDENTIFICATION NUMBER (5) COLOR LABEL

The carburetor identification numbers are stamped on the The color label is attached on the frame under the seat.
rear side of each carburetor.
1-2
GENERAL INFORMATION
SPECIFICATIONS
CALIFORNIA MODEL: I
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,200 mm (86.6 in)

Overall width 725 mm (28.5 in)
Overall height 1,185 mm (46.7 in)
Wheelbase 1,505 mm (59.3 in)
Seat height 775 mm (30.5 in)
Ground clearance 135 mm (5.3 in)
Dry weight 224 kg (493.8 lb) [226 kg (498.2 lb)]
Curb weight 250 kg (551.2 lb) [252 kg (555.6 lb)]
FRAME Type Diamond type
Front suspension, travel Telescopic fork, 1 50 mm (5.9 in)
Rear suspension, travel Swing arm/Shock absorber, 120 mm (4. 7 in)
Front suspension air pressure 0-40 kPa (0-0.4 kg/cm 2. 0-6 psi)
Vehicle capacity load 180 kg (396.8 lb)
Front tire size 110/80V1 7-V270
Rear tire size 140/80V17-V270
I Up to 90 kg Front 36 psi (250 kPa, 2.5 kg/cm2)
Cold tire (200 lbs)loard Rear 42 psi (290 kPa, 2.9 kg/cm2)
pressures Up to vehicle Front 42 psi (290 kPa, 2.9 kg/cm2)
capacity load Rear 42 psi (290 kPa, 2.9 kg/cm2)
Front brake, lining swept area Double disc, 924 cm 2 ( 143.2 sq-in)
Rear brake, lining swept area Single disc, 452 cm 2 (70.1 sq-in)
Fuel capacity 21.0 £ (5.54 US gal, 4.42 Imp gall
Fuel reserve capacity 3.5 £ (0.92 US gal, 0.77 Imp gall
Caster angle 28°
Trail 11 7 mm (4.6 in)
Fork oil capacity Right 485 cc (16.4 US oz, 17.0 Imp oz)
Left 495 cc (16.7 US oz, 17.4 Imp oz)
ENGINE Type Water cooled 4-stroke
Cylinder arrangement 4 cylinders inline
I Bore and stroke 77 x 53.6 mm (3.03 x 2.11 in)
I
Displacement 998 cm 3 (60.9 cu in)
Compression ratio 10.5:1
Valve train Chain
Oil capacity 4.5 £ (4.75 US qt, 3.96 Imp qt) at assembly
3.8 £ (4.02 US qt, 3.34 Imp qt) at oil and filter change
Coolant capacity 3.0 £ (3.17 US qt, 2.64 Imp qt)
Lubrication system Forced pressure and wet sump
Air filtration Paper filter
Cylinder compression 1,250 ± 200 kPa (12.5 ± 2.0 kg/cm 2, 181 ± 29 psi)
1-3
GENERAL INFORMATION
CALIFORNIA MODEL: [
CANADA MODEL:< >
ITEM SPECIFICATION
ENGINE Intake valve Opens 15° [0°] BTDC

Closes 38° [40°JABDC
at 1 mm lift
Exhaust valve Opens 40° BBDC
Closes 10° [0°JATDC
Valve clearance (Cold) 0.10 mm (0.004 in): Intake
0.16 mm (0.006 in): Exhaust
Engine weight (Dry) 85 kg (87.4 lb)
Idle speed 1 . 000 ± 100 rpm
CARBURETION Carburetor type/throttle bore KEIHIN VG/38. 5 mm (1. 52 in)

Identification number VG 90A [VG 90Cl <VG 80D>
Pilot screw initial setting 2 turns out
Float level 9.5 mm (0.37 in)
DRIV E TRAIN Clutch Wet, multi-plate

Transmission 6 speed constant mesh
Primary reduction 1.7857 (75/42)
Final reduction 2.5294 (43/17)
Gear ratios I 2. 7500 (33/1 2)
II 2.0666 (31/15)
Ill 1.6470 (28/17)
IV 1.3684 (26/19)
v 1.1739 (27/23)
VI 1.0454 (23/22)
Gear shift pattern Left foot operated return system, 1-N-2-3-4-5-6
ELECTRICAL Ignition Full transistor ignition

Ignition timing "F" mark 10° BTDC at idle
Full advance 38° BTDC at 5,000 rpm
Starting system Starting motor
Alternator 350 W/5,000 rpm
Battery capacity 12 V-14 AH
Spark plug
NGK ND
DPR 9EA-9 X27 EPR-U9
Spark plug gap 0.8-0.9 mm (0.031-0.035 in)

Firing order 1-2-4-3
Fuse/Main fuse 10 A, 1 5 A/30 A
LIGHTS Head light (high/low beam) 12 V-60/55 W

Position light 12 V-2 cp x 2
Tail/stoplight 12 V-32/2 cp (SAE TRADE No. 11571 x 2
Front turn signal/running light 12 V-32/2 cp (SAE TRADE No. 10341 x 2
Rear turn signal light 12 V-32 cp (SAE TRADE No. 1073) x 2
License light 12 V-3 cp
Instrument lights 12 V-3.4W x 4
Oil pressure warning indicator 12 V-3.4W
Neutral indicator 12 V-3.4W
Turn signal indicator 12 V-3.4W x 2
High beam indicator 12 V-3.4W
1-4
GENERAL INFORMATION
TORQUE VALUES
ENGINE
Thread
ITEM Q'TY Torque N·m (kg-m, ft-lb) Remarks
Dia. (mm)
Connecting rod bearing cap nut 8 8 36 (3.6, 26) Apply molybdenum disulfide
Cylinder head nut 12 10 46 (4.6, 33) grease to the seat and
Camshaft holder bolt 16 6 14 (1.4, 10) threads
Crankcase bolt ( 10 mm) 1 10 40 (4.0, 29)
(9 mm) 12 9 38 (3.8, 28)
(8 mm) 17 8 27 (2.7, 20) Apply molybdenum disulfide
(6 mm) 3 6 12(1.2,9) grease to the seat and
threads
Cam sprocket bolt 4 7 17 (1.7, 12) Apply a locking agent to the
Oil pump driven sprocket bolt 1 6 15 (1 .5, 11)- threads NOTE 1
Alternator chain tensioner bolt 3 6 12 (1.2, 9 ) -
Alternator chain guide bolt 2 6 12 (1.2, 9 ) -
Alternator shaft nut 1 12 50 (5.0, 36)
Alternator base bolt 3 8 29(2.9,21) Apply 3-Bond sealant or its
equivalent to the threads
Pulse generator rotor bolt 1 10 50 (5.0, 36) Apply a locking agent to the
threads
Clutch center lock nut 1 22 90 (9.0, 65)
Cam chain tensioner bracket bolt 4 6 14 (1.4, 10)
Center shift fork bolt 1 7 18(1.8,13)
Shift drum center pin bolt 1 8 23 (2.3, 17) Apply a locking agent to the
Neutral switch 1 10 18(1.8,13) threads NOTE 1
Oil pressure switch 1 - 12(1.2,9) Apply 3-Bond sealant or its
Cylinder head cover bolt 8 6 10 (1.0, 7) equivalent to the threads
Spark plug 4 12 15(1.5,11) NOTE 2
Sealing bolt (20 mm) 1 20 30 (3.0, 22)
(10 mm) 1 10 12(1.2,9)
Clutch slave cylinder bleed valve 1 8 9 (0.9, 7)
Valve adjuster lock nut 16 7 23 (2.3, 17)
Starter flange 1 6 16(1.6,12)
Oil pump chain guide 2 6 12 (1.2, 9) __J Apply a locking agent to the
Oil pass pipe plate 3 6 12 (1.2, 9) threads NOTE 1
Oil drain plug 1 14 38 (3.8, 27)
Oil filter 1 20 10 (1.0, 7)
Starter motor case screw 2 5 4.5 (0.45, 3.3)
NOTE 1: Apply locking agent as shown.
5.5- 7.5 mm (0.22-0.30 in)
NOTE 2: Do not apply locking agent as shown.
~
~
~ 3-4 mm (0.1 -0.2 in)
1-5
GENERAL INFORMATION
CHASSIS
Thread
ITEM Q'ty Torque N·m (kg-m, ft-lb) Remarks
Dia (mm)
Engine hanger bolt (12 mm) 2 12 60 (6.0, 43)

(10 mm) 6 10 45 (4.5, 33)
Engine hanger adjuster 1 20 8 (0.8, 6)
Engine hanger adjuster lock nut 1 20 25 (2.5, 18)
Gearshift pedal bolt 1 6 10 (1.0, 7)
Side stand pivot bolt 1 10 10 (1.0, 7)
Side stand pivot nut 1 10 35 (3.5, 25)
Main stand pivot bolt 1 10 40 (4.0, 29)
Handlebar pinch bolt 2 8 27 (2.7, 20)
Brake hose holder mounting bolt 1 6 9 (0.9, 7)
Foot peg bracket bolt 4 8 27 (2.7, 20)
Oil pipe mounting bolt 6 6 9 (0.9, 7)
Oil cooler mounting bolt 2 6 13 (1.3, 9)
Exhaust pipe joint nut 8 7 17 (1.7, 12)
Fairing stay mounting bolt 2 8 27 (2.7, 20)
Fuel valve lock nut 1 28 38 (3.8, 27)
Steering stem nut 1 24 105 (10.5, 76)
Steering stem adjustment nut 1 26 25 (2.5, 18) Apply oil to the threads
Fork top pinch bolt 2 7 11 (1.1, 8)
Fork bottom pinch bolt 2 10 50 (5.0, 36)
Front axle bolt 1 14 60 (6.0, 43)
Front axle holder pinch bolt 4 8 22 (2.2, 16)
Rear axle nut 1 18 95 (9.5, 69)
Front brake caliper bracket bolt 3 8 27 (2.7, 20)
(right and left upper)
Anti-dive pistqn bolt 1 6 12 (1.2, 9)
Brake/clutch hose bolt 7 10 30 (3.0, 22)
Master cylinder bolt 4 6 12 (1.2, 9)
(brake and clutch)
Brake torque rod (caliper) 1 10 35 (3.5, 25)
(swing arm) 1 8 22 (2.2, 16)
Brake hose holder mounting bolt 1 6 10 (1.0, 7)
Brake hose three way joint mounting 1 6 10 (1.0, 7)
bolt
Shock absorber mounting bolt 2 10 45 (4.5, 33)
(upper and lower)
Shock link-to-frame bolt 1 10 45 (4.5, 33)
Shock link-to-shock arm bolt 1 10 45 (4.5, 33)
Shock arm-to-swing arm bolt 1 10 45 (4.5, 33)
Swing arm pivot nut 1 14 110 (11.0, 80) - �Apply grease to the seat at
Drive chain adjuster lock nut 2 8 22 (2.2, 16) the nut
Bleed valve 3 7 6(0.6, 4.3)
Brake disc bolt 18 8 40 (4.0, 29) Apply a locking agent to the
Drive sprocket bolt 1 10 90(9.0, 65) threads
Front brake lever adjuster pivot screw 1 5 4 (0.4, 2.9) Apply a locking agent to the
Driven sprocket nut 5 12 90 (9.0, 65) threads
Fuel tank mounting bolt, nut 3 6 10 (1.0, 7)
Exhaust muffler mounting bolt 2 8 22 (2.2, 16)
Exhaust muffler band bolt 4 8 22 (2.2, 16)
Clutch lever pivot nut 1 6 6 (0.6, 4.3)
1-6
GENERAL INFORMATION
Thread
ITEM O'ty Torque N•m (kg-m, ft-lb) Remarks
Dia (mm)
Clutch switch screw 1 4 1.2 (0.12, 0.9)

Front brake lever pivot nut 1 6 6 (0.6, 4.3)
Front brake light switch screw 1 4 1.2 (0.12, 0.9)
Rear brake caliper mounting bolt 1 8 23 (2.3, 17)
Front brake caliper pad pin 4 10 18 (1.8, 13)
Front brake pad pin plug 4 10 2.5 (0.25, 1 .8)
I
Rear brake pad retainer bolt 1 6 11 (1.1,8)
Torque specifications listed above are for important fasteners. Others should be tightened to the standard torque values listed
below.
STANDARD TORQUE VALUES
Torque Values Torque Values

Item Item
N•m (kg-m, ft-lb) N•m (kg-m, ft-lb)
5 mm bolt and nut 5 (0.5, 3.5) 5 mm screw 4 (0.4, 3)

6 mm bolt and nut 10(1.0,7) ,- 6 mm screw 9 (0.9, 7)
6 mm bolt with 8 mm head 9 (0.9, 7)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt and nut 12 (1 .2, 9)
10 mm bolt and nut 35 (3.5, 25) 8 mm flange bolt and nut 27 (2.7, 20)
1 2 mm bolt and nut 55 (5.5, 40) 10 mm flange bolt and nut 40 (4.0, 29)
1-7
GENERAL INFORMATION
TOOLS
SPECIAL *Newly designed for this model.
REF.
DESCRIPTION TOOL NUMBER ALTERNATE TOOL TOOL NUMBER
SECTION
Snap ring pliers 07914 - 3230001 - ,_ Equivalent commercial- 9, 15

ly available in U.S.A.
Steering stem socket 07916-3710100 13
Steering stem driver 07946-MBOOOOO - Steering stem driver 07946-3710601 13
Fork seal driver body 07947-KA50100 IAttachment 07964-M B00200 13
Fork seal driver attachment 07947-KF00100 13
Pressure pump IT
ST-AH-255-MC7- U.S .A. only-included in 4
Vacuum pump ST-AH-260-MC7- Turbo kit 4
Valve adjusting wrench set 07GMA-ML70100 -'- Not available in U.S.A. 3
- lock nut wrench 07GMA-ML70120 3
- adjusting wrench 07GMA-ML70110 3
Bearing remover 07936-3710300 14
Remover handle 07936-3710100 14
Remover sliding weight 07741 - 0010201 - ,_ Remover weight 07936-3710200 14
Bearing race remover 07946-3710500 - '-Adjustable bearing 07736-A01OOOA 13
puller
Driver shaft 07946 - MJ00100 -- Attachment, 24 x 26
mm 07746-0010700 14
�Driver 07949-3710001
Attachment, 28 x 30 mm 07946-1870100 14
*Bearing remover attachment 07GMD-KT70200 14
*Bushing driver 07GMD-KT80100 14
Ball race remover 07953-MJ10000- Ball race remover 07953-MJ1OOOA 13
attachment
- attachment 07953-MJ10100 Driver 07947-3710001 13
- handle 07953-MJ10200 Attachement, 37 x 40
mm 07746-0010200 13
Piston ring compressor 07954-2830000 8
Damper spring compressor 07964-ME90000 14
Piston base 07958-2500001 8
*Oil filter wrench 07HAA-PJ70100 2
Valve guide reamer, 5.5 mm 07 984 - 200000A ->- U.S.A. only or valve 07984-200000B 7
guide reamer, 5.5 mm
(U.S.A. only)
Vacuum gauge 07404-0030000 - �Vacuum gauge 07404-0020000 3
*Bushing driver B 07HMF-MM90200 �vacuum gauge (U.S.A. M973B-021-XXXXX 14
only)
Oil pressure gauge 07506-3000000 - r Equivalent commercial- 2
Oil pressure gauge attachment 07510-4220100 - 2
COMMON
REF.
DESCRIPTION TOOL NUMBER ALTERNATE TOOL TOOL NUMBER
SECTION
Float level gauge 07401-0010000 4

L ock nut wrench, 30 x 32 mm 07716-0020400 - Equivalent commercial- 9, 13
Extension bar 07716-0020500 - ly available in U.S.A. 9, 13
Valve 9uide driver, 5.5 mm 07742-0010100 7
Adjustable valve guide driver 07743-0020000 - >-Not available in U.S.A. 7
Attachment, 24 x 26 mm 07746-0010700 14
Attachment, 32 x 35 mm 07746-0010100 14
Attachment, 42 x 47 mm 07746-0010300 13, 14
Attachment, 52 x 55 mm 07746-0010400 13, 14
Attachment, 62 x 68 mm 07"746-0010500 14
1-8
GENERAL INFORMATION
~ ·-- - --- -··- . --·-- - --·· -- ---
I
REF.
I DESCRIPTION
Pilot, 15 mm
TOOL NUMBER
07746-0040300
ALTERNATE TOOL TOOL NUMBER
SECTION
14
Pilot, 17 mm 07746-0040400 14
Pilot, 20 mm 07746-0040500 13, 14
Pilot, 25 mm 07746-0040600 14
Pilot, 22 mm 07746-0041000 14
Inner driver C 07746-0030100 11
Attachment, 30 mm l.D. 07746-0030300 11
Bearing remover shaft J
07746-0050100- Equivalent commercial- 13, 14
Bearing remover head, 20 mm 07746-0050600- ly available in U.S.A. 13, 14
Driver 07749-0010000 11 ' 1 3, 1 4
Clutch center holder 07724-0050001- ,.. Equivalent commercial- 9
Valve spring compressor 07757-0010000 7 ...
VALVE SEAT CUTTERS (NOT AVAILABLE IN U.S.A.)
DESCRIPTION TOOL NUMBER REMARKS
Valve seat cutter, 45° 07780-0010800 Intake, 33 mm

Valve seat cutter, 45° 07780-0010200 Exhaust, 27.5 mm
Valve seat cutter, 60° 07780-0014000 In/Ex, 30 mm
Valve seat cutter, 32° 07780-0012900 Intake, 33 mm
Valve seat cutter, 32° 07780-0012100 Exhaust, 28 mm
Cutter holder, 5.5 mm 07780-0010101
1-9
GENERAL INFORMATION
CABLE & HARNESS ROUTING

Note the following when routing cable and wire harnesses. 0 x
• A loose wire, harness or cable can be a safety hazard. After
clamping, check each wire to be sure it is secure.
Q
• Do not squeeze a wire against the weld or end of its clamp.
• Secure wires and wire harnesses to the frame with their re
spective wire bands at the designated locations. Tighten
the bands so that only the insulated surfaces contact the
wires or wire harnesses.
• Route harnesses so they are neither pulled that nor have ex
cessive slack.
• Protect wires and harnesses with electrical tape or a tube if

they contact a sharp edge or corner. Clean the attaching
surface thoroughly before applying tape.
• Do not use wires or harness with broken insulator. Repair

by wrapping them with protective tape or replace them.
• Route wire harnesses to avoid sharp edges, corners or the

projected ends of bolts and screws.
• Keep wire harnesses away from the exhaust pipes and

other hot parts.
• Be sure grommets are seated in their grooves properly.
• After clamping, check each harness to be certain that it is

not interfering with any moving or sliding parts.
• After routing, check that the wire harnesses are not twisted
or kinked.
• Wire harnesses routed along the handlebars should not be

pulled taut, have excessive slack, be pinched, or interfere
with adjacent or surrounding parts in all steering positions.
• Do not bend or twist control cables. Damaged control

cables will not operate smoothly and may stick or bind.
0: CORRECT
x: INCORRECT
1-10
GENERAL INFORMATION
(2) LEFT HANDLE BAR

SWITCH WIRE
11) IGNITION (3) RIGHT HANDLE BAR

SWITCH SWITCH WIRE
WIRE
(18) VIEW A (12) RIGHT HANDLE SWITCH

WIRE CONNECTOR
(17) LEFT HANDLE 3P MINI
SWITCH WIRE
CONNECTOR (13) FUSE BOX WIRE
9P MINI (RED) CONNECTOR
6P (RED)
(6) LEFT TURN
SIGNAL WIRE - - - ""'
CONNECTOR
(15)
IGNITION SWITCH
WIRE CONNECTOR
(5) FAN MOTOR 9P (BLACK)
WIRE ~~~~~~~~~~~~~~~~~~~~
(7) FRONT BRAKE

HOSE (8) CLUTCH
HOSE
( 11 )
RIGHT TURN
SIGNAL WIRE
CONNECTOR
(9) SPEEDOMETER
CABLE
1-11
GENERAL INFORMATION
(1) THROTTLE (2) INSTRUMENT

CABLES HARNESS CONNECTORS
(9) VIEW A (10) BATTERY

8 TERMINAL
(12) FRAME
(11) GROUND CABLE
(3) ALTERNATOR (4) FUEL PUMP (5) FUEL PUMP

WIRE RELAY WIRE WIRE
CONNECTOR
(6) REGULATOR/
(8) PULSE GENERATOR (7) FUEL UNIT RECTIFIER
WIRE WIRE CONNECTORS
1-12
GENERAL INFORMATION
(1) TEMPERATURE SENSOR WIRE
(3) FAN MOTOR

WIRE
CONNECTOR
(7) NEUTRAL/OIL
PRESSURE SWITCH
WIRE
(2) THROTTLE
CABLES
(6) DRAIN TUBE (5) STARTER

MOTOR
CABLE
1-13
GENERAL INFORMATION
(1) NEUTRAL/OIL PRESSURE (2) DRAIN TUBE

SWITCH WIRE
(4) REAR BRAKE LIGHT (3) STARTER MOTOR CABLE

SWITCH WIRE
(5) RIGHT TURN SIGNAL

WIRE
(6) LEFT TURN SIGNAL

(7) MAIN WIRE
WIRE
HARNESS
1-14
GENERAL INFORMATION
~MISSION CONTROL SYSTEMS

The U.S. Environmental Protection Agency and California Air Resources Board (CARS) require manufacturers 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 , 1 983 comply with applicable noise emis-
sion 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. Complicace with the terms of the Distributor's warranty for Honda Motor-
cycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect.
SOURCE OF EMISSIONS
The coumbustion 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 it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro-
carbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner and into the
combustion chamber. Condensed crankcase vapors are accumulated in a storage tank which must be emptied periodically.
See the Maintenance Schedule in section 3.
( 1) AIR CLEANER
Q : (3) FRESH AIR

- : (4) BLOW-BY GAS
(2) CARBURETOR
1-15
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM)
(Except California model)

The exhaust emission control system is composed of lean carburetor settings, and no adjustment should be made except idle
speed adjustment with the throttle stop screw.
(California model)
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust
gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust
system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of
hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water.
The reed valve prevents reverse air flow through the system. The air injection control valve reacts to high intake manifold
vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust sys
tem.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is rec
ommended.
(1 l AIR INJECTION CONTROL VALVE (AICVl
(2) AIR CLEANER

(5) EXHAUST
PORT
(3) CARBURETOR
1-16
GENERAL INFORMATION
EVAOPRATIVE EMISSION CONTROL SYSTEM !California model only)
This model complies with California Air Resources Board evaporative emission requirements.
Fuel vapor from the fuel tank and carburetor is directed into the charcoal canister where it is adsorbed and stored while the
engine is stopped. When the engine is running and the purge control diaphragm valve is open, fuel vapor in the charcoal canis-
ter is drawn into the engine through the carburetor.
(1) PURGE
CONTROL VALVE
...
G (3) FRESH AIR
(5) DRAIN
(6)
CANISTER
¢::::J (3) FRESH AIR
. _ (4) FUEL VAPOR
~ (7) AIR VENT

CONTROL
VALVE
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYTEM IS PROHIBITED: Federal law prohibits the follwing acts or the causing
thereof: ( 1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replace-
ment, 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; or (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 TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing 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.
1-17
GENERAL INFORMATION
EMISSION CONTROL INFORMATION

LABELS (U.S.A. only)
An Emission Control Information Label is located on the air
cleaner case as shown. It gives basic tune-up specifications.
( 1 l EMISSION CONTROL INFORMATION LABEL
EMISSION CONTROL INFORMATION

UPDATE LABEL
After making a high altitude carburetor adjustment (page

4-18), attach an update label on the air cleaner case as shown.
Instructions for obtaining the update label are given in Service
Letter No. 132.
VACUUM HOSE ROUTING DIAGRAM

LABEL (California model only) ENGINE FAMILY - HHNO 99M4 HX
EVAPORATIVE FAMILY - 87 ZS
CALIFORNIA VEHICLE
The Vacuum Hose Routing Diagram Label is on the air cleaner

case. Route the vacuum hoses as shown on this label.
Cff: N AIR
1-18
MEMO
LUBRICATION
11) (2) 1
1
INT AKE CAMSHAFT
EXHAUST CAMSHAFT
1
(3) OIL COOLER
1
ITCH
11121 OIL FILTER
j
(11) PRESSURE RELIEF
VALVE
2-0
2. LUBRICATION
SERVICE INFORMATION 2-1 OIL PUMP 2-5
TROUBLESHOOTING 2-2 OIL COOLER 2-9
ENGINE OIL LEVEL 2-3 CONTROL CABLE LUBRICATION 2-9
ENGINE OIL & FILTER CHANGE 2-3 LUBRICATION POINT 2-10
OIL PRESSURE CHECK 2-4
OIL STRAINER/PRESSURE RELIEF
VALVE 2-4
SERVICE INFORMATION
GENERAL
• The oil pump can be removed with the engine mounted in the frame.
SPECIFICATIONS
Engine oil
Oil capacity 3.8 £ (4.02 US qt, 3.34 Imp qt) after oil and filter change
4.5 i (4. 75 US qt, 3.96 Imp qt) after disassembly
Oil recommendation
Use HONDA 4-STROKE OIL or equivalent. OIL VISCOSITIES
API SERVICE CLASSIFICATION: SE or SF.
VISCOSITY:
SAE 10W-40
Other viscosities showri in the chart may be

used when the average temperature in your
riding area is within the indicated range.
0 20 40 60 80 100 °F
-20 -10 0 IO 20 30 40 °C
Oil pressure 600- 700 kPa(6.0- 7.0 kg/cm 2 , 85-100 psi) at 5,000 rpm (80°C/176°F)
(at oil pressure switch)
Oil pump delivery 25 i (26.4 US qt, 22.0 Imp qt) /min. at 5,000 rpm
Oil pump service data

unit: mm (in)
STANDARD S!;RVICELIMIT
Rotor tip clearance 0. 1 5 ~0.006) 0.20 (0.008)

Pump body clearance 0.15-0.22 ~0.006-0.009) 0.35 (0.014)
Pump end clearance 0.02-0.007 ~0.001 -0.003) 0. 10 (0.004)
2-1
LUBRICATION
TORQUE VALUES
Engine oil drain plug 38 N•m (3.8 kg-m, 27 ft-lb)

Engine oil filter 10 N•m ( 1 .0 kg-m, 7 ft-lb)
Oil pressure switch 12 N•m (1.2 kg-m, 9 ft-lb) Apply 3-Bond sealant or its equivalent to the
threads (see page 1-5)
Oil pump driven sprocket bolt 15 N•m ( 1.5 kg-m, 11 ft-lb) Apply a locking agent to the threads (see page 1-5)
Oil cooler bolt 13 N•m ( 1 .3 kg-m, 9 ft-lb)
Oil pipe bolt 9 N•m (0.9 kg-m, 7 ft-lb)
TOOLS
Special
Oil pressure gauge 07506-3000000 -r- Equivalent commercially available in U.S.A.
Oil pressure gauge attachment 01510-42201 oo_J
Oil filter wrench 07HAA-PJ70100
TROUBLESHOOTING
Oil level too low Oil contamination
•
Oil level not replenished frequently enough •
Oil or filter not changed often enough
•
External oil leaks • Worn piston rings
•
Worn valve stem seal
•
Worn valve guide Oil emulsification
•
Worn piston rings •
Radiator coolant contamination
•
Improperly installed piston rings - Blown cylinder head gasket
•
Worn cylinder - Leaky coolant passage
•
Water contamination
Oil pressure too high
•
Pressure relief valve stuck closed No oil pressure
•
Clogged oil filter, gallery, or metering orifice • Oil level too low; no oil
•
Incorrect oil used •
Broken oil pump drive chain
•
Broken oil pump drive shaft
Low oil pressure • Internal leaks
•
Oil level low •
Faulty oil pump
•
Plugged oil filter or screen
•
Pressure relief valve stuck open Oil pressure warning indicator stays on
•
Oil pump faulty •
Faulty oil pressure switch
•
Internal oil leakage •
Short circuit in indicator wire
•
Incorrect oil used •
Low or no oil pressure
2-2
LUBRICATION
ENGINE OIL LEVEL ALLERCAPi'll

( 1) OIL
DIPSTICK -· ... !!I
....
....._
Start the engine and let it idle for 2--3 minutes. Turn off the
engine. Remove the oil filler cap cover from the fairing. Sup-
port the motorcycle in an upright position on level ground.
Remove the filler cap/dipstick, wipe it clean and insert it with-
out screwing it in. Remove the filler cap/dipstick and check the
(2) UPPER
-
oil level.
LEVEL
If the level is below the lower level mark on the dipstick, fill to
the upper level mark with the recommanded oil (page 2-1 ). \
(3) LOWER
Check the oil pressure with the oil pressure warning light after LEVEL+:
the engine starts. The light should go off after one or two sec-
onds.
If it does not, stop the engine and do the oil pressure check on
page 2-4. If the pressure check is OK, replace the pressure ( 1) OIL DRAIN PLUG
switch.
ENGINE OIL &FILTER CHANGE

NOTE
• Change engine oil with the engine warm and support the
motocycle on level ground to assure complete and rapid
draining.
Stop the engine.

Remove the oil filler cap/dipstick and oil drain plug, and drain
the oil.
Remove the lower fairing. (page 12-2).
Remove the oil filter with a filter wrench and let the remaining
oil drain out. Discard the oil filter.
TOOL:
Oil filter wrench 07HAA-PJ70100
Check that the sealing washer on the drain plug is in good con-
dition and install the plug.
TORQUE: 38 N·m (3.8 kg-m. 27 ft-lb)

(1) 0-RING
Replace the oil filter with a new one.

Check that the oil filter 0-rings is in good condition, and coat it
with oil before installing it.
Install and tighten the oil filter.
TORQUE: 10 N·m ( 1.0 kg-m. 7 ft-lb)
Fill the crankcase with 3.8 liters (4.02 US qt, 3.34 Imp qt) of
the recommended oil (page 2-1). Reinstall the oil filter cap/
dipstick.
Start the engine and let it idle for 2-3 minutes, then stop the
engine.
Make sure that the oil level is at the upper level mark on the
dipstick.
Make sure that there are no oil leaks.
Install the lower fairing.
2-3
LUBRICATION
OIL PRESSURE CHECK

NOTE
•
If the oil pressure indicator light remains on a few seconds,
check the indicator system, before checking the oil pres
sure.
Check the oil level.

Warm the engine up to normal operating temperature (approxi
mately 80°C/176°F).
Stop the engine and disconnect the oil pressure switch wire
from the switch.
Remove the oil pressure switch and connect an oil pressure
gauge and attachment to the pressure switch hole.
TOOLS: (1 l OIL PRESSURE

Oil pressure gauge 07506-3000000 GAUGE
�
Oil pressure gauge attachment 07510-4220100
Start the engine and check the oil pressure at 5,000 rpm.
OIL PRESSURE: /
I
� �1
600-700 kPa (6.0-7.0 kg/cm2, 85-100 psi) I
I
at 5,000 rpm (80°C/176°Fl I
I
I
I
Stop the engine. I
I
Apply 3-BOND® sealant or its equivalent to the pressure (2) ATTACHMENT
switch threads and install. (See page 1 -5).
TORQUE: 12 N•m (1.2 kg-m, 9 ft-lb)

(1) OIL PAN
CAUTION
•
To prevent crankcase damage, do not overtighten the switch.
\
o o
n <'�
Connect the oil pressure switch wire.
OIL STRAINER/PRESSURE RELIEF

VALVE
NOTE
•
The oil strainer can be removed with the engine mounted in
the frame.
Remove the lower fairing (page 12-2).

Remove the exhaust system (page 12-7).
Drain the engine oil (page 2-3).
Remove the oil pan bolts and oil pan.
Remove the oil strainer and pressure relief valve.

Clean the oil strainer screen.
2-4
LUBRICATION
Check the operation of the pressure relief valve by pushing on

the piston.
Disassemble the relief valve by removing the snap ring.
Inspect the piston for wear, sticking or damage.
Inspect the spring for weakness or damage.
Assemble the relief valve in the reverse order of disassembly.
(41 WASHER
/
o
(51 l
SNAP RING
Apply oil to the 0-ring of the relief valve and strainer.

Install the relief valve and strainer.
Install a new gasket.

Install the oil pan and tighten the bolts in a criss-cross pattern
in 2-3 steps.
Install the exhaust system (page 12-81.

Fill the engine with proper amount of the recommended oil
(page 2-1, 3).
Install the lower fairing (page 12-41.
OIL PUMP
REMOVAL
NOTE
The oil pump can be removed with the engine mounted in
the tram.
Drain the engine oil.

Remove the oil pan (page 2-41.
Remove the oil pass pipes.

Make sure the 0-rings are in good condition.
2-5
LUBRICATION
Remove the oil pump driven sprocket by removing the bolt and
washer.
Remove the three oil pump mounting bolts.

Face the groove on the water pump shaft up to disconnect the
oil pump shaft from the water pump shaft.
Remove the oil pump from the crankcase.
Straighten and remove the cotter pin holding the pressure

relief valve.
Remove the oil pump body cover removing the three bolts.
Disassemble the oil pump.
Assemble the oil pump as shown.
Measure the rotor tip clearance for the feed and cooler pumps.
SERVICE LIMIT: 0.20 mm (0.008 in)
Measure the pump body clearance for the feed and cooler <(1 I FEED PUMP> <(2) COOLER PUMP>
pumps.
2-6
LUBRICATION
Remove the drive pin and remove the rotor shaft.

<( 1) FEED PUMP> <(2) COOLER PUMP>
Measure the pump end clearance for the feed and cooler
pumps.
SERVICE LIMIT: 0.10 mm 10.004 in)
(6) COTTER (7) RETAINER

ASSEMBLY PIN
(2) COOLER PUMP

INNER ROTER
( 12) OIL PUMP

BODY
~~ 0 •
M~\. \"(5(DRIVEPIN
~ (13) WASHER
t (14) FEED PUMP

I INNER ROTER
(15) FEED PUMP
OUTER ROTER
t
(16) FEED PUMP
COVER
Install the rotor shaft onto the cover.

Install the feed pump rotors onto the shaft.
NOTE
• Install the outer rotor with its punch mark facing the body.
Set the drive pin and washer onto the shaft.

Install the dowel pins onto the cover.
Install the pump body.
(5) DOWEL PINS (4) BODY
2-7
LUBRICATION
Install the drive pin onto the shaft.

Install the cooler pump rotors onto the body.
NOTE
•
Install the outer rotor with its punch mark facing the cooler
pump cover.
Install the dowel pins.

Install the cooler pump cover and tighten the three bolts se
curely.
(6)
PUNCH (4) INNER
MARK (5) PIN ROTOR
Install the piston, spring and retainer.

Install a new cotter pin and secure it.
(1) SPRING
I
(4) RETAINER (3) PISTON
INSTALLATION
Install the 0-ring and dowel pins.
Install the oil pump and tighten the three bolts.
NOTE
•
Make sure that the oil pump shaft rotates freely after tight
ening the bolts.
Place the oil pump driven sprocket into the drive chain.
NOTE
•
The "OUT" mark on the driven sprocket should face the
clutch.
Apply a locking agent to the threads of the driven sprocket bolt

(page 1-5).
Install the driven sprocket onto the oil pump driven shaft.
Install the washer and tighten the bolt.
TORQUE: 15 N·m (1.5 kg-m, 11 ft-lb)
2-8
LUBRICATION
Make sure the 0-rings on the oil pass pipes are in good condi-
tion and install the oil pass pipes.
Install the oil strainer and oil pan.
OIL COOLER
REMOVAL
Remove the upper fairing (page 12-3).

Remove the oil pipes from the oil cooler by removing the bolts.
Remove the two oil cooler mounting bolts and oil cooler.
INSPECTION
Inspect the oil cooler pipe joints and seams for leaks.
Check the air passage for clogging or damage.
Straighten the bent fins and collapsed core tubes.
Remove the insects, mud or any obstruction with compressed
air or low water pressure.
INST ALLA Tl ON
Install the oil cooler with the two bolts.
Connect the oil pipes with new 0-rings to the oil cooler and
tighten the bolts.
Install the fairings (page 12-4).

Fill the engine with recommended oil (page 2-1).
Start the engine and check the oil leaks and oil level (page 2-3).
CONTROL CABLE LUBRICATION

Periodically disconnect the throttle and choke cable at their
upper ends. Thoroughly lubricate the cables and their pivot
points with a commercially available cable lubricant or a light
weight oil.
2-9
LUBRICATION
LUBRICATION POINTS
(7) I SPECIAL LUBRICANT I (PAGE 14-12)
-� (1) THROTTLE GRIP ----- · .----
REAR SHOCK ABSORBER
UPPER BUSHING
�
(2) CLUTCH AND BRAKE ----- (8) � FOOT PEG
LEVER PIVOTS
_. PIVOTS
(3) � or I CABLE LUBRICANT I
THROTTLE AND
(9) � SEAT LOCK
--
CHOKE CABLE
(4) � or I CABLE LUBRICANT I
SPEEDOMETER
CABLE
(5) STEERING
HEAD BEARINGS
(6) FORK
(10) �
DRIVE CHAIN
(15) � (GEAR OIL SAE #80-90)
SPEEDOMETER
DRIVE GEAR (11) -�
SUSPENSION LINKAGE NEEDLE
BEARINGS
112) � BRAKE
(16) -� -----' -� PEDAL PIVOT
BRAKE CALIPER PIVOTS

(SILICON GREASE)
'---(--- 13) �· SWING ARM
-�PIVOT
I 17) ISPECIAL LUBRICANT I (PAGE 13-19)

LEFT CALIPER UPPER PIVOT COLLAR
'---(-- 14) _.� SIDE STAND PIVOT
2-10
MEMO
MAINTENANCE
SERVICE ACCESS GUIDE
Remove the seat, side cover and/or fairing pieces as indicated when service one of the following.
Fuel tank
(3) Valve clearance adjustment
(4) Cylinder compression test
(5) Choke Lever free play adjustment
(6) Cooling system inspection
(7) Throttle grip free play adjustment
Upper fairing lower
(8) Radiator pressure test
inner cover
(9) Spark plug removal/installation
(1) Headlight aim adjustment
( 10) Carburetor synchronization
(2) Sub fuse replacement
Seat
( 11) Battery fluid inspection
( 12) Radiator coolant
inspection
Side fairing
Side cover ( 17) Cooling system
( 13) Air cleaner element removal/installation inspection
( 14) Fuel line inspection
( 1 5) Radiator coolant filling
Lower fairing
( 16) Valve clearance
( 18) Oil pressure inspection
adjustment
( 19) Oil filter replacement
(20) Oil strainer cleaning
3-0
3. MAINTENANCE
SERVICE INFORMATION 3-1 CYLINDER COMPRESSION 3-11
MAINTENANCE SCHEDULE 3-3 DRIVE CHAIN 3-12
FUEL LINE 3-4 BATTERY 3-13
FUEL FILTER 3-4 BRAKE FLUID 3-14
THROTTLE OPERATION
CABURETOR CHOKE
3-4
3-5
BRAKE PAD WEAR
BRAKE SYSTEM
3-14
3-15 m
AIR CLEANER 3-5 BRAKE LIGHT SWITCH 3-15
CRANKCASE BREATHER 3-6 HEADLIGHT AIM 3-16
SPARK PLUG 3-6 CLUTCH FLUID 3-16
VALVE CLEARANCE 3-7
.
CLUTCH SYSTEM 3-16
CARBURETOR SYNCHRONIZATION 3-9 SIDE STAND 3-16
CARBURETOR-IDLE SPEED 3-10 SUSPENSION 3-17
RADIATOR COOLANT 3-10 NUTS, BOLTS, FASTENERS 3-18
COOLING SYSTEM 3-10 WHEELS/TIRES 3-18
SECONDARY AIR SUPPLY SYSTEM 3-11 STEERING HEAD BEARINGS 3-19
EVAPORATIVE EMISSION CONTROL
SYSTEM 3-11
.
SERVICE INFORMATION
GENERAL
• Engine oil See page 2-3

• Engine oil filter See page 2-3
SPECIFICATIONS
<ENGINE>
Spark plugs:
NGK ND
DPR9EA-9 X27EPR-U9
Spark plug gap: 0.8-0.9 mm (0.031-0.035 in)
3-1
MAINTENANCE
Valve clearance
Cold (Below 35°C, 95°F): Intake: 0.10 ± 0.02 mm (0.004 ± 0.001 in)
Exhaust: 0.16 ± 0.02 mm (0.006 ± 0.001 in)
Idle speed: 1,000 ± 100 rpm

Carburetor synchronization: All carburetors within 20 mm (0.8 in) Hg of each other
Cylinder compression: 1250 ± 200kPa (12.5 ± 2.0 kg/cm2, 181 ± 29 psi).
Throttle grip free play: 2-6 mm (1/8-1/4 in)
<CHASSIS>
Drive chain slack: 15-25 mm (5/8-1 in)
Tire:
Tire size Front Rear
110/80V1 7-V270 140/80VT7-V270
Cold tire pressure, Up to 90 kg (200 lbs) load 250 (2.5, 36) 290 (2.9, 42)
kPa (kg/cm2, psi)
Up to vehicle capacity load 290 (2.9, 42) 290 (2.9, 42)
Tire brand BRIDGESTONE G547 G548
DUNLOP K505F K505
Suspension air pressure: Front, 0-40 kPa (0-0.4 kg/cm2, 0-6 psi)
TORQUE VALUES
Spark plug 15 N•m (1.5 kg-m,11 ft-lb)

Rear axle nut 95 N•m (9.5 kg-m, 69 ft-lb)
Valve adjusting screw lock nut 23 N•m (2.3 kg-m, 17 ft-lb)
Cylinder head cover bolt 10 N•m ( 1.0 kg-m, 7 ft-lb)
Drive chain adjuster lock nut 22 N•m (2.2 kg-m, 16 ft-lb)
TOOLS
Special
Vacuum gauge 07404-0030000 or 07404-0020000 or M937B-021-XXXXX (U.S.A.
only)
Valve adjusting wre ch set 07GMA-ML70100 -Not available in U.S.A.
- lock nut wrench 07GMA-ML70120
- adjusting wrench 07GMA-ML70110
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate, or Replace if necessary.
C: Clean, R: Replace, A: Adjust, L: Lubricate
WHICHEVER ~ ODOMETER READING (NOTE 1)

FREQUENCY COMES >-~~-,-~-,.-~--,~~.,....-~-.--~-,.-~--,~~--1
FIRST
ITEM
EVERY
FUEL LINE 3-4

THROTTLE OPERATION 3-4
en CARBURETOR CHOKE 3-5

::?: AIR CLEANER NOTE 2 R R 3-5
w
!::: c
Cl
CRANKCASE BREATHER NOTE 3 c c c c c 3-6
w
..... SPARK PLUG R R R R R R 3-6
<I:
....J 3-7
w VALVE CLEARANCE I
CI:
z ENGINE OIL R R R R 2-3
0
ii5 ENGINE OIL FILTER R R R R 2-3
en
CARBURETOR SYNCHRONIZATION 3-9
~
w
CARBURETOR IDLE SPEED 3-10
RADIATOR COOLANT 2 YEARS *R *R 3-10
COOLING SYSTEM 3-10
SECONDARY AIR SUPPLY SYSTEM NOTE 4 3-11
NOTE 4 3-11
SYSTEM
DRIVE CHAIN 3-12
BATTERY 3-13
en BRAKE FLUID 3-14
~
~ BRAKE PAD WEAR 3-14
ow BRAKE SYSTEM 3-15
~ BRAKE LIGHT SWITCH 3-15
....J
~ HEADLIGHT AIM 3-16
~ CLUTCH FLUID 3-16
ii5 CLUTCH SYSTEM 3-16
en
~ SIDE STAND 3-16
w >--------+~~~~~~~~~~~~~~~~~
0z SUSPENSION 3-17
!---+~~~~~~~~~~~~~~~~~
z NUTS, BOLTS, FASTENERS 3-18

WHEELS/TIRES 3-18
STEERING HEAD BEARINGS 3-19
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified.
* * In the interest of safety, we recommended that these items be serviced only by an authorized Honda dealer.
NOTES: 1 . For higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in dusty areas.
3. Service more frequently when riding in rain, or at full throttle.
4. California model only.
3-3
MAINTENANCE
FUEL LINE ( 1) FUEL LINE
Remove the left side covers.

Check the fuel lines and replace any that show deterioration,
damage or leakage.
FUEL FILTER
•
Gasoline is flammable and is explosive under certain condi
tions. Do not smoke or allow flames or sparks in your working
area.
Replace the fuel filter with a new one if necessary.
Remove the left side covers.
Unclip the fuel filter holder from the battery case.

Disconnect the fuel outlet line from the fuel filter. Pull the fuel
filter out and clip the inlet line closed and remove the filter.
Install the fuel filter with its arrow pointing toward the outlet
side.
After installing, turn the fuel valve on and check for fuel leaks.
THROTTLE OPERATION
Check that the throttle grip for smooth operation to full throttle
and that it closes automatically, in all steering positions.
Check the throttle cables and replace them if they are deterio
rated, kinked or damaged.
Lubricate the throttle cables (page 2-9), if throttle operation is

not smooth.
Measure throttle grip free play at the throttle grip flange.
FREE PLAY: 2-6 mm (1/8-1/4 in)
Remove the upper fairing lower inner covers (page 12-3).

Remove the fuel tank forward mounting bolts. Raise the fuel
tank and support it with the rod (page 3-6).
Adjustment can be made at either end of the throttle cable.
Minor adjustment are made with the upper adjuster.
Adjust by loosening the lock nut and turning the adjuster.

Tighten the lock nut and recheck throttle operation.
3-4
MAINTENANCE
r
Major adjustment are made with the lower adjuster.
Adjust by loosening the lock nut and turning the adjuster.
Tighten the lock nut and recheck throttle operation.
Install the fuel tank, and check throttle free play again.
CARBURETOR-CHOKE 11 l CHOKE LEVER
The CBR 1OOOF choke system uses a fuel enrichening circuit

controlled by a bystarter valve. The bystarter valve opens the
enrichening circuit via cable when the choke lever on the
handlebar is pulled back.
Check for smooth operation of the choke lever. Lubricate the
choke cable, if the operation is not smooth.
tank and support it with the rod (page 3-6).
Move the choke lever all the way back to the fully open posi-
tion. Make sure the choke valve is open by trying to move the
choke lever on the carburetor, there should be no free play.
Adjust the free play, by loosening the choke cable clamp on

the carburetor and moving the choke cable casing so the
choke lever is fully open.
Tighten the clamp.
Push the choke lever fully closed. Make sure the choke valve is
fully closed by checking for free play in the cable between the
lever on the carburetor and cable casing.
Reinstall the removed parts in the reverse order of dis-
assembly.
AIR CLEANER
Remove the right side cover.
Remove the air intake duct screws and the duct.
3-5
MAINTENANCE
Remove the retainer and the air cleaner element. Discard the
element in accordance with the maintenance schedule.
Also, replace the element any time it is excessively dirty or

damaged.
Install a new element and secure it with the retainer.

Install the air intake duct and side cover.
CRANKCASE BREATHER
Remvoe the plug from the drain tube to emty any deposits.
Install te drain plug.
NOTE
•
Service more frequently when riding in rain or at full throt
tle, or if the deposit level can be seen in the transparent sec
tion of the drain tube.
( 1) DRAIN PLUG
SPARK PLUG ( 1) LOWER INNER COVERS (2) SCREW
Remove the upper fairing lower inner covers.
Remove the fuel tank forward mounting bolts.
3-6
MAINTENANCE
Pull the side covers outward to disconnect the bosses of the

side covers from the grommets.
Raise the fuel tank and support it with the rod.
CAUTION
• To prevent damage to the rear fuel tank stay, do not force the
fuel tank up beyond the tank's movement limiter while discon-
necting the rod.
Disconnect the spark plug caps.

Clean any dirt from around the spark plug bases. (2) SIDE ELECTRODE
Remove and discard the spark plugs. (1) PLUG GAP
RECOMMENDED SPARK PLUGS (3) CENTER

ELECTRODE
NGK ND
DPR9EA-9 X27EPR-U9
Measure the new spark plug gaps using a wire-type feeler

gauge.
SPARK PLUG GAP: 0.8-0.9 mm I0.031-0.035 in)
Adjust by bending the side electrode carefully. With the plug

washer attached, thread each spark plug in by hand to prevent
crossthreading. Continue tightening by hand until the spark
plug bottoms. Then, tighten the spark plugs another 1 /2 turn
with a spark plug wrench to compress the plug washer. Con-
nect the spark plug caps.
VALVE CLEARANCE
NOTE
• Inspect and adjust valve clearance while the engine is cold
(below 35°C, 95°F).
Remove the following:

- fuel tank (page 4-3)
- side covers (apge 1 2-2)
- lower and side fairings (page 12-2)
Disconnect the cylinder head cover breather tube, throttle ca-

bles, choke cable and spark plug caps.
Remove the cylinder head cover by removing the bolts and

washers.
NOTE
• Do not damage the cylinder head cover gasket.
3-7
MAINTENANCE
Remove the crankshaft hole cap.

Rotate the crankshaft counterclockwise and align the index
mark on the pulse generator rotor with the ''T'' mark on the
crankcase.
Make sure No. 1 piston is at TDC (Top Dead Center) on the
compression stroke; if it is not, turn the crankshaft one full
turn counterclockwise (until the mark is aligned again).
Insert the feeler gauge between the rocker arm slipper surface
and the cam lobe. (2) FEELER
Measure the valve clearance as follow: GAUGE
- No. 1 (IN/EX)
- No. 2 (EX)
- No. 3 (IN)
Rotate the crankshaft one full turn counterclockwise and align

the index mark with the "T" mark.
Measure the valve clearance as follow:
- No. 2 (IN)
- No. 3 (EX)
- No. 4 (IN/EX)
VALVE CLEARANCE:
IN: 0.10 ± 0.02 mm (0.004 ± 0.001 in)
EX: 0.16 ± 0.02 mm (0.006 ± 0.001 in)
ADJUSTMENT
Install the valve adjusting wrench set.
TOOLS:
Valve adjusting wrench set 07GMA-ML70100
Not available in U.S.A.
- lock nut wrench 07GMA-ML70120
- adjusting wrench 07GMA-ML70110
Adjust by loosening the valve adjusting screw lock nut and

turning the adjusting screw with the adjusting wrench until
there is a slight drag on the feeler gauge.
Hold the adjusting wrench and tighten the adjusting screw

lock nut.
CAUTION
•
The lock nuts will come loose if the proper torque is not ap
plied.
Make sure that the cylinder head cover gasket is in good condi
tion.
Apply the sealant to the cylinder head as shown.
3-8
MAINTENANCE
Install the cylinder head cover and tighten the bolts and wash-
ers to the specified torque.
NOTE
• Tighten the forward outside bolts first then tighten the
other bolts.
• Note the direction of the washer (page 7-22).
TORQUE: 10 N·m ( 1.0 kg-m, 7 ft-lb)
Install the removed parts.

Adjust the throttle grip free play (page 3-4) and choke lever
free play (page 3-5).
CARBURETOR-SYNCHRONIZATION
NOTE
• Synchronize the carburetors with the engine at normal op-
erating temperature, transmission in neutral and motor-
cycle on its center stand.
Remove the rubber plugs from the carburetor.
Connect the vacuum gauge to the carburetor.
TOOL:
Vacuum gauge: 07404-0030000 or
07404-0020000 or
M937B-021-XXXXX (1 l VACUUM GAUGE
(U.S.A. only)
Start the engine and adjust the idle speed with the throttle
stop screw.
IDLE SPEED: 1.000 ± 100 rpm
Check that all carburetors are within 20 mm (0.8 in) Hg of

each other.
(1) SCREWS
Synchronize all carburetors by turning the adjusting screws
with a screw driver.
NOTE
• No. 2 carburetor is base one.
Recheck the idle speed and synchronization.

Remove the vacuum gauge and install the rubber plugs.
Install the removed parts.
3-9
MAINTENANCE
CARBURETOR-IDLE SPEED (2) RUBBER COVER
NOTE
•
Inspect and adjust idle speed after all other engine adjust
ments are within specifications.
• The engien must be warm for accurate adjustment. Ten
minutes of stop-and-go riding is sufficient.
Warm up the engine, shift to NEUTRAL, and support the

motorcycle on its center stand.
Push the rubber cover in and turn the throttle stop screw as re
quired to obtain the specified idle speed.
(2) THROTTLE STOP SCREW
IDLE SPEED: 1,000 ± 100 rpm
RADIATOR COOLANT
Remove the seat.
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.
If necessary, remove the right side cover and reserve tank cap
and fill to the "UPPER" level line with 50/50 mixture of dis
tilled water and antifreeze.
Reinstall the cap, side cover and seat.
COOLING SYSTEM
Remove the lower and side fairings (page 12-2).
Check the radiator air passages for clogging or damage.

Straighten bent 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.
3-10
MAINTENANCE
Remove the fuel tank forward bolts. Raise the fuel tank and
support it by the rod.
Inspect the hoses for cracks or deterioration, and replace if
necessary.
Check the tightness of all hose clamps and fasteners.
SECONDARY AIR SUPPLY SYSTEM

(California model only)
Remove the side_ fairings (page 1 2-2).
Check the air supply tubes between the valve and intake pipes
for deterioration, damage, or loose connections. Make sure the
ENGINE FAMILY - H HNO 99844 HX
tubes are not kinked or pinched. EVAPORATIVE FAMILY - 87 ZS
CALIFORNIA VEHICLE
NOTE
• If the tubes show any signs of heat damage, inspect the air
injection control valve for damage (page 4-18).
Check the vacuum tube between the intake pipe and valve for
deterioration, damage or a loose connection. Make sure the
tube is not kinked or pinched.

SYSTEM (California model only)
Check the hoses between the tank cap, canister, purge control
valve and carburetors for deterioration, damage or loose con-
nections.
Check the charcoal canister for cracks or other damage.
CYLINDER COMPRESSION OPEN AIR
Warm up the engine. MM5 - 740

Remove the fuel tank forward bolts.
Raise the fuel tank and support it by the rod.
Stop the engine, then disconnect the spark plug caps and
remove the spark plugs.
Insert the compression gauge.
Turn the engine stop switch to the OFF position.

Open the throttle all the way and crank the engine with the
starter motor.
NOTE
• Crank the engine until the gauge reading stops rising. The
maximum reading is usually reached within 4- 7 seconds.
COMPRESSION PRESSURE:
1,250 ± 200 kPa I 12. 5 ± 2.0 kg/cm 2 , 181 ± 29 psi)
3-11
MAINTENANCE
If compression is low, check the following:

- Improper valve clearance
- Leaky valves
- Leaking cylinder head gasket
- Worn piston/ring/cylinder
If compression is high, it indicates that carbon deposits have
accumulated on the combustion chamber and/or the piston
crown.
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
•
Never inspect or adjust the drive chain while the engine is run
ning.
Turn the engien off, place the motorcycle on its center stand
and shift the transmission into neutral. Check slack in the drive
chain lower run midway between the sprockets.
SLACK: 15-25 mm (5/8-1 in)
CAUTION
•
Excessive chain slack, 40 mm (J-518 in) or more, may damage
the frame.
DRIVE CHAIN ADJUSTMENT
Loosen the axle nut.

Loosen the lock nuts.
Turn both adjusting nuts an equal number of turns until the
correct drive chain slack is obtained.
CAUTION
•
Make sure that the same index marks on both adjusting plates
align with the cut-out ends of the swingarm.
Tighten the rear axle nut.
Tighten the lock nuts.
Recheck chain slack and free wheel rotation.
Check the chain wear label. If the red zone on the label aligns
with, or is beyond, the index mark, the chain must be replaced.
REPLACEMENT CHAIN: RK50LFO
Check the drive chain slider for wear or damage if you have re
placed the drive chain.
3-12
MAINTENANCE
Inspect the drive chain and sprockets for damage or wear. A

drive chain with damaged rollers, loose pins, or missing 0-
rings must be replaced. Replace any sprocket which is dam- (1) DAMAGED
aged or excessively worn.
NOTE
• Never install a new drive chain on worn sprockets or a worn
drive chain on new sprockets. Both chain and sprockets
must be in good condition or the replacement chain or
sprockets will wear rapidly.
(3) NORMAL
Lubrication and cleaning:

The drive chain on this motorcycle is equipped with small 0- (1 l SAE #80 or 90
rings between the link plates. The 0-rings can be damaged by GEAR OIL
steam cleaners, high pressure washers, and certain solvents.
Clean the chain with soapy water. Wipe dry and lubricate only
with SAE #80 or 90 gear oil. Commercial chain lubricants may
contain solvents which could damage the rubber 0-rings.
BATTERY
Support the motorcycle on its center stand on level ground.
Remove the seat.
Remove the battery cover and tool kit.
Inspect the battery fluid level.

When the fluid is near the lower level mark, remove the battery
from the frame. Remove the filler caps and add distilled water
to raise it to the upper level.
NOTE
• Add only distilled water. Tap water will shorten the service
life of the battery.
IJll.Mifrld
• The battery electrolyte contains su(furic acid. Protect your
eyes, skin, and clothing. If electrolyte gets in your eyes, flush
them throughly with water and get prompt medical attention.
3-13
MAINTENANCE
BRAKE FLUID
Check the front brake fluid level with the handlebar turned so
that the reservoir is level.
Check the rear brake fluid level after supporting the motor
cycle upright on level ground.
If the fluid nears the lower level mark, fill the reservoir with
DOT 4 BRAKE FLUID to the upper level mark.
Check the entire system for leaks.
CAUTION
•
Do not remove the cover until the handlebar has been turned so
•
Avoid spilling fluid on painted, plastic, or rubber parts. Place a
rag over these parts whenever the system is serviced.
•
Do not mix different types of fluid, as they are not compatible.
Refer to section 1 5 for brake bleeding procedures.
BRAKE PAD WEAR

Check the front brake pads for wear visually from below the
caliper.
Check the rear brake pads for wear, visually from the rear of
the caliper.
Replace the brake pads if they are worn down to the wear
groove on the pads. (1) BRAKE DISC (2) WEAR GROOVE
CAUTION
•
Always replace the brake pads in pairs to assure even disc pres
sure.
(3) BRAKE PADS
3-14
MAINTENANCE
BRAKE SYSTEM
Inspect the brake hoses and fittings for deterioration, cracks
and signs of leakage. Tighten any loose fittings.
Replace hoses and fittings as required.
FRONT BRAKE LEVER
Check the brake lever distance "A" between the tip of the
brake lever and grip.
Adjust distance "A" by turning the adjuster.
CAUTION
• Align the index mark on the adjuster with arrow on the brake
lever.
REAR BRAKE PEDAL
Check the rear brake pedal height.

To adjust the brake pedal height, loosen the lock nut and turn
the master cylinder push rod. Tighten the lock nut.
NOTE
• Adjust the brake light switch after adjusting the brake pedal
height.
BRAKE LIGHT SWITCH

Adjust the brake light switch so that the brake light will come
on when the brake engagement begins.
Adjust by turning the adjuster holding the switch body.
Tighten the adjuster and recheck the brake light switch opera-
tion.
MAINTENANCE
HEADLIGHT Al M (1) HORIZONTAL

ADJUSTER
Remove the upper fairing lower inner covers (page 12-3). L

Adjust vertically by turning the vertical adjuster. Turn the ad
juster counterclockwise to direct the beam down.
Adjust horizontally by turning the horizontal adjuster using a

screwdriver.
Turn the screwdriver clockwise to direct the beam toward the
right side of the rider.
NOTE
•
Adjust the headlight beam as specified by local laws and
regulations.
IJll.MllJ!'
•
An improperly adjusted headlight may blind oncoming drivers,
or it may fail to light the road for a safe distance.
CLUTCH FLUID
Check the clutch fluid level with the handlebar turned so that
the reservoir is level.
If the fluid is near the lower level mark, fill the reservoir with
DOT 4 BRAKE FLUID until the level is between the upper and
lower level marks.
CAUTION
•
Do not remove the cover until the handlebar has been turned so
•
A void spilling fluid on painted, plastic, or rubber parts. Place a
•
Do not mix d{fjerent types of fluid, as they are not compatible.
CLUTCH SYSTEM
Inspect the clutch hoses and fittings for deterioration, cracks
and signs of leakage. Tighten any loose fitting.
Replace hoses and fittings as required.
SIDE STAND
Check the rubber pad for deterioration or wear. Replace if any
wear extends to wear line as shown. Check the side stand
spring for damage or loss of tension, and the side stand as
sembly for freedom of movement. Make sure the side stand is
not bent.
NOTE
•
When replacing a pad, use one marked "Over 260 lbs ON
LY".
Spring tension is correct if the measurements fall within 2-
3 kg (4.4-6.6 lb), when pulling the side stand lower end
with a spring scale.
(1) WEAR LINE

TORQUE:
Side stand pivot nut 25 N•m (2. 5 kg-m, 18 ft-lb)
3-16
MAINTENANCE
SUSPENSION
liMMl!fl'
• Do not ride a vehicle with faulty suspension. Loose, worn or
damaged suspension parts impair vehicle stability and control.
FRONT
Check the action of the fork by compressing it several times.

Check the entire fork assembly for leaks or damage. Replace
damaged components which cannot be repaired.
Tighten all nuts and bolts.
Check the fork air pressure when the fork is cold.

Raise the front wheel off the gound using a jack under the en-
gine.
Remove the air valve cap and measure the air pressure.
AIR PRESSURE: 0-40 kPa (0-0.4 kg/cm 2 , 0-6 psi)
REAR
Check the action of the shock absorber by compressing the

rear end several times.
Support the motorcycle on its center stand to raise the rear
wheel.
Move the swing arm sideways with force to see if the swing-
arm bearings are worn.
Replace the bearings if there is any looseness (page 14-15).
Check the shock absorber for leaks or damage.
Tighten all rear suspension nuts and bolts.
DAMPING FORCE ADJUSTMENT
The damping force adjuster can be turned with a screwdriver

to three adjustment positions.
The adjuster is located behind the left side cover. Remove the
left side cover. The standard position is "2".
To reduce-turn the adjuster to "1" position for a light load
and smooth road conditions.
To increase-turn the adjuster to "3"position for firmer ride
and rough road conditions.
3-17
MAINTENANCE
SPRING PRELOAD ADJUSTMENT
The spring preload adjuster can be set to any of 22 positions to

turn it with a 8 mm hex wrench.
The adjuster is located behind thfl right side cover. Remove the
right side cover.
To reduce preload-turn the adjuster in counterclockwise di
rection to Low from the standard position.
To increase preload-turn the adjuster in clockwise direction
to High from the standard position.
To adjust the spring preload to standard setting, proceed as
follows:
1. Turn the adjuster counterclockwise until it will no longer
turn. This is the lowest position.
2. Turn the adjuster clockwise to 12 clicks (6 revolutions)
from the lowest position.
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to their cor
rect torque values (Section 1) at the intervals shown in the
Maintenance Schedule (page 3-3).
Check all cotter pins, safety clips, hose clamps and cable
stays.
WHEELS/Tl RES
Check the front and rear wheels for trueness(Section 1 3 and
14.)
NOTE
•
Tire pressure should be checked when tires are COLD.
Check the tires for cuts, or imbedded objects.
RECOMMENDED TIRES AND PRESSURES
Front Rear
Tire size
110/80V17-V270 140/80V17-V270
Cold tire Up to 90 kg
pressure (200 lbs) 250 (2.5, 36) 290 (2.9, 42)
k Pa ( kg /
, load
cm2, psi)
Up to vehicle
capacity 290 (2.9, 42) 290 (2.9, 42)
load
Tire BRIDGE-
G547 G548
brand STONE
DUNLOP K505F K505
Measure the tread depth at the center of the tires.

Replace the tires if the tread depth reaches these limits:
Minimum tread depth:

Front: 1.5 mm (1 /16 in)
Rear: 2.0 mm (3/32 in)
3-18
MAINTENANCE
STEERING HEAD BEARINGS

NOTE
• Check that the control cables do not interfere with handle-
bar rotation.
Raise the front wheel off the ground and check that the
handlebar rotates freely.
If the handlebar moves unevenly, binds, or has vertical move-

ment, adjust the steering head bearings by turning the steering
head adjustment nut (page 1 3-20).
3-19
FUEL SYSTEM
10 N·m ( 1 .0 kg-m, 7 ft-lb)
<�
�
4-0
4. FUEL SYSTEM
SERVICE INFORMATION 4-1 LIMITER CAP INSTALLATION 4-17
TROUBLESHOOTING 4-2 HIGH ALTITUDE ADJUSTMENT
(U.S.A. only) 4-18
FUEL TANK 4-3
SECONDARY AIR SUPPLY SYSTEM
AIR CLEANER CASE 4-4
(California model only) 4-18
CARBURETOR 4-5
FUEL PUMP INSPECTION 4-16 SYSTEM (California model only) 4-19
PILOT SCREW ADJUSTMENT 4-17 ID
SERVICE INFORMATION
GENERAL
G'HMl!fl'
• Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Do not smoke or allow
flames or spark in the work area.
CAUTION
• Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
• To prevent damage to the rear fuel tank stay, do not force the fuel tank up beyond the tank's movement limiter while disconnect-
ing the rod.
• Refer to section 3 for throttle and choke cable adjustments.

• When disassembling fuel system parts, note the locations of the 0-rings. Replace them with new ones on reassembly.
California model:
• All hoses used in the evaporative emission control system are numbered for identification. When connecting one of these
hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 1-18 for its routing.
SPECIFICATIONS
Item 49-state and Canada models California model
I
Throttle valve dia. 38.5 mm (1.52 in)
Venturi dia. primary: 11.6 mm (0.46 in) secondary: 35.6 mm (1.40 in) I
I Identification No. VG90A CM: VG80D I VG91A
Slow jet #35
Main jet #120
Float level 9.5 mm (0.37 in)
Idle speed 1 ,000 ± 100 rpm
Throttle grip free play 2-6 mm (1/8-1/4 in) J
Pilot screw initial opening See page 4- 1 7
TORQUE VALE
Fuel tank mounting bolt, nut 10 N·m (1.0 kg-m, 7 ft-lb)
Fuel valve lock nut 38 N·m (3.8 kg-m, 27 ft-lb)
TOOLS
Special
Pressure pump ST-AH-255-MC7---rU .S.A . only-included in
Vacuum pump ST-AH-260-MC7 _J Turbo kit
Common
Float level gauge 07401-0010000
4-1
FUEL SYSTEM
TROUBLESHOOTING
Engine cranks but won't start Backfiring
• No fuel in tank • Ignition malfunction
• No fuel to carburetors • Carburetor malfunction
• Engine flooded with fuel • Lean mixture
• No spark at plug (ignition system faulty) • Rich mixture
• Clogged air cleaner
• Intake air leak Lean mixture
• Improper choke operation • Clogged fuel jets
• Improper throttle operation • Faulty float valve
• Faulty fuel pump • float level low
• Faulty fuel pump relay Blocked fuel tank cap vent hole
• Clogged fuel strainer screen
Engine idles roughly, runs poorly or stalls • Restricted fuel line
• Improper choke operation • Clogged air vent tube
• Ignition malfunction • Intake air leak
• Fuel contaminated • Restricted or faulty fuel pump or relay
• Intake air leak • Vacuum piston stuck closed
• Incorrect idle speed
• Incorrect carburetor synchronization Rich mixture
• Incorrect pilot screw adjustment Clogged air cleaner
• Low cylinder compression Worn jet needle or needle jet
• By-starter valve stuck open Faulty float valve
• Damaged by-starter valve seat Float level too high
• Rich mixture By-starter valve stuck open
• Lean mixture Damaged by-starter valve seat
• Clogged carburetor Clogged air jet
• Faulty purge control valve (California model only) Faulty fuel pump or relay
• Faulty air vent control valve (California model only)
• Faulty hoses of the emission control system (California Incorrect fast idle speed
model only) • Incorrect choke cable free play
• By-starter valve stack or damage
Misfiring during acceleration • By-starter valve not synchronized
• Ignition system faulty
• Lean mixture
Afterburn during deceleration

• Lean mixture
• Incorrect carburetor synchronization
• Faulty secondary air supply system (California model
only)
• Faulty hoses of the emission control system (California
model only)
Poor performance ldriveability) and poor fuel economy

• Fuel system clogged
• Air cleaner clogged
• Faulty air vent control valve (California model only)
• Faulty hoses of the emission control system (California
model only)
4-2
FUEL SYSTEM
FUEL TANK
REMOVAL
• Do not allow flames or sparks near gasoline.

Wipe up spilled gasoline at once.
Turn the fuel valve OFF.

Remove the side covers and the seat.
Disconnect the fuel line at the fuel valve.
NOTE
• Do not pull the fuel line when disconnecting because it may
be disconnected at the fuel pump.
Disconnect the fuel level sensor connector.
Remove the fuel tank mounting boltsfnut.

Use a suitable gasoline container and make sure the fuel flows
freely by turning the fuel valve ON.
If the fuel flow is restricted, drain the fuel tank and loosen the
lock nut. Clean the fuel strainer.
Check the vent hole of the fuel tank cap for blockage.
INSTALLATION
1 0 N•m ( 1 .0 kg-m, 7 ft-lb)
~~
Install the fuel tank in the reverse order of removal.
(2) TANK CAP
Tighten the shown bolts and nut to the specified torque.
~
NOTE
• After installation, make sure there are no fuel leaks.
38 N·m (3.8 kg-m, 27 ft-lb)
(4) FUEL LEVEL SENSOR
4-3
FUEL SYSTEM
Al R CLEAN ER CASE
REMOVAL
Remove the fuel tank (page 4-3).
Disconnect the cylinder head cover breather tube.

Remove the air cleaner case mounting bolts.
Remove the carburetor (page 4-5).
Remove the bolt and inlet duct from the element cover.
( 1) INLET DUCT
(2) ELEMENT COVER
Remove the screws and element cover from the case.
Remove the air cleaner case from the frame. \ �
(�
I
'.._\_
INSTALLATION
Install the air cleaner case in the reverse order of removal.
(1) AIR CLEANER CASE
(2) ELEMENT
(4) INLET DUCT
(3) ELEMENT COVER
4-4
FUEL SYSTEM
CARBURETOR
REMOVAL
Remove the fuel tank (page 4-31.
Remove the air cleaner mounting bolts and free the air cleaner
case.
Disconnect the head cover breather tube.
Disconnect the fuel tube at the fuel tube joint.
Loosen all carburetor bands and remove the carburetor as-
sembly.
NOTE
• Seal the cylinder head intake ports with tape or a clean
cloth to keep dirt and debris from entering the intake ports.
Loosen the cable clamp screw and disconnect the choke cable
from the carburetors.
Remove the throttle cables from the cable holder and discon-
nect the throttle cables from the throttle drum.
DISASSEMBLY
NOTE
• You can service the vacuum chamber and float chamber
without separating the carburetors.
Disconnect the fuel lines.
Remove the rear bracket. (1) SCREWS
(2) REAR BRACKET
4-5
FUEL SYSTEM
Remove the cotter pin and disconnect the throttle linkage of

the No.2 and No.3 carburetors.
Remove the front bracket.

Separate the carburetors.
Loosen the by-starter arm screws and remove the by-starter

arm shaft, spring and by-starter arms.
NOTE
•
Do not lose the three synchronization adjusting springs and
two thrust springs.
•
Do not damage the fuel and air joint pipes.
(5) ADJUSTING SPRINGS (4) SCREWS
Remove the four float chamber screws and the float chamber. (1) SCREWS
Remove the float pin, float and float valve.
Inspect the float for damage.
4-6
FUEL SYSTEM
Inspect the float valve seat for grooves and nicks.
Check the operation of the float valve.
Remove the main jet, needle jet holder, slow jet and float valve (1) MAIN JET (2) NEEDLE JET HOLDER
seat/filter.
Pilot screw removal/installation see page 4-9.

(3) VALVE
SEAT
(4) SLOW
JET
Inspect the float valve seat and filter for grooves, nicks or de- (1) VALVE SEAT
posits.
Clean the filter with compressed air.
NOTE
• Do not use high pressure air.
Inspect each jet for wear or damage and replace if necessary.
Clean each jet with non-flammable or high flash point solvent.

(2) FILTER
Remove the screws and vacuum chamber cover. .......---(1 l SCREWS

Q
CAUTION
• Do not interchange vacuum chamber covers, springs, pistons or
jet needles between carburetors.
(2) VACUUM CHAMBER COVER
4-7
FUEL SYSTEM
Remove the compression spring and diaphragm/vacuum pis

ton.
Inspect the vacuum piston for wear, nicks, or other damage.

Make sure the piston moves up and down freely in the cham
ber.
(2) SPRING
Push the jet needle holder down and turn it counterclockwise (1) JET NEEDLE HOLDER
90 degrees with an 8 mm socket. Then remove the needle
holder, spring, jet needle and washer from the vacuum piston.
Inspect the jet needle for excessive wear at the tip or other (1) JET NEEDLE
damage.
Check for a torn diaphragm or other deterioration.
(3) DIAPHRAGM
1
(2) WASHER
(2) SPRING
Remove the by-starter nut, spring and valve.
\
Remove the plug.
Check the valve for wear or damage.

Check the spring for damage or fatigue.
\
(3) VALVE
4-8
FUEL SYSTEM
Remove the screws and air-cut off valve cover. ( 1 I AIR-CUT OFF VAL VE
Remove the spring, diaphragm, and 0-ring.
Check the diaphragm for pin holes or at.her damage.
111 DIAPHRAGM
NOTE
• The pilot screws are factory pre-set and should not be re-
moved unless the carburetors are overhauled.
• The pilot screw limiter caps are factory installed and ce-
mented in place to prevent pilot screw misadjustment.
Remove the limiter caps.
Turn each pilot screw in and carefully count the number of
turns before it seats lightly. Make a note of this to use as a ref-
erence when reinstalling the pilot screws.
CAUTION
• Damage to the pilot screw seat will occur if the pilot screw is 11 I LIMITER CAP
tightened against the seat.
Remove the pilot screws and discard them.
Blow open each jet with compressed air.
Revised: August 1987

© 1987 American Honda Motor Co., Inc. - All Rights Reserved
MSV 1965 (8708) '87 CBR1 OOOF
4-9
FUEL SYSTEM
ASSEMBLY
Install new pilot screws and perform pilot screw adjustment

{page 4-17).
NOTE
• Do not install limiter caps on new pilot screws until adjustment

has been made (page 4-17). ( 1 l PILOT SCREW
•
If you replace the pilot screw in one carburetor, you must
replace the pilot screws in the other carburetors for proper
adjustment.
--------------------------------------------------------------------------------"""''
/
4-10
•
© 1987 American Honda Motor Co., Inc. - All Rights Reser'

MSV 1965 (8708) '87 CBR1000F
FUEL SYSTEM
Install the diaphragm, spring, 0-ring and valve cover to the car-
buretor body.
NOTE
• Install the 0-ring with its flat side toward the carburetor
body.
Tighten the screws securely. (1) SCREWS
Install the by-starter valve, spring and by-starter nut to the car-
buretor body.
Check the plug for damage or pin holes and install the plug.
Install the valve seat, slow jet, needle jet holder and main jet. (1 I MAIN JET (2) NEEDLE JET HOLDER
4-11
FUEL SYSTEM
Install the float with float valve to the carburetor body and in (1) FLOAT
stall the float arm pin through the body and float.
FLOAT LEVEL
Measure the float level with the carburetor inclined 1 5 ° -45 °

from vertical so that the float tang just contacts the float
valve.
FLOAT LEVEL: 9.5 mm (0.37 inl
TOOL:
Float level gauge 07401-0010000
Adjust the float level by carefully bending the float tang.
Install a new 0-ring to the float chamber.
Install the float chamber and tighten the screws securely.
Install the washer, jet needle, spring and jet needle holder to (1) WASHER
the vacuum piston.
Push the jet needle holder in and turn it 90 degrees clockwise.
(4) JET NEEDLE
4-12
FUEL SYSTEM
Install the vacuum chamber with the tab of the diaphragm

aligned with the groove of the carburetor and with the vacuum
piston held up to almost full open so it does not pinch the dia-
phragm on the chamber cover.
Install the chamber cover with the spring, aligning its tab with
the hole in the carburetor, and secure with at least two screws
before releasing the vacuum piston.
(3) SPRING
Install the remaining screws of the vacuum chamber cover. (1 l VACUUM CHAMBER
NOTE
• Do not bite the diaphragm into the chamber cover.
CAUTION
• Do not pinch the diaphragm on the chamber cover.
Assemble the No.1 and No.2 carburetors as follow: (1 l AIR JOINT (2) SYNCHRONIZATION
- install new 0-rings to the fuel joint and air joint. SPRING
- assemble the carburetors with the joints and thrust spring.
- install the synchronization adjusting screw.
Set each part in proper position as shown.
CAUTION
• Be careful not to damage the 0-rings during assembly.
(6) No. 2 CARB. 151 FUEL ~I No. 1 CARB.
Install the rear bracket with the throttle stop screw holders to
the No.1 and No.2 carburetor assembly and loosely tighten the
screws.
I
4-13
FUEL SYSTEM
Install the by-starter arms, spring and shaft to the No.1 and
No.2 carburetors.
Loosely tighten the arm screws.
Assemble the No.3 and No.4 carburetors in the same way. (2) SYNCHRONIZA
TION SPRING
\
CAUTION
•
Be careful not to damage the 0-rings during assembly.
Install the by-starter shaft and arms to the No.3 and No.4 car
buretors.
Install the rear bracket to the No.3 and No.4 carburetor as
sembly and loosely tighten the screws.
/0
(1) REAR BRACKET SCREWS
4-14
FUEL SYSTEM
Tighten the rear bracket screws in the pattern shown, in 2- 3

steps.
( 11 REAR BRACKET
Tighten the front bracket screws in the pattern shown, in 2- 3

steps.
Make sure the by-starter shaft is set securely and by-starter

arm is installed to the by-starter valve.
Tighten the by-starter arm screws securely.
(3) ARMS/SCREWS
Connect the throttle linkage of the No.2 and No.3 carburetors

and install the washer and new cotter pin.
Connect the fuel lines to the fuel joints securely. ~~ (1) LEVER
;, .
Operate the choke lever and check its operation for drag. I I a..
Operate the throttle drum and check its operation for drag.
4-15
FUEL SYSTEM
Align the edge of the by-pass holes with the throttle valves,
turning the synchronization adjusting screws.
NOTE
•
No. 2 carburetor is the base.
(2} BY-PASS HOLES

INSTALLATION
Connect the throttle cable ends to the throttle drum and install
the throttle cables onto the cable holder.
Connect the choke cable end to the choke lever and install the
choke cable with the cable clamp.
Coat the inside of the carburetor insulators with engine oil.

Install the carburetors onto the cylinder head.
Tighten the carburetor band screws securely.
Connect the fuel tube to the fuel tube joint.
Connect the cylinder head cover breather tube.
Install the air cleaner case (page 4-4).

Install the fuel tank (page 4-3).
Adjust as follows:
- pilot screw (page 4-17)
- carburetor synchronization (page 3-9)
- throttle grip free play (page 3-4)
- carburetor idle speed (page 3-10}
- carburetor choke (page 3-5)
FUEL PUMP INSPECTION

Turn the ignition switch off.
Disconnect the fuel pump relay wire connector and temprarily
connect the black and brown/red wire terminals at the main
wire harness connector with a jumper wire.
disconnect the fuel outlet tube at the fuel tube joint.

Hold a graduated beaker under the pump outlet line.
(1} JUMPER WIRE
turn the fuel valve ON.
f
l@&.i;fr@ld
• Do not allow flames or sparks near gasoline.
Turn the ignition switch on and let fuel flow into the beaker for
5 seconds, then turn the ignition switch off.
Multiply the amount in the beaker by 12 to determine the fuel
pump flow capacity per minute.
FUEL PUMP FLOW CAPACITY:

900 cc 130.4 US oz, 31.6 Imp oz) min./minute
4-16
FUEL SYSTEM
PILOT SCREW ADJUSTMENT

IDLE DROP PROCEDURE (U.S.A. ONLY)
NOTE
• The pilot screws are factory pre-set and no adjustment is
necessary unless the pilot screw is replaced.
• Use a tachometer with graduations of 50 rpm or smaller
that will accurately indicate a 50 rpm change.
1. Turn each pilot screw clockwise until it seats lightly and

back it out to the specification given.
This is an initial setting prior to the final pilot screw adjust-
ment.
INITIAL OPENING: 2 (California model: 2-3/41 turns out
CAUTION
• Damage to the pilot screw seal will occur if the pilot screw is
tightened against the seat.
2. Warm up the engine to operating temperature. Stop and

go driving for 10 minutes is sufficient.
3. Attach a tachometer.
4. Adjust the idle speed with the throttle stop screw.
IDLE SPEED: 1,000 ± 100 rpm
5. Turn all pilots screw 1/2 turn out from the initial setting.
6. If the engine speed increases by 50 rpm or more, turn all
pilots screw out by a continual 112 turn until it no longer
increases.
8. Turn the No. 1 carburetor pilot screw in until the engine
speed drops 50 rpm.
9. Turn the No. 1 carburetor pilot screw 1 turn out from the
position obtained in step 8.
11. Perform steps 8, 9 and 10 for the No. 2, 3 and 4 carbure-
tor pilot screws.
12. Install a new limiter caps on the pilot screws.
LIMITER CAP INSTALLATION

If the pilot screws are replaced, a new limiter cap must be in-
stalled after pilot screw adjustment is completed.
After adjustment cement the limiter caps over the pilot
screws, using LOCTITE® 601 or equivalent. The limiter cap
should be placed against its stop, preventing further adjust-
ment that would enrich the fuel mixture (limiter cap position
permits clockwise rotation and prevents counterclockwise ro-
tation).
NOTE
(11 LIMITER CAP
• Do not turn the pilot screw when installing the limiter cap.
4-17
FUEL SYSTEM
HIGH ALTITUDE ADJUSTMENT (U.S.A. only)

When the vehicle is to be operated continuously above 2,000
m (6,500 feet) the carburetor must be readjusted as follows to
improve driveability and decrease exhaust emissions.
Turn each pilot screw clockwise 3/4 turn.
Warm up the engine to operating temperature. Stop and go
driving for 10 minutes is sufficient.
Adjust the idle speed to 1 ,000 ± 1 00 rpm with the throttle
stop screw.
NOTE
•
This adjustment must be made at high altitude to ensure
proper high altitude operation.
Attach a Vehicle Emission Control Information Update Label

onto the air cleaner case as shown. Refer to Service Bulletin
#SL 132 for information on obtaining the label.
NOTE
•
Do not attach the label to any part that can be easily re
moved from the vehicle.
''¥4MM!d
•
Operation at an altitude lower than 1,500 m (5,000 feet) with
the carburetors adjusted for high altitudes may cause the engine
to idle roughly and stall.
When the vehicle is to be operated continuously below 1,500

m (5,000 feet), turn each pilot screw counterclockwise 1 (Cal
ifornia model: 1-3/4) turn to its original position and adjust the
idle speed to 1 ,000 ± 1 00 rpm.
Be sure to do these adjustments at low altitude.
SECONDARY AIR SUPPLY SYSTEM (Cali ( 1) AIR INJECTION CONTROL VALVE (AICV)
(2) No. 1 5 HOSE
fornia model only) (6) INTAKE (3) SECONDARY AIR
PORT / INTAKE PORT
SYSTEM INSPECTION L (4) AIR CLEANER
Start the engine and warm it up to operating temperature.

Stop the engine and remove the air cleaner element (page 3-5).
Check that the secondary air intake ports are clean and free of
carbon deposits.
Check the reed valves in the secondary air passege if the ports \ (5) CARBURETOR
are carbon fouled.
4-18
FUEL SYSTEM
Disconnect the air cleaner-to-air injection control valve (AICV)

No. 15 hose from the air cleaner case.
Remove the vacuum tube from the three-way joint; install a
plug to keep air from entering.
Connect a vacuum pump to the No. 10 (vacuum) hose.
Tool:
Vacuum Pump ST-AH-260-MC7 (U.S.A. only)
Start the engine and open the throttle slightly to be certain that
air is sucked in through the No. 1 5 hose. (4) No. 10 (VACUUM) HOSE
If air is not drawn in, check the No. 15 hose and No. 10 hose
for clogging.
With the engine running, gradually apply vacuum to the No. 10
hose.
Check that the air intake port stops drawing air, and that the
vacuum does not bleed.
SPECIFIED VACUUM: 360 mm 114.2 in) Hg ENGINE FAMILY - HHNO 99844 HX
EVAPORATIVE FAMILY - 87 ZS
CALIFORNIA VEHICLE
If air is still drawn in, or if the specified vacuum is not main-
tained, install a new AICV.
If afterburn occurs on deceleration, even when the secondary
air supply system is normal, check the slow air cutoff valve for
correct vacuum operation.

SYSTEM (California model only)
Check the system tubes for deterioration, clogging, damage,
loose joints and connection.
Replace any hose that shows signs of damage or deterioration.
PURGE CONTROL VALVE (PCV) INSPECTION
NOTE
OPEN AIR
• The purge control valve should be inspected if hot restart is
difficult. MMS-740
Disconnect the PCV hoses from their connections and remove

the PCV from its mount. Refer to the routing label on the air
cleaner cover for hose connections.
Connect a vacuum pump to the hose that goes to the No. 3

carburetor body. Apply the specified vacuum to the PCV.
TOOL:
Vacuum pump: ST-AH-260-MC7 (U.S.A. only)
SPECIFIED VACUUM: 250 mm (9.8 in) Hg
(1) VACUUM PUMP
The specified vacuum should be maintained.
Replace the PCV if vacuum is not maintained. /
CAUTION
• To prevent damage to the purge control valve, do not use high
air pressure sources. Use a hand operated air pump only.
4-19
FUEL SYSTEM
Remove the vacuum pump and connect it to the hose that

goes to the each carburetor bodies. (1) PURGE CONTROL VALVE
Apply the specified vacuum to the PCV.
(2)
SPECIFIED VACUUM: 250 mm (9.8 in) Hg TO CHARCOAL
""---...-- _____,.., CA NI STER

(3)
Replace the PCV if vacuum is not maintained.
(5) / ��
VACUUM PUMP
TO NO. 3 I
CARBURETOR
(4) TO EACH CARBURETORS
Connect a pressure pump to the 8 mm l.D. hose that goes to

(1) PRESSURE PUMP
the charcoal canister. While applying the specified vacuum to
I
the PCV hose that goes to the No. 3 carburetor body, pump air
through the canister hose. Air should flow through the PCV
and out the hose that goes to the each carburetor bodies. Re
place the PCV if air does not flow out.
TOOL:
Pressure pump ST-AH-255-MC7 (U.S.A. only)
Remove the pump, install the PCV on its mount, route and re
connect the hoses according to the routing label.
(2) VACUUM PUMP
AIR VENT CONTROL VALVE (AVCV) INSPECTION ( 1) TO NO. 1, 2 CARBURETOR BODIES
NOTE
•
The air vent control valve should be inspected if engine re
start is difficult. (6)
TO
,
CHARCOAL.
Disconnect the AVCV hoses from their connections and
CANISTER
remove the AVCV from its mount. Refer to the routing label on
the air cleaner case for hose connections.
Connect a vacuum pump to the hose that goes to the No. 1, 2

carburetor three-way joint.
Apply the specified vacuum to the AVCV.
SPECIFIED VACUUM: 250 mm (9.8 in) Hg

Replace the AVCV if vacuum is not maintained.
CAUTION
•
To prevent damage to the air vent control valve, do not use
high air pressure sources. Use a hand operated air pump only.
Connect the vacuum pump to the air vent port of the AVCV.
Apply vacuum to the AVCV. The vacuum should hold steady.
Replace the AVCV if vacuum leaks.
4-20
FUEL SYSTEM
Connect the vacuum pump to the hose that goes to the No. 1,
2 carburetor three-way joint.
Connect the pressure pump to the air vent port of the A VCV.
TOOL:
Pressure pump ST-AH-255-MC7 (U.S.A. only)
While applying the vacuum to the A VCV hose that goes to the
No. 1, 2 carburetor three-way joint, pump air through the air
vent port of the A VCV. Air should flow through the A VCV and
out the hose that goes to the carburetor air joint pipe.
(2) PRESSURE PUMP
Plug the hose that goes to the No. 2, 4 carburetor air vent port (1) BLOCKED
of the AVCV. TUBE
Connect the pressure pump to the air joint pipe.
(2)
While applying vacuum to the AVCV hose that goes to the No.
VACUUM PUMP
1, 2 carburetor three-way joint, apply air pressure.
It should hold steady.
Replace the AVCV if pressure is not retained.
Remove the pumps, install the AVCV on its mount, route and
reconnect the hoses according to the routing label.
(3)
PRESSURE PUMP
4-21
COOLING SYSTEM
5-0
5. COOLING SYSTEM
SERVICE INFORMATION 5-1 THERMOSTAT 5-3
TROUBLESHOOTING 5-1 RADIATOR/COOLING FAN 5-4
SYSTEM TESTING 5-2 WATER PUMP 5-5
COOLANT REPLACEMENT 5-2 RESERVE TANK 5-7
!SERVICE INFORMATION
GENERAL
'%''·Mifri9
• Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result.
The engine must be cool before servicing the cooling system.
• Use only distilled water and ethylene glycol the cooling system. A 50- 50 mixture is recommended for maximum corro-
sion protection. Do not use alcohol-based antifreeze.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• All cooling system service can be done with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system. check for leaks with a cooling system tester.
• Refer to Section 19 for fan motor thermostatic switch and temperature sensor inspections.
SPECIFICATIONS
Radiator cap relief pressure 110-140 kPa (1.1-1.4 kglcm 2 , 16-20 psi)
Freezing point (Hydrometer test): 55% Distilled water+45% ethylene glycol: -32°C (-25°F)
50% Distilled water+50% ethylene glycol: -37°C (-34°F)
45% Distilled water+55% ethylene glycol: -44.5°C (-48°F)
Coolant capacity:
Radiator and engine 2.6 £ (2. 75 US qt, 2.29 imp qt)
Reserve tank 0.4 £ (0.42 US qt, 0.35 imp qt)
Total system 3.0 £ (3.17 US qt, 2.64 imp qt)
Thermostat Begins to open: 80°to 84°C (176° to 183°F)
Valve lift: Minimum of 8 mm at 95°C (0.32 in at 203°F)
Bolling point (with 50-50 mixture): Unpressurized: 107.7°C (226°F)
Cap on, pressurized: 125.6 °C (258°F)
TROUBLESHOOT ING
Engine temperature too high Engine temperature too low
• Faulty temperature gauge or gauge sensor • Faulty temperature gauge or gauge sensor
• Thermostat stuck closed • Thermostat stuck open
• Faulty radiator cap
• Insufficient coolant or coolant level too low Coolant leaks
• Passages blocked in radiator, hoses, or water jacket • Faulty pump mechanical seal
• Cooling fan motor does not turn • Deteriorated 0-rings
- Broken or loose subfuse
- Faulty fan motor
- Faulty thermostatic switch
- Poor contact or open circuit in harness
• Faulty water pump
5-1
COOLING SYSTEM
SYSTEM TESTING ( 1) ANTIFREEZE TESTER
COOLANT
Test the coolant mixture with an antifreeze tester.

For maximum corrosion protection, a 50- 50% solution of
ethylene glycol and distilled water is recommended.
RADIATOR CAP INSPECTION
Remove the fuel tank (page 4-3) and the radiator cap.
•
Be sure the engine is cool before removing the cap.
( 1) COOLING SYSTEM TESTER

Pressure test the radiator cap. Replace the radiator cap if it
does not hold pressure, or if it's relief pressure is too high or
too low. It must hold specified pressure for at least six sec
onds.
NOTE
Before installing the cap on the tester, wet the sealing sur
faces with water.
RADIATOR CAP RELIEF PRESSURE: (2) RADIATOR CAP

110-140 kPa (1.1-1.4 kg/m2, 16-20 psi)
SYSTEM PRESSURE TEST
Remove the radiator cap.
Pressurize the radiator, engine and hoses, and check for leaks.
CAUTION
•
Excessive pressure can damage the radiator.
Do not exceed 140 kPa (1.4 kglcm2, 20 psi)
Repair or replace components if the system will not hold speci

fied pressure for at least six seconds.
COOLANT REPLACEMENT
The engine must be cool be/ore servicing the cooling system, or

severe scalding may result.

Remove the lower and left side fairings (page 1 2-2).
Drain the coolant from the system by removing the d rain bolt
on the water pump cover.
Install the d rain bolt after making sure their sealing washer is in
good condition.
5-2
COOLING SYSTEM
Fill the system with a 50- 50 mixture of distilled water and

ethylene glycol.
Bleed air from the cooling system as follows:
• Apply center stand and shift the transmission into neutral.
• Start the engine and snap the throttle grip, 3-4 times at
4,000- 5,000 rpm. Then add coolant up to the radiator
filler neck.
• Install the radiator cap.
• Check the level of coolant in the reserve tank and fill to the
upper level if the level is low.
• Install the lower and left side fairings (page 12-4).
THERMOSTAT
REMOVAL

Drain the coolant (page 5-2).
Disconnect the thermosensor connector.
Remove the thermostat housing cover by removing the two
cover bolts.
Remove the thermostat from the housing.

Make sure that the 0-ring not damaged or deteriorated.
INSPECTION
Inspect the thermostat visually for damage.

Suspend the thermostat in heated water to check its opera-
tion.
NOTE
• If the thermostat or thermometer touches the pan, you'll
get a faise reading.
Replace thermostat if valve stays open at room temperature,

or if it responds at temperatures other than those specified.
Technical Data
Start to open 80°to 84°C (176-183°F)

Valve lift 8 mm (0.32 in) minimum when
-
heated to 95°C (203°F) for five
minutes.
5-3
COOLING SYSTEM
INSTALLATION
� Install the thermostat into the housing with the air bleed hole
� facing upward.
Install the 0-ring and housing cover.
Tighten the two cover bolts securely.
Connect the thermosensor connector.
Fill the cooling system (page 5-3).
RADIATOR/COOLING FAN
REMOVAL

tank and support tank with the rod (page 3-6).
Remove the lower fairing and side fairings (page 12-2).
Disconnect the fan motor connector. (2) WATER HOSES

Disconnect the water hoses from the radiator (right side). (RIGHT SIDE)
..-.....-·--
Disconnect the water hose from the radiator (lower).

Remove the bolts and radiator from the frame.
Remove the screws and radiator grille from the radiator.
(3) GRILLE
DI SASS EMBLY
� Remove the bolts and cooling fan motor assembly from the ra
§ diator.
For the radiator core check, see section 3.

5-4 © 1987 American Honda Motor Co.. Inc. - All Rights Reserved
MSV 1965 (8708) '87 CBR1000F
COOLING SYSTEM
[ ; : love the nut and fan motor.
ASS EMBLY /INSTALLATION (1 l NUTS (2) ALIGN
Check each part for damage.

Assembly and installation are in the reverse orders of removal
and disassembly.
NOTE
• Align the motor shaft with the fan groove.
• Clamp the wires properly and securely.
• Take care not to damage the radiator fins.
WATER PUMP
MECHANICAL SEAL INSPECTION
Inspect the telltale hole for signs of mechanical seal coolant

leakage.
Replace the water pump as an assembly if the mechanical seal
is leaking.
(1) TELL TALE HOLE (BOTTOM OF THE

WATER PUMP BODY)
REMOVAL
Remove the lower and left side fairings (page 12-2).

Disconnect the water pipe clamp and water pipe bolt.
5-5
COOLING SYSTEM
Remove the water hoses.

Remove the bolts and water pump.
Remove the cover bolts and disassemble the water pump.

(2) BOLTS
INSPECTION
Check the water pump rotor for damage.

Replace the pump as an assembly if necessary.
NOTE
•
Do not disassemble the pump rotor.
INSTALLATION
Install a new 0-ring onto the pump cover.
Assemble the water pump with two attaching bolts.

Install a new 0-ring to the water pump.
5-6
COOLING SYSTEM
Install the water pump onto the crankcase, aligning the groove
of the water pump shaft with the oil pump shaft.
Install and tighten the two mounting bolts.

Connect the water hoses with the bands securely.
Check the 0-ring for wear or fatigue.

Connect the water pipe to the water pump.
Tighten the water pipe bolt and clamp bolt securely.
RESERVE TANK
REMOVAL
(2) ELEMENT COVER
Remove the inlet duct and element cover. /l'"G_
Remove the starter relay switch from the battery holder.
Remove the reserve tank mounting nut and reserve tank.
._,_r
INSTALLATION
Install the reserve tank in the reverse order of removal.

62
'.7~
NOTE
• Route the tubes properly (page 1-10 thru 14) and do not
pinch the battery breather tube. (31 RESERVE TANK
5-7
ENGIN E REMOVAL/INSTALLATION
10 N•m
(1.0 kg-m,
7 ft-lb)
90 N•m 5
6
(9.0 kg-m, ft-lb)
22 N•m
6
17 N•m (1 .7 kg-m, 12 ft-lb) (2.2 kg-m, 1 ft-lb)
6-0
6. EN_GINE REMOVAL/~N_STALLAJION
SERVICE INFORMATION 6-1 ENGINE INSTALLATION 6-5
ENGINE REMOVAL 6-2
SERVICE INFORMATION
GENERAL
CAUTION
• Put a piece of plywood or an old blanket on the floor under the motorcycle to protect the engine during removal/installation.
• A floor jack or other adjustable support 1s required to support and maneuver the engine.
• The following parts or components can be serviced with the engine installed in the frame:
• Clutch • Alternator stator coil • Cooling system • Balancer
• Gearshift linkage • Starter motor • Camshaft
• Cylinder head • Carburetor • Cylinder/piston
• The muffler of the CBR 1000F is black chromeplated. To clean the muffler, use a soft sponge and flush with sufficient
water. After washing, let it dry and coat with non-compounded silicone wax. Apply a heat-resistant black paint if the black
chrome plating is scratched or scored.
SPECIFICATIONS
Enging dry weight 85 kg (187.4 lb)

Oil capacity 4.5 f (4.75 US qt, 3.96 Imp qt) after disassembly
TORQUE VALUES
Drive sprocket bolt 90 N•m (9.0 kg-m, 65 ft-lb)

Engine hanger bolt (12 mm) 60 N•m (6.0 kg-m, 43 ft-lb)
(10mm) 45 N•m (4.5 kg-m, 33 ft-lb)
Oil pipe bolt 10 N•m (1.0 kg-m, 7 ft-lb)
Engine hanger adjuster 8 N·m (0.8 kg-m, 6 ft-lb)
Engine hanger adjuster lock nut 25 N•m (2.5 kg-m, 18 ft-lb)
Side stand bracket bolt 45 N•m (4.5 kg-m, 33 ft-lb)
Gearshift pedal bolt 10 N·m (1.0 kg-m, 7 ft-lb)
Exhaust pipe joint nut 17 N·m (1.7 kg-m, 12 ft-lb)
Exhaust muffler band bolt 22 N·m (2.2 kg-m, 16 ft-lb)
Exhaust muffler mounting bolt 22 N•m (2.2 kg-m, 16 ft-lb)
6-1
ENGINE REMOVAL
Place the motorcycle on its center stand on level ground.

- side covers (page 12-2)
- both side fairings (page 12-2)
- fuel tank (page 4-3)
Drain the engine oil (page 2-3) and coolant (page 5-2).
Remove the carburetors (page 4-5).
Remove the exhaust system (page 12-7).
Discconnect the spark plug caps.
Remove the water pipes from the cylinder head.
Disconnect the starter motor cable at the starter motor by re

moving the terminal nut.
Disconnect the pulse generator wire connector and alternator

wire connector.
�i '
��
UJJ _;,,-:i
(2) PULSE GENERATOR CONNECTOR
NOTE
•
Pull the clutch lever in and tie it to the handlebar grip to pre
vent the slave cylinder piston from moving.
Remove the shift pedal and clutch slave cylinder.
Remove the drive sprocket cover.
Remove the side stand bracket bolts.
(4) PEDAL
6-2
Loosen the drive chain adjuster.

Loosen the rear axle nut and push the rear wheel forward.
Remove the drive sprocket bolt and sprocket from the counter-
shaft and drive chain.
Disconnect the neutral switch/oil pressure switch wire con-

nector.
Disconnect lower radiator hose.

Remove the oil pipes by removing the four bolts.
Remove the radiator lower mounting bolt and nut.
6-3
Remove the rubber heat protectors.
CAUTION
•
Put a piece of plywood or an old blanket on the floor under the
motorcycle to protect the engine during removal/installation.
Place the floor jack or other adjustable support under the en
gine.
NOTE
•
The jack height must be continuously adjusted to relieve
stress from bolts that are being removed.
Remove the front engine hunger bolts, washers, spacers and

nut.
Loosen the rear engine hanger bolts and nuts.
Loosen the rear upper engine hanger adjuster and lock nut.
Remove the rear engine hanger bolts.
(3) ADJUSTER (2) RIGHT SIDE FRAME
Carefully lower the engine moving the rear end of engine for
ward and cylinder head upward at the same time.
Remove the jack and rest the engine on a piece of plywood or

old blanket.
6-4
Turn the engine clockwise slightly and pull the engine out from
the right side of the frame.
ENGINE INSTALLATION
Engine installation is essentially the reverse order of removal.
NOTE
• Note the engine hanger bolt collar locations before engine
installation.
Use a floor jack or other adjustable support to carefully maneu-

ver the engine into place.
CAUTION
Carefully align mounting points with the jack to prevent
damage to the mounting bolt threads, wire harness and cables.
(1 I ADJUSTER
Install all engine hanger bolts.

Tighten the rear upper engine hanger adjuster to the specified
torque.
TORQUE: 8 N·m I0.8 kg-m, 6 ft-lb)
Tighten the lock nut to the specified torque.
TORQUE: 25 N•m 12.5 kg-m, 18 ft-lb)
Tighten all fasteners to the torque values given on page 6-1. (3) LOCK NUT
\
(2) RIGHT SIDE FRAME
Release the clutch lever then install the clutch slave cylinder.
NOTE
• Route the wires and cables ptoperly (pages 1-10 thru 1-141.
• Fill the engine to the proper level with the recommended oil
(page 2-1, 3).
• Fill the cooling system (page 5-3).
6-5
CYLINDER HEAD/VALVE
14 N·m (1.4 kg-m, 10 ft-lb) 10 N•m (1 .0 kg-m, 7 ft-lb)
� /
�@J
��
� @�
@�
14 N·m
(1.4 kg-m,
10 ft-lb)
7-0
7. CYLINDER HEAD/VALVE
SERVICE INFORMATION 7-1 VALVE GUIDE REPLACEMENT 7-12
TROUBLESHOOTING 7-2 VALVE SEAT INSPECTION/REFACING 7-13
CAMSHAFT REMOVAL 7-3 CYLINDER HEAD ASSEMBLY 7-15
CYLINDER HEAD REMOVAL 7-7 CYLINDER HEAD INSTALLATION 7-17
CYLINDER HEAD DISASSEMBLY 7-10 CAMSHAFT INSTALLATION 7-19
SERVICE INFORMATION
GENERAL
• Lubricate the camshaft journals and cam lobes with molybdenum disulfide grease for initial lubrication.
• The exhaust and intake camshaft holders are identified by the respective markings (EXR and EXL, for the exhaust cam-
shaft holders and INR and INL, for intake camshaft holders).
SPECIFICATION
unit: mm (in)
I ITEM STANDARD SERVICE LIMIT
Cylinder compression pressure 1250 ± 200 kPa (12.5 ± 2.0 kg/cm 2

--
181 ± 29 psi)
Camshaft Cam lobe height IN 35.608-35.808 (1.4019-1.4098) 35.55 (1 .400)
EX 35.480-35.680 (1.3969-1.4047) 35.43 (1 .395)
Oil clearance IN 1, 4
0.020-0.074 (0.0008-0.0029 0. 1 2 (0.005)
EX 1, 4
IN 2, 3
0.050-0.104 (0.0020-0.0041) 0. 14 (0.006)
EX 2, 3
Run out -- 0.03 (0.001)
Valve spring Free length IN, EX Outer 47.08 (1.854) 45.7 (1.80)
IN, EX Inner 43.1 5 (1 .699) 41.8 (1 .65)
Preload/length IN, EX Outer 33.5-38.5 kg/28.6 32.94 kg/28.6
(73.85-84.88 lb/1.13) (72.620 lb/1.13)
IN, EX Inner 15.3-17.7 kg/25.1 14.88 kg/25.1
(33.73-39.02 lb/0.99) (32.804 lb/0.99)
Valve, valve Valve stem O.D. IN 5.4 75- 5.490 (0.21 56-0.2161) 5.47 (0.215)
guide EX 5.455-5.470 (0.2148-0.2154) 5.45 (0.215)
Valve guide l.D. IN, EX 5.500-5.512 (0.2165-0.2170) 5.55 (0.219)
I Stem-to-guide IN 0.010-0.037 (0.0004-0.0015) 0.07 (0.003)
clearance EX 0.030-0.057 (0.0012-0.0022) 0.09 (0.004) I
Cylinder head Warpage -- 0.07 (0.003)
Valve seat width IN, EX 0.9-1.1 (0.035-0.043) 1.5 (0.06)
7-1
CYLINDER HEAD/VALVE
TORQUE VALUES
Cylinder head cover bolt 10 N·m (1 .0 kg-m, 7 ft-lb)

Camshaft holder bolt 14 N·m (1.4 kg-m, 10 ft-lb)
Cam sprocket bolt 17 N·m (1.7 kg-m, 12 ft-lb) Apply a locking agent to the threads
Cylinder head nut 46 N•m (4.6 kg-m, 33 ft-lb)
Engine hanger bolt (12 mm) 60 N•m (6.0 kg-m, 43 ft-lb)
(10 mm) 45 N•m (4.5 kg-m, 33 ft-lb)
Engine hanger adjuster 8 N•m (0.8 kg-m, 6 ft-lb)
Engine hanger adjuster lock nut 25 N•m (2.5 kg-m, 18 ft-lb)
Cam chain tensioner bracket bolt 14 N·m (1 .4 kg-m, 10 ft-lb)
Oil pipe bolt 9 N·m (0.9 kg-m, 7 ft-lb)
TOOLS
Special
Valve guide reamer, 5.5 mm 07984-200000A (U.S.A. only) or 07984-200000B (U.S.A. only)
Common
Valve guide driver, 5.5 mm 07742-0010100
Adjustable valve guide driver 07743-0020000-Not available in U.S.A.
Valve spring compressor 07757-0010000
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing
noises with a sounding rod or stethoscope.
Low compression Compression too high

Valves Excessive carbon build-up on piston or combustion
-Incorrect valve adjustment chamber
-Burned or bent valves
- Incorrect valve timing Excessive noise
-Broken valve spring •
Incorrect valve adjustment
•
Cylinder head •
Sticking valve or broken valve spring
- Leaking or damaged head gasket •
Damaged or worn camshaft
-Warped or cracked cylinder head •
Loose or worn cam chain
•
Cylinder and piston (Refer to Section 8) •
Worn or damaged cam chain tensioner
•
Worn cam sprocket teeth
7-2
CYLINDER HEAD/VALVE
CAMSHAFT REMOVAL
Remove both side fairings (page 12-2).
Remove the fuel tank (page 4-31.
CAUTION
Do not let dirt enter the engine. Clean the cylinder head are,
before removal.
Disconnect the throttle cables. choke cable and cylinder ·hea1

cover breather tube.
Remove the spark plug caps.
Remove the cylinder head cover.
NOTE
Check the cylinder head cover gasket for deterioration o

damage and replace if necessary.
Remove the four bolts attaching the cam chain guide and th1
guide.
7-3
CYLINDER HEAD/VALVE
Remove the cam sprocket bolts.

Turn the crankshaft counterclockwise and then remove the
two other cam sprocket bolts.
Remove the cam sprockets from the camshaft flange

shoulders.
Remove the cam chain from the sprockets.

Remove the camshaft holder bolts and the holders.
NOTE
•
Loosen the holder bolts in 2-3 steps in crisscross patterm.
(1) CAMSHAFTS
Remove the camshafts and sprockets.
Remove the dowel pins and a-rings.
(3) DOWEL PIN AND 0-RING
INSPECTION
Camshaft Bearing Surfaces

Inspect the camshaft bearing surfaces for scoring, scratches,
or evidence of insufficient lubrication.
(2) BEARING SURFACES
Cam Chain Guide (1) CAM CHAIN GUIDE

Inspect the guard for wear or damage.
7-4
CYLINDER HEAD/VALVE
Camshaft Runout
Check camshaft run-out with a dial indicator.
Support both ends of the camshaft with V-blocks.
Cam Lobe Height

Check the cam lobes for wear or damage.
If the lobes are scored, inspect the rocker arm surfaces also.
Measure the cam lobe height with micrometer.
SERVICE LIMIT: IN: 35.55 mm (1.400 in)

EX: 35.43 mm (1.395 in)
Camshaft Oil Clearance (2) CAMSHAFTS

Wipe any oil from the camshaft journals.
Lay a strip of plastigauge lengthwise on top of each camshaft

journal.
Install the camshaft holders and tighten in a crisscross pattern.
NOTE
• Do not rotate the camshaft when using plastigauge.
7-5
CYLINDER HEAD/VAlVE
Remove the camshaft holders and measure the width of each

plastigauge. The widest thickness determines the oil clear
ance.
N 2, 3
EX 2, 3'. O 14 mm (O OOS l
SERVICE LIMITS: I
· · .'"
�NX �: : 0.12 mm (0.005 in)

:
When the service limits are exceeded, replace the camshaft

and recheck the oil clearance. Replace the cylinder head and
camshaft holders if the clearance still exceeds service limits.
Rocker arm ( 1) SPRING, HOLDER AND DOWEL PIN

Remove the rocker arm springs, rocker arm holders and dowel
pins.
Inspect the rocker arm for damage of threads and slipper

surefaces.
ADJUSTING SCREW REPLACEMENT
Remove the lock nut and rocker arm from the adjusting screw.
Install the 8 x 1 6 mm dowel pin and lock nut to the adjusting
screw.
Pull the adjusting screw out of the cylinder head gradually and
carefully not to damage the pivot seat, tightening the lock nut
with the adjusting screw held by a screwdriver.
7-6
CYLINDER HEAD/VALVE
If the screw threads are damaged, place a piece of wood be-

tween the rocker arm and cylinder head and remove the screw
by tapping the edge of the rocker arm with a soft hammer,
OTE
Make sure the pivot seat is firmly seated to the cylinder
(2) WOOD
head after removing the screw.
)
(1) PIVOT SEAT
Install the rocker arm and lock nut to a new adjusting screw.
Install the socket attachment to the lock nut and install the
adjsuting screw to the pivot seat, tapping the attachment
gently with a soft hammer and keeping vertical against the
pivot seat.
Temporarily set the rocker arm on the adjusting screw by mea-

suring height from the top of the screw and seat of the lock
nut.
TEMPORARITV SETTING: 7 mm (0.3 in) from the seat
(1) SOCKET ATTACHMENT
CYLINDER HEAD REMOVAL

- carburetor (page 4-3)
- exhaust system (page 12-7)
- camshaft (page 7-3)
Drain the coolant from the cooling system (page5-2).

Drain the oil from the engine (page 2-3).
Remove the water pipes from the cylinder head.
Remove the ignition coils/thermostat housing bracket.
7-7
CYLINDER HEAD/VALVE
Remove the oil pipes from the engine.

Disconnect the lower radiator hose from the water pipe.
Remove the rubber heat protectors.
Remove the radiator lower mounting bracket.
Place a floor jack or other adjustable support under the engine.
Remove the engine hanger bolts except the rear upper one.
Loosen the drive chain adjusters all the way (page 3-12).
Loosen the adjuster.

Loosen the rear upper engine hanger bolt.
Raise the engine onto the frame by pivoting it from the rear
upper engine hunger bolt.
Remove the four bolts mounting the cam chain tensioner.
7-8
CYLINDER HEAD/VALVE
Remove the cam chain tensioner from the cylinder head. (2) PINS AND CLIPS
Remove the clips and from the tensioner.
OTE
• Use care when removing the clips and pins to prevent them
from falling into the crankcase.
Place a piece of wire through the cam chain. Tie it so the chain
does not fall into the crankcase.
Separate the tensioner body and slider and remove them.
Loosen the cylinder bolt.

Remove the cylinder head mounting bolts, nuts, washers, and
spacers.
NOTE
Loosen the nuts in 2-3 steps in a crisscross pattern to pre-
vent cylinder head warpage.
Raise the cylinder head a little and pry off the cam chain slider
from the cylinder grooves.
Remove the cylinder head from the cylinder.
Remove the gasket and dowel pins.
r----
CAM CHAIN GUIDE AND TENSIONER

NSPECTION
Inspect the cam chain guide and tensioner for damage or ex-
cessive wear.
Inspect the cam chain tensioner slipper for damage or exces-

sive wear.
7-9
CYLINDER HEAD/VALVE
Turn the tensioner body upside down and drain the oil from the (2) SPRING
(1 l TENSIONER ARM
chamber.
Drain the oil from the plunger by moving the tensioner arm
slowly as shown.
Check the spring tension by moving the tensioner arm.

Replace the tensioner body if necessary.
Fill up the oil chamber with oil. (1 l TENSIONER ARM

Fill up oil to the plunger by moving the tensioner arm slowly.
The tensioner is good, if the arm locks w hen· you try to move it
quickly.
After inspection, drain the oil from the chamber and plunger.
(2) OIL CHAMBER
CYLINDER HEAD DISASSEMBLY

Remove the carburetor insulators.
Remove the rocker arms or adjusting screws in the four cor

ners of the cylinder head.
7-10
CYLINDER HEAD/VAl VE
Remove the valve cotters, retainers, springs, spring seats,

stem seals and valves using a valve spring compressor.
TOOL:
CAUTION
To prevent loss of tension, do not compress the valve springs
more than necessary to remove the cotters.
Remove the valve spring compressor large spring retainer
before using to avoid damaging the cylinder head.
OTE
• Mark all disassembled parts to ensure correct reassembly.
INSPECTION
Cylinder Head
Remove carbon deposits from the combustion chamber
OTE
• Avoid damaging the gasket surfaces.
Check the spark plug holes and valve areas for cracks.
Check the cylinder head for warpage with a straight edge and
a feeler gauge in an 'X'pattern.
Valve Spring Free Length

Measure the free length of the inner and outer valve springs.
SERVICE LIMITS:
INNER SPRING: 41.8 mm (1.65 in)
OUTER SPRING: 45.7 mm (1.80 in)
Replace them if they are shorter than the service limit.

-
Valve Stem-To-Guide Clearance
Clean all intake and exhaust valves thoroughly to remove
carbon deposits.
Inspect each valve for bending, or abnormal stem wear.
Measure and record the O.D. of each valve stem.
SERVICE LIMITS:
Intake: 5.47 mm (0.215 in)
Exhaust: 5.45 mm (0.215 in)
7-11
CYLINDER HEAD/VALVE
Run the proper reamer through the guides to remove carbon (1I VALVE GUIDE
deposits. REAMER, 5.5 mm
TOOL:
Valve guide reamer, 5.5 mm 07984-200000A
(U.S.A. only)
or 07984-2000008
(U.S.A. only)
Measure and record the l.D.of each valve guide.
SERVICE LIMIT: 5.55 mm I0.219 in)
Calculate the valve stem-to-guide clearance.
SERVICE LIMIT:
Intake: 0.07 mm I0.003 in)
Exhaust: 0.09 mm I0.004 in)
If the stem-to-guide clearance exceeds the service limits, de

termine if a new guide would bring the clearance within toler
ance. If so, replace any guides as necessary and ream to fit.
If clearance is still over the service limit, replace the valves.
VALVE GUIDE REPLACEMENT

(1) VALVE GUIDE DRIVER.
NOTE 5.5 mm
•
Reface the valve seats whenever the valve guides are re
placed.
Heat the cylinder head to 100-150°C (212-302°F) with a

hot plate or oven.
CAUTION
•
Do not use a torch to heat the cylinder, it may cause warping.
•
To avoid burns, wear heavy gloves when handling the heated (2) VALVE
cylinder head. GUIDE
Support the cylinder head and drive out the old guides from the
combustion chamber side of the cylinder head. (21 DEPTH
TOOL:
Valve guide driver, 5.5 mm 07742-0010100
Adjust the tool setting depth with a pair of vernier calipers as

shown.
c
DEPTH (HEIGHT OF THE VALVE GUIDE): 18 mm (0.7 in)
TOOL:
f
(1 I ADJUSTABLE VALVE
GUIDE DRIVER
Adjustable valve guide driver 07743-0020000-Not
available in U.S.A.
7-12
CYLINDER HEAD/VALVE
Drive new guides in from the rocker arm side of the cylinder (1 l ADJUSTABLE VALVE
head. GUIDE DRIVER
TOOL:
Adjustable valve guide driver 077 43- 0020000- Not
available in U.S.A.
OTE
Cylinder head heat should still be at 1 00-150° C (21 2-
3020 F)for installation of the new guides.
Install the new valve guide using the valve guide driver, 5.5
mm (07742-0010100). Also check the valve guide height
(see page 7-12) using vernier calipers (U.S.A. only) (2) VALVE GUIDE
Let the cylinder head cool to room temperature and ream the
new valve guides.
TOOL:
Valve guide reamer, 5.5 mm 07984-200000A
(U.S.A. only)
or 07984-2000008
(U.S.A. only)
NOTE
• Rotate the reamer in the same direction when inserting and
removing.
Reface the valve seats and clean the cylinder head thoroughly
to remove any metal particles.
VALVE SEAT INSPECTION/REFACING

Clean all intake and exhaust valves thoroughly to remove
carbon deposits.
Apply a light coating of valve Prussian blue to each valve face.
Lap each valve and seat using a rubber hose or other
handlapping tool.
Remove the valve and inspect the face.
CAUTION
• The valves can not be ground. If the valve face is rough, worn
unevenly, or contacts the seat improperly, the valve must be re-
placed.
Inspect the valve seat width.

(1) VALVE SEAT
STANDARD: 0.9-1.1 mm (0.035-0.043 in) WIDTH
If the seat is too ·wide, too narrow, or has low spots, the seat
must be ground.
7-13
CYLINDER HEAD/VAlVE
Honda Valve Seat Cutters, grinder or equivalent valve seat

refacing equipment is recommended to correct a worn valve ( 1 I SEAT CUTTER
seat.
NOTE
•
Follow the refacer manufacture' s operating instructions.
I,____,�0o
_
\��/_\
(2) FLAT CUTTER (31 INTERIOR CUTTER
Use a 45 degree cutter to remove any roughness or irregulari

ties from the seat.
NOTE
•
Reface the seat with a 45 degree cutter when the valve
guide is replaced.
Use a 32 degree flat cutter remove 114 of the existing valve

seat material.
Use a 60 degree interior cutter to remove the bottom 114 of

the old seat. Remove the cutter and inspect the area.
Install a 45 degree seat cutter and cut the seat to the proper
width.
STANDARD: 0.9-1.1 mm (0.035-0.043 in)
7-14
CYLINDER HEAD/V Al VE
Apply a thin coating of Prussian Blue to the valve seat.
Press the valve through the valve guide and onto the seat to
make a clear pattern.
OTE
• The location of the valve seat in relation to the valve face is
very important for good sealing.
If the contact area is too high on the valve, the seat must be (1) CONTACT TOO HIGH
lowered using the 32 degee flat cutter.
If the contact area is too low on the valve, the seat must be
raised using a 60 degree interior cutter.
( 1) CONT ACT TOO LOW
Refinish the seat to specifications, using a 45 degree seat cut-

ter.
After cutting the seat, apply lapping compound to the valve

face, and lap the valve using light pressure.
After lapping, wash all residual compound off the cylinder

head and valve.
CYLINDER HEAD ASSEMBLY (1) VALVE
Clean the cylinder head assembly with solvent and blow ' (31 INNER
through all oil passages with compressed air. SPRING
Install new valve stem seals.
Lubricate each valve stem with molybdenum disulfide grease

and insert the valve into the valve guide.
. / 00 II (4) OUTER
(5)
SPRING
COTTERS
..~
NOTE (8)
OUTER
/~ #
To avoid damage to the stem seal, turn the valve slowly SPRING (7) (6) /
when inserting. SEAT STEM SEAL RETAINER
7-15
CYLINDER HEAD/VAl VE
Install the valve springs and retainers. 11 I VALVE SPRING

COMPRESSOR
NOTE
•
Install the valve springs with the tightly wound coils facing
the cylinder head.
Install the valve cotters.
TOOL:
CAUTION
•
To prevent loss of tension, do not compress the valve spring
more than necessary to install the valve cotters.
Tap the valve stems gently with a soft hammer to firmly seat
the cotters.
NOTE
•
Support the cylinder head above the work bench surface to
prevent possible valve damage.
Install the valve adjusting screws in the four corner of the cyl (1 I ROCKER ARMS
inder head following replacement procedure (page 7-6).
Apply molybdenum disulfide grease to the rocker arm pivots

and slipper surfaces.
Install the carburetor insulators. (1) PINS (2) ---= SCREW HEAD
LOCATION
(3) INSULATORS
7-16
CYLINDER HEAD/VALVE
CYLINDER HEAD INSTALLATION (1) DOWEL PINS
Install the dowel pins and a new gasket.
Install the cam chain guide.
Pull the cam chain slider slightly and push it backward, then ( 1) CYLINDER HEAD
~\
lower the cylinder head.
Set the cam chain slider properly and set the cylinder head.
1
Tighten the 12 cylinder head nuts in the sequence shown.
NOTE
• Apply oil to the threads of the cylinder studs.
• Spacers are used at four studs of both side.
Tighten the cylinder head socket bolts.
Tighten the cylinder bolt.
Install the engine hanger bolts.
Install the rubber heat protectors securely.
1-11
CYLINDER HEAD/VALVE
Tighten the rear upper engine hanger adjuster and lock nut.
( 1) ADJUSTER (2) LOCK NUT
TORQUE: Lock nut: 25 N·m (2.5 kg-m, 18 ft-lb)

Adjuster : 8 N•m 10.8 kg-m, 6 ft-lb)
Tighten the engine hanger bolts to the specified torque.
TORQUE: 12 mm: 60 N•m (6.0 kg-m, 43 ft-lb)

10 mm: 45 N•m (4.5 kg-m, 33 ft-lb)
Install the radiator lower mounting bracket.
Install the oil pipes applying oil to the 0-rings.

Tighten the oil pipe bolts to the specified torque.
Connect the lower radiator hose to the water pipe.
(3) BOLTS (2) HOSE
Install the ignition coils/thermostat housing bracket.
7-18
CYLINDER HEAD/V Al VE
Install the water pipes applying oil to the 0-rings.
Install the following:

- exhaust system (page 12-8)
- carburetor (page 4-16).
Fill the crankcase with the recommended oil (page 2-1).
Fill the cooling system (page 5-3).
Put the cam chain over the tensioner body and install the ten- (2) PINS AND
sioner slider with the clips and pins as shown. CLIPS
NOTE
• Be careful not to drop the pins and clips into the crankcase.
Tighten the cam chain tensioner with the four bolts. (2) BOLTS
CAMSHAFT INSTALLATION
Install the dowel pins and rocker arm holders.
(31 HOLDER
Install the rocker arm springs and tighten the bolts securely.
7-19
CYLINDER HEAD/V AlVE
Turn the crankshaft counterclockwise and align the index

mark on the rotor with the "T" mark on the crankcase.
NOTE (1 I "IN" MARK

•
The camshaft has an "IN" mark for intake, or an "EX"mark
for exhaust.
Install the dowel pins and 0-rings.
Apply molybdenum disulfide grease to the journals of the cam

shaft and cylinder head.
Position the cam sprockets onto the camshaft with the timing
marks facing left of the engine.
Place the intake and exhaust camshaft onto the cylinder head
facing. "IN" and "EX" marks up.
Apply molybdenum disulfide grease to the journal of the hold

ers .
Install each camshaft holder on its original position.
NOTE
•
The camshaft holders have their location marks.
"INR" mark: Intake right
"INL" mark: Intake left
"EXR" mark: Exhaust right
"EXL" mark: Exhaust left
Tighten the camshaft holder bolts to the specified torque in a

crisscross pattern in 2-3 steps.
UP marks on the sprockets should face upward as shown.
Align the "IN" marks on the intake cam sprocket and

"EX"mark on the exhaust cam sprocket with the cylinder
head upper surface.
Place the cam chain over the cam sprockets.
Install the exhaust cam sprocket onto the exhaust camshaft
shoulder.
7-20
CYLINDER HEAD/VALVE
Install the intake cam sprocket onto the intake camshaft flange
shoulder while depressing the cam chain tensioner arm with a
screwdriver.
NOTE
• Make sure that the cam chain is engaged on the sprocket of
the crankshaft.
Make sure "IN" mark on the intake cam sprocket and "EX" (1) ''UP" MARKSIBOLTS
mark on the exhaust cam sprocket with the cylinder head
upper surface.
Apply a locking agent to the threads of the sprocket bolts.
(See page 1-5)
Align the cam sprocket bolt holes by turning the crankshaft
slightly counterclockwise and install the cam sprocket bolts.
Tighten the "UP" mark side sprocket bolts first, then tighten
the other them.
TORQUE: 17 N•m ( 1. 7 kg-m, 12 ft-lb)
Realign the index mark on the pulse generator rotor with the
"T"mark on the crankcase.
Make sure that the "IN"and "EX"marks on the sprockets
align with the cylinder head upper surface.
Fill the cam chain tensioner oil chamber with clean engine oil.
7-21
CYLINDER HEAD/VALVE
Install the cam chain guide.
Adjust the valve clearance (page 3-7).
Apply the 3 - Bond sealant or its equivalent to the cylinder 5-10 mm (0.2-0.4 in)
1 _ 1/1 r
head as shown.
/ .�� I
;' ,
II r;-
-- -- �,
Install the cylinder head cover and tighten the bolts to the
specified torque.
NOTE
• Tighten the forward outside bolts first then tighten the

other bolts.
•
Do not damage the cylinder head cover gasket.
•
Note the direction of the washer.
Connect the spark plug caps.

Connect the cylinder head cover breather tube and secure it by
a clip.
Connect the choke cable and throttle cables to the carburetor.
Adjust the following:

- throttle grip free play (page 3-41
- carburetor choke (page 3-5)
Install the fuel tank (page 4-3).

Install both side fairings (page 12-4).
7-22
MEMO
CYLINDER/PISTON
8-0
8. CYLINDER/PISTON
SERVICE INFORMATION 8-1 PISTON REMOVAL 8-4
TROUBLESHOOTING 8-2 PISTON INSTALLATION 8-5
CYLINDER REMOVAL 8-3 CYLINDER INSTALLATION 8-6
SERVICE INFORMATION
GENERAL
• All cylinder/piston maintenance and inspection can be accomplished without removing the engine from the frame.
SPECIFICATIONS
unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder l.D. 77 .000- 77.010 (3.0315-3.0319) 77.10 (3.035)

Taper -- 0.05 (0.002)
Out-of-round -- 0.05 (0.002)
Warpage -- 0.07 (0.003)
Piston, Piston ring-to-ring TOP/
0.01 5-0.045 (0.0006-0.0018) 0. 10 (0.004)
piston rings groove clearance SECOND
and piston Ring end gap TOP/
pin 0.320-0.470 (0.0126-0.0185) 0.65 (0.026)
SECOND
OIL
0.300-0.900 (0.0118-0.0354) 1. 10 (0.043)
(SIDE RAIL)
Piston 0.D. 76.960-76.990 (3.0299-3.0311) 76.86 (3.026)
Piston pin bore 20.002-20.008 (0.7875-0.7877) 20.06 (0. 790)
Connecting rod small end l.D. 20.016-20.034 (0.7880-0.7887) 20.08 (0. 791)
Piston pin 0.D. 19.994-20.000 (0.7872-0. 7874) 19.98 (0. 787)
Piston-to-piston pin clearance 0.002-0.014 (0.0001-0.0006) 0.04 (0.002)
Connecting rod-to-piston pin
0.016-0.040 (0.0006-0.0016) 0.06 (0.002)
clearance
Oylinder-to-piston clearance 0.010-0.050 (0.0004-0.0020) 0. 10 (0.004)
TOOLS
Special
Piston base (2 required) 07958-2500001
Piston ring compressor (2 required) 07954-2830000
8-1
CYLINDER/PISTON
TROUBLESHOOTING
Compression low Overheating
•
Worn cylinder or piston rings •
Excessive carbon build-up on the piston or combustion
•
Leaking valve seats chamber wall
•
Incorrect spark plug
Excessive smoke
•
Worn cylinder or piston Knocking or abnormal noise
•
Improper installation of piston rings •
Worn piston and cylinder
•
Scored or scratched piston or cylinder wall •
Excessive carbon build-up
•
Low octane fuel
8-2
CVLI NDER/PISTON
CYLINDER REMOVAL ( 1) CYLINDER (2) WATER PIPE
Remove the cylinder head (Section 7).
Remove the water pipe from the cylinder.

Remove the cylinder bolt and cylinder.
Inspect the top of the cylinder for warpage.Check in an X pat-

tern as shown.
Inspect the cylinder walls for scratches and wear.
Measure and record the cylinder l.D. at three levels in both an

X and Y axis. Take the maximum reading to determine the cyl-
inder wear.
SERVICE LIMIT: 77 .10 mm (3.035 in)
Calculate the piston-to-cylinder clearance. Take the maximum

reading to determine the clearance.
Refer to page 8-4 for measurement ·piston O.D.
Calculate the cylinder for taper at three levels in an X and Y

axis. Take the maximum reading to determine the taper.
Calculate the cylinder for out-of-round at three levels in an X

and Y axis. Take the maximum reading to determine the out-
(1) IN O Q (2) EX
of-round. (3) TOP

(4) MIDDLE
The cylinder must be rebored and an oversize piston fitted if

the service limits are exceeded.
The following oversize pistons are available:
0.25 mm (0.010 in) and 0.50 mm (0.020 in)
The cylinder must be rebored so that the clearance to an over-
size piston is 0.010-0.050 mm (0.0004-0.0020 in)
8-3
CYLINDER/PISTON
PISTON REMOVAL
Place rags in the crankcase openings.
Remove each piston pin clip with needle nose pliers being care
ful not to allow clips to fall into the crankcase.
Press the piston pins out.
Mark each piston to indicate its cylinder position for re

assembly.
Remove the piston rings and mark them to indicate the correct
cylinder and piston position.
Inspect the piston sliding surfaces for abnormal wear or dam ( 1 ) PISTON RING
I
age.
Inspect the piston for cracks or other damage and the ring
grooves for excessive wear and carbon build-up.
Clean the piston crown, removing all carbon deposits.
Measure the piston ring-to-groove clearance.
SERVICE LIMIT ITop/Secondl: 0.10 mm I0.004 in)
Measure and record the piston 0.0.at a point 10 mm (0.4 in)

from the bottom, and 90° to the piston pin bore.
Using a piston, push the ring into the cylinder squarely and (11 PISTON RING
measure the end gap.
SERVICE LIMITS:
Top: 0.65 mm 10.026 in)
Second: 0.65 mm 10.026 in)
Oil lside rail) : 1.10 mm 10.043 in)
If the gap exceeds the service limit, measure the cylinder 1.0.
Replace the piston ring if the cylinder 1.0. is within specifica
tion.
8-4
CYLINDER/PISTON
Measure each piston pin hole l.D.
--
Measure each piston pin O.D.

--
Calculate the piston pin-to-piston clearance.

-
Measure the connecting rod small end l.D.lf the reading ex-
ceeds the service limit, replace the rod.
Connecting rod removal (Section 111.
Calculate the piston pin-to-connecting rod clearance.
PISTON INSTALLATION
Clean the piston domes, ring lands, and skirts.
Carefully install the piston rings onto the piston and stagger (11 MARK
~-~TOP
the ring end gaps as shown.
NOTE
• Be careful not to damage the piston and piston rings during
assembly.
-
• All rings should be installed with the marks facing up.
After installing the rings they should rotate freely, without
sticking.
... ~(3)
SECOND
(41 SIDE RAIL .._____C

(51 SPACER
(6) GAP
8-5
CYLINDER/PISTON
Apply oil to the connecting rod small ends and piston pins.
Install the pistons, piston pins and clips. Be careful not to drop
clips into the crankcase.
NOTE
• Position the "IN"mark on the piston crown toward the

intake side.
•
Install the pistons in their original positions.
CYLINDER INSTALLATION
Apply oil to the cylinder walls and pistons.
Position the N0.1 and N0.4 pistons at T.D.C.

Insert the piston bases under the pistons and attach piston ring
compressors to the NO. 1 and N0.4 pistons.
TOOLS:
Piston base 07958-2500001
Piston ring compressor 07954-2830000
Slide the cylinder over the pistons.

Remove the piston bases and compressors.
Install the dowel pins.
Attach the piston ring compressors to the N0.2 and N0.3 pis
tons and slide the cylinder over the pistons.
Install the water pipe to the cylinder applying a small amount

of oil to the 0-rings.
Tighten the water pipe bolts securely.
Install the cylinder head (Section 7)
Tighten the cylinder bolt securely.
8-6
CLUTCH
90 N•m (9 0 kg-m, 65 ft-lb)

·
9-0
9.CLUTCH
SERVICE INFORMATION 9-1 CLUTCH SLAVE CYLINDER 9-7
TROUBLESHOOTING 9-2 CLUTCH DISASSEMBLY 9-9
CLUTCH FLUID REPLACEMENT/ CLUTCH ASSEMBLY 9-12
AIR BLEEDING 9-3
CLUTCH MASTER CYLINDER 9-4
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the clutch hydraulic system and the clutch.
• DOT4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in the section. Do not use other types of
fluid as they are not compatible.
• Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic, and
rubber parts by covering them with a rag. If fluid does get on these parts, wipe it off with a clean cloth.
• Clutch maintenance can be done with the engine in the frame.
• To keep slave cylinder piston from being forced out of the cylinder, squeeze the clutch lever and tie it to the handlebar grip.
• Clutch maintenance can be done with engine in the frame. EJ
SPECIFICATIONS
unit: mm (in)

Clutch master cylinder Cylinder l.D. 14.000-14.043 (0.5512-0.5529) 14.06 (0.554)
Piston O.D. 13.957-13.984 (0.5495-0.5506) 13.94 (0.549)
Clutch slave cylinder Cylinder l.D. 35. 700-35.762 (1.4055-1.4080) 35.78 (1.409)
Piston O.D. 35.650-35.672 (1.4035-1.4044) 35.63 (1.403)
Clutch Spring free length 46.70 (1.839) 46.0 (1.81)
Disc thickness A 3.42-3.58 (0.135-0.141) 3.1 (0.12)
B 3.72-3.88 (0.146-0.153) 3.1 (0.12)
Plate warpage
. -- 0.30 (0.012)
Outer l.D. 47.005-47.030 (1.8506-1.8516) 47.10 (1.854)
Outer guide l.D. 27.995-28.012 (1.1022-1.1028) 28.08 (1.106)
Mainshaft O.D. 27.980-27.993 (1.1016-1.1021) 27.97 (1.101)
TORQUE VALUES
Clutch master cylinder bolt 12 N·m ( 1.2 kg-m, 9 ft-lb)

Clutch hose oil bolt 30 N•m (3.0 kg-m, 22 ft-lb)
Clutch lock nut 90 N•m (9.0 kg-m, 65 ft-lb)
Bleed valve 9 N•m (0.9 kg-m, 7 ft-lb)
Clutch lever pivot nut 6 N·m (0.6 kg-m, 4.3 ft-lb)
Clutch switch screw 1.2 N·m (0.12 kg-m, 0.9 ft-lb)
9-1
CLUTCH
TOOL
Special
Snap ring pliers 07914-3230001-Equivalent commercially available in U. S. A.
Common
Look nut wrench, 30 x 32 mm
Extension bar
07716-0020400
07716-0020500
3- Equivalent commercially available in U. S. A.
Clutch center holder 07724-0050001
Attachment, 32 x 35 m m 07746-0010100
Pilot, 1 7 mm 07746-0040400
Driver 07749-0010000
TROUBLESHOOTING
Clutch lever soft or spongy Motorcycle creeps with clutch disengaged
Air bubbles in hydraulic system •
Air bubbles in hydraulic system
Low fluid level • Low fluid level
Hydraulic system leaking •
Hydraulic system leaking
•
Plates warped
Clutch lever too hard
•
Sticking piston(s) Excessive lever pressure
• Clogged hydraulic system •
Lifter mechanism damaged
Lifter plate bearing damaged
Clutch slips - Clutch push rod bent
•
Discs worn
•
Spring weak Clutch operation feels rough
•
Hydraulic system sticking •
Outer drum slots rough
• Sticking piston(s)
Clutch will not disengage
•
Air bubbles in hydraulic system
•
Low fluid level
•
Hydraulic system leaking
•
Plates warped
9-2
CLUTCH
CLUTCH FLUID REPLACEMENTI

Al R BLEED ING
Check the fluid level with the fluid reservoir parallel to the
ground.
CAUTION
• Do not remove the cover until the handlebar has been turned so
• A void spilling fluid on painted, plastic, or rubber parts. Place a
CLUTCH FLUID DRAINING
Remove the left side fairing (page 12-2).

Remove the reservoir cover.
Connect a bleed hose to the bleed valve.
Loosen the slave cylinder bleed valve and pump the clutch
lever.
Stop operating the lever when no fluid flows out of the bleed
valve.
CLUTCH FLUID FILLING
Connect the Brake Bleeder to the bleed valve.

Pump the Brake Bleeder and loosen the bleed valve.
Add clutch fluid when the fluid level in the master cylinder res-
ervoir is low.
Repeat above procedure until air bubbles do not appear in the

bleed hose.
NOTE
• If air is entering the bleeder from around the bleed valve (1) BRAKE BLEEDER
threads, seal the threads with teflon tape. (COMMERCIALLY AVAILABLE)
If the Brake Bleeder is not available, fill the system as follows:

Close the bleed valve, fill the reservoir, and install the dia-
phragm.
Pump up the system pressure with the lever until there are no
air bubbles in the fluid flowing out of the reservoir small hole
and lever resistance is felt.
Then bleed the system.
9-3
CLUTCH
AIR BLEEDING
NOTE
•
Check the clutch fluid level often while bleeding the clutch
to prevent air from being pumped into the system.
1) Squeeze the clutch lever, open the bleed valve 1 /2 turn

then close the valve.
NOTE
•
Do not release the clutch lever until the bleed valve has
been closed.
2) Release the clutch lever slowly and wait several seconds

after it is fully released, before repeating the procedure.
Repeat the above procedures until bubbles no longer appear at

the end of the hose.
Tighten the bleed valve.
TORQUE: 9 N•m 10.9 kg-m, 7 ft-lbl
Fill the brake fluid !DOT 41 reservoir to the upper level.
CLUTCH MASTER CYLINDER

DISASSEMBLY
Drain clutch fluid from the hydraulic system.

Disconnect the clutch switch wires, and remove the clutch
hose bolt and two sealing washers.
CAUTION
•
Cover the end of the hose with a clean rag to prevent contami
nation of the system. Then secure the hose to the handlebar.
Remove the master cylinder from the handlebars. (11 CLUTCH SWITCH
Remove the lever, boot and clutch switch
(3) BOOT
9-4
CLUTCH
Remove the circlip from the master cylinder body. (1 l CIRCLIP
TOOL:
Snap ring pliers 07914-3230001 or
equivalent commercially
available in U.S.A.
(2)
SNAP RING PLIERS
Remove the washer, piston/secondary cup, primary cup and (1 l SPRING (2) PRIMARY CUP
~
spring from the master cylinder body.
Check the primary cup and secondary cup for wear, damage or
deterioration.
(6) SECONDARY
CUP
/
(5)
WASHER
/
t'
i, 7
(4)
CIRCLIP
MASTER CYLINDER LO.INSPECTION
Check the master cylinder for scores or nicks.

Measure the master cylinder l.D.
MASTER PISTON 0.0. INSPECTION
Measure the master piston O.D.
9-5
CLUTCH
ASSEMBLY I 11 SPRING 121 PRIMARY CUP
� /I /
f3)PISTON
CAUTION
•
Replace the master poston, spring, primary cup and secondary
cup as a set.
WASHER
Coat the primary and secondary cups with clean brake fluid
before assembly.
I
Install the spring, primary cup and piston.
{
I
CAUTION
c)
When installing the cups, do not allow the lips to turn inside
161 SECONDARY /
•
CUP 151 CIRCLIP
out.
111 CIRCLIP
Install the circlip making sure it is seated firmly in the groove.
TOOL:
available in U.S.A.
Install the boot and lever.

I 1 l SCREW 121 CLUTCH SWITCH
\/
Tighten the pivot nut to the specified torque.
TORQUE: 6 N•m 10.6 kg-m, 4.3 ft-lb)
Install the clutch switch and tighten the screw to the specified
torque.
TORQUE: 1.2 N·m 10.12 kg-m, 0.9 ft-lb)
(51 BOOT (41 NUT
Place the master cylinder on the handlebar and install the

holder with the "UP" mark facing up. (11 PUNCH (2) MASTER
Align the end of the holder with the handlebar punch mark. MARK CYLINDER
Tighten the upper holder mounting bolt first. then tighten the
lower bolt.
�-.....
TORQUE: 12 N•m I 1.2 kg-m, 9 ft-lb)
Install the clutch hose with the bolt and the two sealing wash
ers.
Connect the clutch switch wires to the switch terminals.

Fill the reservoir and bleed the clutch system (page 9-3).
9-6
CLUTCH
CLUTCH SLAVE CYLINDER

DISASSEMBLY

Place a container under the slave cylinder, remove the hose
bolt and disconnect the clutch hose.
CAUTION
Remove the slave cylinder.
Remove the piston from the cylinder. If piston removal is hard,

place a shop towel over the piston to cushion the piston when
it is expelled, and position the cylinder with the piston down.
Apply compressed air to the fluid inlet to remove the piston.
Use the air in short spurts.
Remove the spring from the slave cylinder.

Check the piston spring for weakness or damage.
Inspect the oil and piston seals for damage or deterioration.
Remove the oil and piston seals.
Clean the piston groove with brake fluid.
(4) OIL SEAL (3) PISTON
PISTON O.D. INSPECTION
Check the piston for scoring or scratches.

Measure the outside diameter of the piston with a micrometer.
9-7
CLUTCH
CYLINDER l.D. INSPECTION
Check the slave cylinder for scoring or scratches.

Measure the inside diameter of the cylinder bore.
SERVICE LIMIT: 35.78 mm(1.409 inl
ASSEMBLY
(2) SPRING
Assemble the slave cylinder in the reverse order of disassem
I I
bly. The oil seals must be replaced with new ones whenever (3) PISTON SEAL
they have been removed.
4
(4) PISTON
Lubricate the piston and piston seal with a medium grade of Hi
Temperature silicone grease or brake fluid before assembly.
I
Be certain the piston seal is seated in the piston groove. Place
the piston in the cylinder with the seal end facing out.
Install the dowel pins and a new gasket.
Install the slave cylinder and tighten the bolts securely.

Connect the clutch hose with the hose bolt and the two seal
ing washers.
Fill the clutch fluid reservoir and bleed the clutch system (page
9-31.
9-8
CLUTCH
UTCH DISASSEMBLY
emove the right side fairing (page 12-2).
emove the clutch cover and heat protector.
Remove the gasket.
emove the clutch bolts, springs and clutch lifter plate.
Remove the lifter guide and clutch lifter rod.

Remove the clutch discs,plates, judder spring and spring seat.
nstake the lock nut.

Hold the clutch center with the clutch center holder.
iTOOL:
Clutch center holder 07724-0050001 or
available in U.S.A.
Remove the lock nut using lock nut wrench.

Discard the lock nut.
OOLS:
Lock nut wrench, 30 x 32 mm 07716-0020400 or
equivalent tool commer-
cially available in U.S.A.
Extension bar 07716-0020500 or
equivalent tool commer-
cially available in U.S.A.
Remove the lock washer and clutch center.
Pull the clutch outer guide out with needle nose pliers.
Remove the needle bearing.
9-9
CLUTCH
Remove the clutch outer until it clears the crankcase and

crankshaft.
Remove the washer.
INSPECTION
Clutch Plate
Check for plate warpage on a surface plate, using a feeler
gauge.
Clutch disc
Replace the clutch discs if they show signs of scoring or dis
coloration.
Measure the thickness of each disc.
SERVICE LIMIT: DISC A: 3.1 mm (0.12 in)

DISC B: 3.1 mm (0.12 in)
Replace any discs that are thinner than the service li mit.
Clutch spring
Measure the clutch spring free length.
Mainshaft
Measure the mainshaft 0.D.
SERCICE LIMIT: 27.97 mm (1.101 in)
( 1) CLUTCH SPRING
9-10
CLUTCH
Clutch outer guide (2) NEEDLE

Measure the l.D.of the clutch outer guide. BEARING
SERVICE LIMIT: 28.08 mm (1.106 in) ~

Clutch outer
Check the slots in the clutch outer for nicks,or indentations
made by the friction discs.
Measure the I. D.of the clutch outer.
SERVICE LIMIT: 4 7. 10 mm( 1 .854 in)

(3) CLUTCH
Check the clutch outer needle bearing for damage or excessive (4) CLUTCH OUTER OUTER GUIDE
play.
( 1 l LIFTER ROD
Check the clutch lifter rod for wear and trueness.
Judder spring/spring seat (1) JUDDER SPRING

Check the spring and seat for damage or warpage.
\
-
/
(2) SPRING SEAT
(1 l BEARING (2) DRIVER

Lifter plate bearing
Turn the inner race of the bearing with your finger. The bearing
should turn smoothly and quietly. Also check that the bearing
outer race fits tightly in the lifter plate.
Remove and discard the bearing if necessary.

Drive a new bearing into the lifter plate.
TOOLS:
Attachment, 32 x 35 mm 07746-0010100
Pilot, 17 mm 07746-0040400
Driver 07749-0010000
(3) ATTACHMENT AND
PILOT
9-11
CLUTCH
CLUTCH ASSEMBLY
Apply molybdenum disulfide grease to the primary driven gear.
Install the washer on the mainshaft.

Install the clutch outer on the mainshaft.
Engage the primary drive and driven gear and install the needle
bearing and clutch outer guide.
Install the clutch center and washer.
Hold the clutch center with the clutch center holder.
TOOL:
Clutch center holder 07724-0050001 or
available in U.S.A.
Install a new lock nut and tighten it.
NOTE
•
Never re-use the removed nut.
TOOLS:
Lock nut wrench. 30 x 32 mm 07716-0020400 or
available in U.S.A. (1) STAKE
available in U.S.A.
TORQUE: 90 N·m 19.0 kg-m, 65 ft-lb)
Stake the lock nut into the mainshaft end groove, as shown.
(2) 2.2-2.5 mm
(0.08-0.09 in)
Coat the discs, plates, spring seat and judder spring with clean
oil.
Install the spring seat, judder spring and clutch discs and
plates. (1) DISC B (2) SPRING (3) CLUTCH
18 pieces) SEAT CENTER
NOTE
•
Note the direction of the judder spring as shown.
11) DISC A
(5)
CLUTCH PLATE (4) JUDDER
131 JUDDER SPRING (1 l SPRING SEAT (8 pieces) (5) DISC A SPRING
9-12
CLUTCH
Apply grease into the lifter guide.

Install the clutch lifter rod and lifter guide.
Install the clutch lifter plate.

Tighten the clutch bolts in a crisscross pattern in 2 or 3 steps.
Apply 3-Bond sealant or its equivalent to the crankcase mating (1) GASKET 10-15 mm (0.4-0.6 in)
surfaces as shown. \
Install the clutch cover and heat protector, then tighten the
cover bolts in a crisscross pattern in 2 or 3 steps.
Clamp the neutral/oil pressure switch wire with two clamps.
Install the fairings (page 12-4).
9-13
18N•m (1 8k g-m. 13 ft-lb)

·
23 N•m (2.3 k g-m, 1 7 ft-lb)
10 N•m (1 . 0 kg-m, 7 ft-lb)
90 N·m (9 0 kg-m, 65 ft-lb)

·
10-0
10. GEARSHIFT LINKAGE/BALANCER
SERVICE INFORMATION 10-1 GEARSHIFT LINKAGE 10-2
TROUBLESHOOTING 10-1 BALANCER 10-8
SERVICE INFORMATION
GENERAL
• The gearshift linkage (including the shift drum, shift fork and fork shaft) and balancer can be removed with the engine in
the frame.
SPECIFICATIONS
unit: mm (in)
Shift fork Claw thickness 5.43-5.50 ( 0.214-0.217 ) 5.1 (0.20 )

Right and left fork l.D. 14.000-14.018 (0.5512-0.5519) 14.04 (0.553)
Fork shaft 0.D. 13.957-13.968 (0.5495-0.5499) 13.90 (0.547)
TORQUE VALUES
Center shift fork bolt 18 N•m ( 1.8 kg-m, 13 ft-lb)

Shift drum center pin bolt 23 N·m (2.3 kg-m, 17 ft-lb)-Apply a locking agent to the threads
Side stand bracket bolt 45 N·m (4.5 kg-m, 33 ft-lb)
Engine hanger bolt ( 1 2 mm) 60 N·m (6.0 kg-m, 43 ft-lb)
Drive sprocket bolt 90 N·m (9.0 kg-m, 65 ft-lb)
Gearshift pedal bolt 10 N•m ( 1 .0 kg-m, 7 ft-lb)
TROUBLESHOOTING
Hard to shift
Improper clutch operation
• Shift forks bent
• Fork shaft bent
• Fork claw bent
• Shift drum cam grooves damaged
• Shift spindle bent
Transmission jumps out gear

• Gear dogs worn
• Fork shaft bent
• Shift drum stopper broken
• Shift forks bent
• Broken shift linkage return spring
Excessive noise or vibration

• Improper balancer installation
• Improper balancer adjustment
10-1
GEARSHIFT LINKAGE
GEARSHIFT LINKAGE REMOVAL

Remove the clutch slave cylinder.
NOTE
•
Do not disconnect the clutch hose.
Remove the water pipe bolt.

Remove the water pump.
Loosen the lower engine hanger bolt and remove the side
stand bracket bolts.
Remove the gearshift pedal.
Remove the drive sprocket cover and dowel pins.
Remove the drive sprocket.

Remove the gearshift linkage cover and drive chain guide.
Check the oil seals and needle bearing for wear or damage.
Replace if necessary.
(2) OIL SEALS
10-2
Remove the following parts:

- shift spindle
- shift collar
- drum shifter plate and drum shifter
Remove the collar and stopper arm.
Remove the gearshift cam if necessary.
Disassemble the drum shifter.

Check the ratchet pawls, springs, plungers and body for wear
or damage.
Check the spindle and return spring for wear, damage or (1) SPINDLE
fatigue.
(2) RETURN SPRING
10-3
SHIFT FORKS AND SHIFT DRUM REMOVAL
Remove the oil pump (page 2-51.

Remove the clutch outer (page 9-9).
Remove the center shift fork bolt and lock washer.
Pull the shift fork shaft out.
Remove the shift drum bearing set plate and dowel pins and
pull the shift drum out.
Remove the shift forks.
Ill BEARING (2) GROOVES

Check the shift drum grooves for wear or damage.
\
Turn the outer race of drum bearing with your finger.
The bearing should turn smoothly and quietly. Also check that
the bearing inner race fits tightly on the drum.
Remove and discard the bearing if the race does not turn
smoothly, quietly, or if it fits loosely on the drum.
10-4
Check the shift fork shaft for scratches, scoring or evidence of

insufficient lubrication.
Measure the shift fork shaft 0. D. at right and left shift fork sur-
faces.
Measure the right and left shift fork l.D.
SERVICE LIMIT
l.D. (right and left fork): 14.04 mm (0.553 in)
Measure the shift fork claw thickness.
SERVICE LIMIT: 5. 1 mm (0.20 in)
( 1) "L" MARK
NOTE
• The shift forks have location marks.
"R" for right
"C" for center
"L" for left
(3) "C" MARK
SHIFT FORKS AND SHIFT DRUM INSTALLATION
Apply the molybdenum disulfide grease to shift fork grooves of

M3/M4, C5 and C6 gears.
Install the shift forks on the transmission.
Face the "R" mark on the right shift fork and "L" mark on the
left shift fork toward the drive sprocket side.
Face the "C" mark on the center shift fork toward the clutch
side.
Install the shift drum.

Set the bearing set plate and dowel pin.
Apply a locking agent to the threads of the set plate bolt.
NOTE
• Apply locking agent as shown.
5.5- 7 .5 mm (0.22-0.30 in)
10-5
Install the shift fork shaft.
Install a new lock washer and the bolt in the center shift fork
and tighten the bolt.
TORQUE: 18 N·m I 1 .8 kg-m, 13 ft-lb)
Bend up the lock washer's tabs.

Install the oil pump and oil pan (Section 21.
GEARSHIFT LINKAGE INSTALLATION
If you removed the gearshift cam, follow the procedures

below.
Install the dowel pin on the shift drum.
Install the gearshift cam aligning the cut-out on the cam with
pin on the drum.
Apply a locking agent to the threads of the pin bolt.

Tighten the center pin bolt to the specified torque.
TORQUE: 23 N•m (2.3 kg-m. 17 ft-lb)
Install the dowel pin.

Install the washer on the dowel pin.
Install the collar, stopper arm and return spring as an assembly
on the dowel pin.
10-6
Assemble the plungers, springs and shift pawls to the drum (1) PAWL (2) SHIFTER
shifter. BODY
lnstan the drum shifter on the shifter plate.
(5)
PLUNGER (3) PLATE
Install the drum shifter plate and tighten the bolts securely.
Assembly the gearshift spindle if disassembled.

Install the washer on the spindle.
Install the gearshift collar on the drum shifter.
Install the spindle aligning the hole on the plate with gearshift
collar and return spring with pin bolt on the crankcase.
Apply the 3-Bond sealant or its equivalent to the crankcase

mating surfaces as shown.
Install the dowel pins and a new gasket on the crankcase.

Apply grease to the oil seal lips on the gearshift linkage cover.
Install the gearshift linkage cover.
10-7
Install the drive chain guide.

Tighten the screws first and then bolts securely.
NOTE
• Install the cover bolt with sealing washer into the hole of in-
dicated the "6." mark on the cover.
• Apply a locking agent to the threads of the "*" mark bolt.
Install the drive sprocket and tighten the bolt to the specified
torque.
Install the drive sprocket cover and tighten the bolts securely.
Install the gearshift pedal.
Install the side stand bracket and tighten the bolts.
Tighten the lower engine hanger bolt.
Install the water pump and clutch slave cylinder.
(6)
BOLT
BALANCER
REMOVAL
Remove the oil pan (page 2-4).
Remove the bolts.

Pull the balancer shaft out and remove the balancer weight as-
sembly.
NOTE
• The balancer assembly will only come out from one particu-
lar position. Rotate it until it comes out easily; do not force
it out.
10-8
Disassemble the balancer weight and check all parts for wear,
damage or scoring.
INSPECTION
(6) COLLAR
(1) WEIGHT
(5) BEARING
'
(41 WASHER
NOTE
• Replace the weight, shaft and needle bearings as an as-
sembly.
Check the needle bearing sliding surfaces of the balancer

weight for wear, damage or excessive scratches.
(2) SLIDING SURFACES
Check the needle bearing sliding surfaces of the balancer shaft

for wear, damage or excessive scratches.
(2) SHAFT
Check the needle bearings for smooth operation or damage.
10-9
ASSEMBLY /INSTALLATION (3) WEIGHT
Apply oil to the dampers.
I
(6)
WASHER
Assemble the balancer weight aligning the index line on the ( 1 l PUNCH MARK (2) INDEX LINE
weight with punch mark on the gear.
Draw the aligning mark of the balancer weight inline with the
index mark as shown.
(1)MARKI\
(2) INDEX LINE

Rotate the crankshaft counterclockwise and align the index
mark on the pulse generator rotor with "T" mark on the crank-
case.
10-10
Apply oil to the balancer gear.

Install the weight aligning the mark on the weight with index
line on the crankcase.
Install an 0-ring on the shaft and apply a small amount of oil to

it.
Install the shaft tacing the l.D. code number forward.
Apply 3-Bond sealant or its equivalant to the threads of the

shaft holder bolt and tighten it securely.
Tighten the stopper bolts.
lnsatll the oil pan (page 2-5).
BACKLASH ADJUSTMENT
NOTE
• Adjust the backlash while the engine is cold (below 35°C/
95°F) and stopped.
Loosen the pinch bolt and turn the shaft counterclockwise up

to dead end and back off by one graduation.
Apply a locking agent to the threads of the pinch bolt and

tighten it securely.
10-11
TRANSMISSION/CRANKSHAFT
38 N•m (3.8 kg-m, 27 ft-lb) 27 N•m (2. 7 kg-m, 20 ft-lb)

Cloo...--:::::;;~
36 N•m (3.6 kg-m, 26 ft-lb)
~
~
0
50 N•m (5.0 kg-m, 36 ft-lb)
~27 N·m 12.7 kg·m, 20 ft·lb
40 N•m (4.0 kg-m, 29 ft-lb)
11-0
11. TRANSMISSION/CRANKSHAFT
SERVICE INFORMATION 11-1 CRANKSHAFT REMOVAL 11-11
TOUBLESHOOTING 11-2 CRANKSHAFT INSTALLATION 11-14
CRANKCASE SEPARATION 11-3 STARTER CLUTCH/ ALTERNA TOR
SHAFT INSTALLATION 11-15
TRANSMISSION DISASSEMBLY 11-3
OIL PASS PIPE PLATE/ALTERNATOR
DRIVE CHAIN TENSIONER
DRIVE CHAIN TENSIONER REMOVAL 11-5
INSTALLATION 11-16
CONNECTING ROD REMOVAL 11-6
TRANSMISSION ASSEMBLY 11-17
STARTER CLUTCH/ AL TERNA TOR
CRANKCASE ASSEMBLY 11-19
SHAFT REMOVAL 11-9
SERVICE INFORMATION
GENERAL
• For internal transmission repairs the crankcase must be separated.

• All bearing inserts are a select fit and are identified by color codes. Select replacement bearings from the code tables. After
insta lling new bearings, recheck them with plastigauge to verify clearance. Apply molybdenum disulfied grease to the main
journals and crankpins during assembly.
• The crankcase assembly must be separated to service the crankshaft, transmission and starter clutch.
e Refer to section 18 for starter system troubleshooting.
• The following parts must be removed before separating the crankcase.
m
For transmission service Oil pan/oil pump (Section 2)
Clutch (Section 9)
Gearshift linkage cover (Section 10)
I
Pulse generator (Section 17)
Right side crankshaft cover
For connecting rod service Oil pan/oil pump (Section 2)
Gearshift linkage cover (Section 1 0)
Clutch cover (Section 9)
' Pulse generator (Section 17)
Cylinder head (Section 7)
Cylinder/piston (Section 8)
For crankshaft service Oil pan/oil pump (Section 2)
Camshaft/cam chain tensioner (Section 7)
Pulse generator/rotor (Section 1 7)
Starter motor (Section 18)
For starter clutch/alternator services Oil pan/oil pump (Section 2)
Pulse generator (Section 1 7)
Starter motor (Section 18)
11-1
SPECIFICATIONS
unit: mm (in)
- • ITEM STANDARD SERVICE LIMIT
Transmission Gear l.D. M5, M6 31.000-31.016 (1.2205-1.2211) 31.04 (1.222)

C3, C4 33.000-33.016 (1.2992-1.2998) 33.04 (1.301)
Gear bushing O.D. M5, M6 30.955-30.980 (1.2187-1.2197) 30.93 (1.218)
C3,C4 32.955-32.980 (1.2974-1.2984) 32.93 (1.296)
Gear bushing l.D. M5 27.985-28.006 (1.1018-1.1026) 28.02 (1.103)
C3 29.985-30.006 (1.1805-1.1813) 30.02 (1.182)
Mainshaft O.D. M5 27.967-27.980 (1.1011-1.1016) 27.94 (1.100)
Countershaft O.D. C3 29.950-29.975 (1.1791-1.1801) 29.92 (1.178)
Gear-to-bushing M5, M6, C3, C4
0.020-0.061 (0.0008-0.0024) 0.10 (0.004)
or shaft clearance gear to bushing
M5 bushing
0.005-0.039 (0.0002-0.0015) 0.06 (0.002)
to shaft
C3 bushing to
0.005-0.056 (0.0002-0.0022) 0.06 (0.002)
shaft clearance
Crankshaft Connecting rod big end side clearance 0.05-0.25 (0.002-0.010) 0.3 (0.01)
Run out -- 0.03 (0.001)
Crankpin oil clearance 0.028-0.052 (0.0011 -0.0020) 0.08 (0.003)
Main journal oil clearance 0.021-0.045 (0.0008-0.0018) 0.08 (0.003)
TORQUE VALUES
Crankcase bolt ( 10 mm) 40 N•m (4.0 kg-m, 29 ft-lb)

(9 mm) 38 N•m (3.8 kg-m, 27 ft-lb)
(8 mm) 27 N•m (2. 7 kg-m, 20 ft-lb)J Apply molybdenum disulfide grease to the seat
(6 mm) 12 N•m (1.2 kg-m, 9 ft-lb) and threads
Connecting rod bearing cap nut 36 N•m (3.6 kg-m, 26 ft-lb)
Alternator chain tensioner bolt 12 N•m ( 1.2 kg-m, 9 ft-lbl----r-Apply locking agent to the threads
Alternator chain guide bolt 12 N•m (1.2 kg-m, 9 ft-lb)__J
Alternator shaft nut 50 N·m (5.0 kg-m, 36 ft-lb)
Alternator base bolt 29 N·m (2.9 kg-m, 21 ft-lb)-Apply 3-Bond sealant or its equivalent to the
Crankcase sealing bolt (20 mm) 30 N•m (3.0 kg-m, 22 ft-lb) threads
(10 mm) 12 N•m ( 1 .2 kg-m, 9 ft-lb)
Oil pump chain guide bolt 12 N•m ( 1 .2 kg-m, 9 ft-lb)-,- Apply locking agent to the threads
Oil pass pipe plate bolt 12 N•m ( 1 .2 kg-m, 9 ft-lb)__J
TOOLS
Common
Inner driver C 07746-0030100
Attachment, 30 mm l.D. 07746-0030300
TROUBLESHOOTING
Excessive noise Transmission jumps out of gear
• Worn main journal bearing • Gear dogs worn or damaged.
• Worn crank pin bearing
• Worn chain slider Hard to shift
• Faulty clutch system (clutch drag)
Excessive noise while engine starting • Incorrect engine oil weight
• Damaged damper
11-2
CRANKCASE SEPARATION
Remove the engine from the frame (Section 6).
Remove the necessary parts before disassembling the crank-
case (page 11-1 ).
If servicing the crankshaft or starter clutch/alternator, remove

the following:
- bolt, sealing washer and alternator shaft nut cover.
- alternator shaft nut.
Remove the three upper crankcase bolts.
Loosen the 8 mm bolts (with sealing washers) first, then

loosen the 10 mm bolt.
Turn the engine upside down and remove the crankcase lower
bolts.
0
Loosen the 6 mm bolts, loosen the 8 mm bolts and then loosen 0
9 mm bolts.
NOTE
• Loosen the bolts in 2- 3 steps and in a criss-cross pattern
to prevent case warpage.
Remove the lower crankcase from the upper crankcase.
CAUTION
• Do not pry between the upper and lower cases.
TRANSMISSION DISASSENBLY
Remove and disassemble the mainshaft and countershaft.
11-3
Remove the oil orifice and pin.
INSPECTION
Check the gear dogs, holes and teeth for excessive or

abnormal wear, or evidence of insufficient lubrication.
Measure the l.D. of eech gear.
SERVICE LIMITS:
MS. M6: 31.04 mm (1.222 in)
C3. C4: 33.04 mm (1.301 in)
Mesaure the l.D. and O.D. of each gear bushing.
SERVICE LIMITS:
MS, M6 bushings 0.0.: 30.93 mm (1.218 in)
C3. C4 bushings 0.0.: 32.93 mm (1.296 in)
MS bushing 1.0.: 28.02 mm (1.103 in)
C3bushing1.0.: 30.02 mm (1.182 in)
- --- -
Measure the O.D. of the mainshaft and countershaft. (1) M5
SERVICE LIMITS:
Mainshaft 0.0. (at MS bushingl: 27.94 mm (1.100 in)
Countershaft 0.0. (at C3 bushing): 29.92 mm (1.178 in)
Calculate the clearance between the gear bushing and the gear
or shaft.
SERVICE LIMITS:
MS, M6. C3, C4 gear
to bushing 0.10 mm (0.004 in)
MS bushing to shaft: 0.06 mm (0.002 in)
C3 bushing to shaft: 0.06 mm (0.002 in)
11-4
TRANSMISSION BEARING INSPECTION
Turn the races of each bearing with your finger.

Also check that the bearing inner race fits tightly on the shaft.
Remove and discard the mainshaft bearing if the race does not
turn smoothly, quietly, or if fits loosely on the mainshaft.
Replace the countershaft, collar bearing and C2 gear as an as-
sembly if the race does not turn smoothly, quietly, or if it fits
loosely on the countershaft.
NOTE
• Do not try to remove the countershaft bearing from the
countershaft. The bearing is pressed into the countershaft.
BEARING REPLACEMINT
NOTE
• Do not remove the countershaft bearing.
Press the mainshaft bearing out.
Press the new bearing onto the mainshaft. (1 l DRIVER
TOOLS:
Inner driver C 077 46- 00301 00
Attachment, 30 mm l.D. 07746-0030300

DRIVE CHAIN TENSIONER REMOVAL
Separate the crankcase (page 11-3).
Remove the transmission (page 11-3).
Unstake the tabs on the oil pass pipe plate.
CAUTION
• Unstake the tabs until should be able to remove the pass plate
bolts because tabs break easily.
Remove the three bolts, plate and 0-rings.
11-5
Check that the pass pipe plate for damage or clogging.
Remove the three bolts and chain tensioner.
Check the slider of the tensioner for wear and replace tension-
er assembly if necessary.
CONNECTING ROD REMOVAL

SIDE CLEARANCE INSPECTION

Check the connecting rod side clearances.
If either side clearance exceeds the service limit, replace the

rod. Recheck clearances.
If still beyond the limit, replace the crankshaft.
Inspect the crankshaft for rough spots damage.
11-6
REMOVAL (1) BOLT
CAUTION
• Do not interchange the bearing inserts. They must be installed
in their original positions or the correct bearing oil cleatance
may not be obtained causing engine damage.
NOTE
• Mark the connecting rods and bearing caps to indicate the
correct cylinder and position on the crankpins before re-
moval.
Remove the bearing cap nuts, bearing caps and connecting

rods.
CRANKPIN BEARING INSPECTION
Wipe all oil from the bearing inserts and crankpins.

Put a piece of plastigauge on each crankpin.
NOTE
Do not put the plastigauge over the oil hole in the crankpin.
• Do not rotate the crankshaft during inspection.
Install the bearing caps and rods on the correct crankpins, and
tighten them evenly.
Remove the caps and measure the compressed plastigauge on

each crankpin.
If the rod bearing clearance is beyond tolerance, select re-

placement bearings.
11-7
CRANKPIN BEARING SELECTION
Determine and record the corresponding rod l.D. code number.
I
(1) l.D. CODE NUMBER
Determine and record the corresponding crankpin 0.D. code

letter (or measure the crankpin 0.D.).
The letter A or B on the outside crankshaft weight is the code

for each crank pin 0.D. from left-to-right. In this example, the
0.D. code for the No.1 crankpin is "A".
Cross reference the crankpin and connecting rod codes to de-

termine the replacement bearing color.
CRANKPIN BEARING SELECTION TABLE
CRANKPIN 0.D. CODE LETTER .

A B
39.995-40.003 mm 39.987-39.994 mm
(1.57460-1.57492 in) (1.57429-1.57456 in)
CONNECTING ROD 43.000-43.007 mm
1 YELLOW GREEN
l.D.CODE NUMBER (1.69291-1.69318 in)
43.008-43.015 mm
2 GREEN BROWN
( 1 .69322-1 .69354 in)
BEARING INSERT THICKNESS:

Brown: 1.492-1.496 mm
(0.05874-0.05890 in)
Green: 1.488-1.491 mm
(0.05858-0.05870 in)
Yellow: 1 .484- 1.487 mm
(0.05843-0.05854 in)
( 1) COLOR CODES
11-8
CONNECTING ROD SELECTION
If a connecting rod requires replacement, you should select a

rod with the same weight code as the original. But if that is
unavailable, you may one of the others specified in the follow-
ing chart.
NOTE
• Do not assenble the connecting rods which differ two ranks
I
or more each other.
( 1) WEIGHT CODE
Code on original rod

(the rod you must re- ReplacemSnt
place). chaises
·~
A
B
c
===================~B
D
E
STARTER CLUTCH/ALTERNATOR
SHAFT REMOVAL
Remove the oil pass pipe plate and altenator drive chain ten-
sioner (page 11-5).
Remove the three alternator base bolts.
Pull the alternator base out and remove the starter damper,
collar.washer, starter clutch and alternator base.
11-9
AL TERNA OR INSPECTION
Turn the alternator shaft. The alternator shaft bearing should

turn smoothly and quietly. Also cheak that the bearing outer
race fits tightly in the case and the inner race fits tightly on the
shaft.
Check the inside of the alternator case for oil leaks.

Replace the alternator case, shaft and bearing as an assembly
if there are signs of leaks.
ST ARTER CLUTCH INSPECTION
Check the starter one-way clutch by turning the starter driven

gear.
The starter driven gear should turn counterclockwise freely
and should not turn clockwise.
Remove the starter driven gear and needle bearing, if replaced
starter clutch.
Install the needle bearing and the atarter driven gear and check
the one-way clutch operation.
DAMPER INSPECTION
Check the damper for wear or damage.
Check the cam lobes for damage indicated by noise during

engine starting.
11-10
ST ARTER DRIVE GEAR
Remove the bolt and retainer then pull the drive gear shaft out
and remove the starter drive gear.
Check the drive gear and shaft for wear, damage or scraches (1) GEAR
and replace if necessary.
ALTERNATOR SHAFT BEARING
Turn the inner race of the bearing with your finger. The bearing
should turn smoothly and quietly. Also check that the beaing
outer race fits in the crankcase.
Remove and discaed the bearing if the race does not turn
smoothly, quietly or if it fits very loosely in the crankcase.
The seal end of the bearing should face the inside.
If can not remove the bearing by hand, use the follow tools:
Removal:
Bearing remover, 17 mm 07936-3710300
Remover handle 07936-3710100
Remover weight 07741-0010201 or
07936-3710200
Installation:
Driver 07947-3710001
Attachment, 42 x 47 mm 07746-0010300
Pilot, 17 mm 07746-0040400 (1) OIL PUMP (2) CAM (3) ALTERNATOR
DRIVE CHAIN CHAIN DRIVE CHAIN
CRANKSHAFT REMOVAL
Remove the oil pass pipe plate and alternator drive chain ten-
sioner (page 11-5).
Remove the connecting rod (page 11-6).
Remove the starter clutch/alternator shaft (page 11-9).
Remove the crankshaft.

Remove the chains.
11-11
INSPECTION
Crankshaft Runout
Place the crankshaft on a stand or V-blocks
Set a dial indicator on the center main journal of the crank-
shaft. Rotate the crankshaft two revolutions and read runout
at the center journal.
MAIN BEARING INSPECTION (1 l BEARINGS
Inspect the main bearing inserts for damage or separation.
Inspect the bearing inserts for unusual wear or damage. ( 1 l PLASTIGAUGE

Reinstall the upper crankcase's main bearing inserts, then
carefully lower the crankshaft in place.
Wipe all oil from the bearing inserts and journals.
put a piece of plastigauge on each journal.
NOTE
• Do not put the plastigauge over the oil hole in the main bear-
ing journal of the crakshaft.
• Do not rotate the crakshaft during inspection
Assemble the crankcase halves.

Tighten the 9 mm bolts to the specified torque.
TORQUE: 38 N•m (3.8 kg-m. 27 If-lb)
Q
G Q
11-12
TRANS"'1!1SSION/CRANKSHAFT
Remove the lower crankcase and measure the compressed

plastigauge on each journal.
SERVICE LIMIT: 0.08 mm I0.003 inl
If main bearing clearance is beyond tolerance,select a replace-

ment bearing.
MAIN BEARING SELECTION
Determine and record crankcase l.D. cord letter on the upper

crankcase.
The letters A, B or C on the upper crankcasse are the codes for

the main journal l.D.'s from left-to-right. In this example, the
l.D. code for the right main journal is "B".
Determine and record the corresponding main journal O.D.

code numbers (or measure the main journal O.D.).
The numbers 1 or 2 on the crank weight are the codes for the
main journal O.D.'s from left-to-right. In this example, O.D.
code for the right main journal is "1 ".
Cross reference the crankcase and crank journal codes select

the correct replacement bearing.
MAIN BEARING SELECTION TABLE
~
CRANKCASE l.D. CODE LETTER
A B c
39.000-39.007 mm 39.00B-39.015 mm 39.016-39.024 mm
(1.53543-1.53571 in) (1.53574-1.53602 in) (1.53606-1.53638 in)
CRANKSHAFT 35.984-35.991 mm
1 PINK YELLOW GREEN
0.D. CODE (1.41669-1.41697 in)
NUMBER 35.992-36.000 mm
2 YELLOW GREEN BROWN
(1.41700-1.41732 in)
11-13
MAIN BEARING INSERT THICKNESS:

Brown: 1.508-1.512 mm
(0.05937-0.05953 in)
Green: 1.504-1.507 mm
(0.05921-0.05933 in)
Yellow: 1.500-1.503 mm
(0.05906-0.05917 in)
Pink: 1.496-1.499 mm
(0.05890-0.05902 in)
CAUTION
• After selecting new bearings, recheck the clearance with
plastigauge. Incorrect clearance can cause major engine dam-
age.
CRANKSHAFT INSTALLATION
If you removed cylinder stud bolts, install them as shown and
tighten them to the proper torque.
Check the alterntor drive chain slider for wear or damage.

Apply a locking agent to the threads of the slider bolts if re-
placed.
Tighten the bolts securely.
NOTE
• Apply locking agent as shown.
(1 l BEARINGS (MOLYBDENUM
DISULFIDE)
5.5- 7.5 mm (0.22-0.30 in)
Install the main bearings into the upper and lower crankcases.
CAUTION
• The bearing tabs should be aligned with the grooves in the case.
Apply molybdenum disulfide grease to the upper and lower

main bearings.
(1 I OIL PUMP (2) CAM (3) AL TERNA TOR
DRIVE CHAIN CHAIN DRIVE CHAIN
Install the oil pump drive, cam and altermator drive chains over
the crankshaft.
Install the crankshaft into upper crankcase.
11-14
STARTER CLUTCH/ALTERNATOR
SHAFT INSTALLATION
Install the starter gear as shown.
Push the starter gear shaft into the crankcase.
Apply a small amount of oil to the 0-ring.
Install the retainer to the crankcase and tighten the retainer
bolt securely.
Install the starter clutch, washer and spacer on the alternator

shaft.
NOTE
• Install the damper onto the alternator shaft aligning the oil
holes of the shaft and damper.
Install the damper on the alternator drive chain.

Apply small amount of oil to the 0-rings.
Install the alternator shaft assembly to the crankcase.
Apply 3 - Bond sealant or its equivalent to the threads of the al-

ternator base bolts.
Face the arrow mark on the alternator base to upward.
CAUTION
• Make sure that the starter driven gear is engaged with starter
drive gear. If you do not make sure, it will damage the gears.
Tighten the alternator base bolts to the specified torque.
TORQUE : 29 N·m 12.9 kg-m, 21 ft-lb)
11-15
Align the boss on the bearing insert with the groove in the con- (1 I -~ (MOLYBDENUM DISULFIDE)
necting rod or cap and install the bearing inserts on the rods
and caps.
Apply molybdenum disulfide grease to the bearing inserts and
connecting rod bolts.
Apply molybdenum disulfide grease to the seats of the nuts. (1) NUT
Install the connecting rods and caps to the crankshaft.
NOTE
• Be sure the connecting rods are installed in their original po-
sitions and the I. D. code number is to the rear.
• Cross reference the connecting rod and cap I. D. codes to
insure correct assembly.
Tighten the bearing cap nuts to the specified torque.
TORUE: 36 N·m (3.6 kg-m, 26 ft-lb)
OIL PASS PIPE PLATE/ALTERNATOR (1 I NOTCH
DRIVE CHAIN TENSIONER INSTALLATION

Push the notch on the chain tensioner with a screwdriver and
push the tensioner rod until hole on the rod appears.
Insert a wire or equivalent into the hole to lock the tensioner.
(3) ROD
Install the tensioner to the crankcase.

Apply a locking agent to the threads of the bolts (page 1-51.
Tighten the bolts to the specified torque.
Remove the wire from the hole of the tensioner rod.
11-16
Install the 0-rings on the oil pass pipe plate.

Apply oil to the 0-rings.
Install the oil pass pipe plate to the crankcase.
Clean the threads of the bolts and apply a thin amount of lock-
ing agent, (page 1-5).
TORQUE: 12 N·m ( 1.2 kg-m, 9 ft-lb I
Stake only the tips of the tabs.

Check that the tabs for cracks.
TRANSMISSION ASSEMBLY
Clean all parts in solvent and dip them in clean engine oil.
NOTE
• Align the circclip end gaps with the shaft gtooves. Note the
installation direction,
(21 SHAFT
11-17
(1) OIL ORIFICE
(2) COUNTERSHAFT
(4) NEEDLE
a
BEARING
(18) MAINSHAFT
BEARING
j ( 51 Cl
(33T )
GEAR
(19)
MAIN SHAFT/ ~
~~
~@ ~7)
M1 GEAR , ..;;,, 141 NEEDLE
BEARING (6) C OUNTERSHAFTI C2 GEAR (31T)
(12Tl -~-
~
(13) R C5 GEAR
~~UN~~
WASHE I 127T) '
!\\\ \\\lv;.::ti @~ (8) CIRCLIP
~
WASHER 12
~~)GEAR ~ ~~SHER ---b.

lis) SPLINE
122Tl / ) M5GEAR YJ
,#~ WASHER
~~)BUSHING ~ / ~~19?,? (23T) ({2). ~
lJ?r ,l ~~'1""'7)/q
f, / ~~sH1Nv
1101
~6 ~K
1
WASHER /-~ ...,..,.,,l--i'v::.
~~B~KPLATE// ..
~"'""
I((2j~
.(gJ . WAs7;~)
( 1 1) LOCK
(23) ~
0
M2 GEAR C4 EAR C3 GEAR
(15Tl (26T) (28T)
(13)
WASHER ~.
(16) PLATE
LOCK (13) W ASHER
ro-""
~~
(4)
(
NEEDLE
/ (14) C6 GEAR
f
BEARING
123Tl
(22)
M3/M4 GEAR (17/19T) 1 5 ) C3 BUSHING \ \ {
(8) CIRCLIP
11-18
Install the lock washers (M6 and C3 gear) on the shaft (1) PLATE
grooves.
Install the lock plates aligning the tabs on the plates with the
cut-outs of the washers.
(2) LOCK WASHER
Install the oil orifice and pin as shown.
Install the mainshaft and countershaft on the crankcase align-

ing the rings on the bearings with grooves on the case and pins
with cut-outs.
CRANKCASE ASSEMBLY
Check the oil pump drvie chain slider for wear or damage.
Apply locking agent to the threads of the slider bolts id re-
placed (page 1-5).
TORQUE: 12 N•m I 1.2 kg-m. 9 ft-lb)
11-19
Apply molydenum disulfide grease to the gear fork grooves

and the crankshaft main bearings.
Clean the crankcase mating surface thoroughly and apply

liqyid sealant to both of the mating serfaces.
CAUTION
• Do not apply sealant to the area near the main bearings and ta-
pered holes.
Install the 0-ring onto the oil pass pipe plate.
NOTE
• When assembling the crankcase halves, note the balancer
timing (page 10-10).
Assemble the crankcase halves, aligning the shift fork claws

with the grooves in the corresponding gears.
Apply molybdenum disulfide grease to the lower crankcase 8
mm bolts threads and seats of the bolts.
CAUTION
• Be sure that the components are properly engaged when mating
the case haves and that tha case haves slide together easily. Im-
proper component engagement will cause damage when tight-
ening crankcase bolts.
Install the sealing washer and lower crankcase bolts.
NOTE
• Note the locations of the sealing washers,
Tighten the 9 mm and 8 mm bolts to the specified torque

values in a crisscross pattern in 2-3 steps.
TORQUE VALUES:
9 mm bolt: 38 N•m (3.8 kg-m, 27 ft-lb)
8 mm bolt: 27 N·m (2.7 kg-m, 20 ft-lb)
Tighten the 6 mm bolts in a crisscross pattern and in 2-3 setps. (2)

9 mm BOLTS
TORQUE: AND
WASHER"'=::::::::::;;;~1.,,i;::::=;;:i:::;;i..o.J;
6 mm bolt: 12 N·m (1.2 kg-m, 9 ft-lb)
(3)
8 mm BOLTS AND
SEALING
WASHERS
11-20
Turn the crankcase upright and tighten the upper crankcase ( 1 ) 8 mm BOLTS
bolts. AND
Install the sealing washers on the 8 mm bolts. SEALING
~--W...,~A.,; SHERS
TORQUE:
10 mm Bolt: 40 N•m (4.0 kg-m, 29 ft-lb)
8 mm Bolt: 27 N•m (2. 7 kg-m, 20 ft-lb)
Tighten the alternator shaft nut with a washer to the specified

torque if removed.
Apply a small amount of oil to the 0-ring.
Install the alternator shaft nut cover.

Tighten the bolt with the sealing washer securely.
Install the remaining removed parts (page 11 -1 ) .
Install the engine (section 6).
11-21
Remove the seat, side cover and/or fairing pieces as indicated

when you service the following:
Upper fairing lower

inner cover
( 1) Instrument meter assembly removal/installation
(2) Headlight bulb replacement
(3) Front turn signal bulb replacement
(4) Front turn signal assembly replacement
(5) Headlight aim adjustment
(6) Sub fuse replacement
Fuel tank
(25) Valve clearance adjustment
(26) Cylinder compression inspection Upper fairing
(27) Thermostat removal/installation (7) Headlight assembly
(28) Temperature sensor removal/installation replacement
(29) Throttle cable free play adjustment
(30) Radiator pressure test
(31) Spark plug removal/installation
(32) Carburetor synchronization
Seat
(24) Battery fluid
level inspection
/~I----=- Side fairing

(8) Cylinder head, cylinder, piston
removal/installation
(9) Ignition timing inspection
Seat cowling (10) Pulse generator removal/
(22) Taillight assembly replacement installation
(23) Spark unit, turn signal ( 11) Clutch removal/installation
relay replacement ( 12) Starter motor removal/
installation
( 13) AC generator removal/
installation
(14) Water pump removal/
installation
( 1 5) Exhaust system removal/
Side cover installation
(20) Carburetor-idle speed adjustment ( 16) Radiator removal/
(21) Air cleaner element removal/installation installation
Lower fairing
( 17) Oil pressure switch removal/installation
( 18) Oil filter replacement
( 19) Oil strainer cleaning
12-0
12. FAIRING/EXHAUST SYSTEM ~~--- -
SERVICE INFORMATION 12-1 WINDSHIELD 12-5

FAIRING REMOVAL 12-2 SEAT COWLING/REAR FENDERS 12-6
FAIRING INSTALLATION 12-4 EXHAUST SYSTEM 12-7
SERVICE INFORMATION
GENERAL
• Do not service the exhaust system while it is hot.
TORQUE VALUES
Exhaust pipe joint nut 17 N•m ( 1. 7 kg-m, 12 ft-lb)

Exhaust muffler band bolt 22 N•m (2.2 kg-m, 16 ft-lb)
Exhaust muffler mounting bolt 22 N•m (2.2 kg-m, 16 ft-lb)
Fairing stay bolt 27 N·m (2.7 kg-m, 20 ft-lb)
12-1
FAIRING REMOVAL (1) PRO NGS (2) GROMMETS
SIDE COVER
Turn the left side cover holder 90°and release the holder.
Release the four prongs from each grommet and remove the
side cover.
CAUTION
When release the side cover prongs from the seat cowling, hold
the forward side of the seat cowling to prevent damage to the
side cover prongs.
LOWER FAIRING
Remove the pivot under cover mounting bolts and each pivot
under cover.
Remove the six bolts attaching the lower fairing. (1) LOWER -
FAIRING
Remove the lower fairing.
SIDE FAIRING
Remove the side cover and lower fairing.

Remove the four bolts attaching the side fairing.
Remove the side fairing.
12-2
UPPER FAIRING
Remove the side fairing.

Remove the three bolts attaching lower inner cover.
Remove the lower inner covers.
(2) SCREW
Remove the upper inner cover mounting bolts. ( 1) UPPER INNER COVER
Remove the upper inner cover.
Move the protect rubber of the rear view mirror. (1) RUBBER
Remove the rear view mirror mounting bolts and mirror.
Remove the upper fairing mounting bolts.

Move the upper fairing to the forward.
Disconnect the headlight wire and turn signal wire connectors.
Remove the upper fairing.
12-3
FAIRING INSTALLATION
Install the fairings in the reverse order of removal.
(1) UPPER
FAIRING
(6) LOWER FAIRING
12-4
Remove the upper inner cover mounting bolts and upper inner
covers.
Remove the two screws, two collars and two nuts.

Remove the windshield from the upper fairing.
Install the windshield in the reverse of removal.
NOTE
The windshield can be removed without removing the
upper fairing.
~(2)SCREW
~
~(3)COLLAR
~(4)NUT
12-5
SEAT COWLING/REAR FENDERS

SEAT COWLING/REAR FENDER A
Remove the seat.
Remove the side covers (page 12-2).
Disconnect the taillight and rear turn signal connectors.
Remove the passenger grip mounting bolts and seat cowling

bolts.
Pull the seat cowling back and remove the seat cowling.
Remove the rear fender A mounting bolts and remove the rear
fender A.
INSTALLATION
Install the rear fender A and seat cowling in the reverse order
of removal.
(1) SEAT
(2) GRIP
f (3) SEAT COWLING
12-6
REAR FENDER B
Remove the rear fender B mounting bolts. (each side)
Pull the rear fender B backward.
Install the rear fender B in the reverse order of removal.
EXHAUST SYSTEM
•M·fofll.fa
• Do not service the exhaust system while it is hot.
Remove the pivot under covers. (page 12-2)
MUFFLER REMOVAL
Remove the muffler by removing the muffler mounting bolt

and loosing the muffler band bolts.
EXHAUST PIPE REMOVAL
Remove the side covers, lower fairing and side fairing. (page
12-2)
Remove the muffler.

Remove the exhaust pipe by removing the joint nuts, mounting
bolt.
(1) JOINT
NUT
12-7
EXHAUST PIPE/MUFFLER INSTALLATION
Install the exhaust pipe and muffler in the reverse order of re-
moval.
TORQUE:
Exhaust pipe joint nut:
17 N.m (1.7 kg-m, 12 ft-lb)
Exhaust muffler band bolt:
22 N.m (2.2 kg-m, 16 ft-lb)
Exhaust muffler mounting bolt:
22 N.m (2.2 kg-m, 16 ft-lb)
Install the pivot under cover mounting bolts and screws.
22 N·m
(2.2 kg-m, 16 ft-lb)
17 N·m 22 N·m
( 1 . 7 kg-m, 1 2 ft-lb) (2.2 kg-m, 16 ft-lb)
12-8
MEMO
FRONT WHEEL/SUSPENSION
27 N•m (2.7 kg- m . 20 ft-lbl
10 N·m (1.0 kg- m , 7 ft-lbl
27 N·m (2. 7 kg- m • 20 ft-lbl

11 N•m ( 1. 1 k g- m • 8 ft-lbl
_J
10N· ~ (10 l'

k m 7 ft-lbl
-~~ CJlliitJ)
22 N•m (2.2 kg-m, 16 ft-lbl
13-0
13. FRONT WHEEL/SUSPENSION
SERVICE INFORMATION 13-1 FRONT WHEEL 13-5
TROUBLESHOOTING 13-2 FORK 13-11
HANDLEBARS 13-3 STEERING STEM 13-20
SERVICE INFORMATION
GENERAL
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
• Support the motorcycle on its center stand when servicing front wheel/suspension.
• For front brake service information, refer to section 1 5, Hydraulic Brake.
SPECIFICATIONS
unit: mm (in)
Axle runout -- 0.2 (0.01)

Front wheel rim runout . Radial -- 2.0 (0.08)
Axial -- 2.0 (0.08)
Fork spring free length 468.8-478.2 (18.46-18.83) 464 (18.3)
Fork tube runout -- 0.2 (0.01)
Fork fluid capacity Right 485 cc (16.4 US oz, 17.0 Imp oz) --
I
Left 495 cc (16.7 US oz, 17.4 Imp oz) --
Fork oil level 148 (5.8) --
Fork air pressure 0-40 kPa (0-0.4 kg/cm 2 , 0-6 psi) - -
TORQUE VALUES
Steering stem nut 105 N·m (10.5 kg-m, 76 ft-lb)

Steering adjustment nut 25 N·m ( 2.5 kg-m, 18 ft-lb)
Front axle holder pinch bolt 22 N·m ( 2.2 kg-m, 16 ft-lb)
Front axle bolt 60 N·m ( 6.0 kg-m, 43 ft-lb)
Fork top pinch bolt 11 N•m ( 1 .1 kg-m, 8 ft-lb)
Fork bottom pinch bolt 50 N•m ( 5.0 kg-m, 36 ft-lb)
Handlebar pinch bolt 27 N•m ( 2.7 kg-m, 20 ft-lb)
Brake caliper bracket bolt 27 N•m ( 2.7 kg-m, 20 ft-lb)
Anti-dive pin bolt 12 N·m ( 1.2 kg-m, 9 ft-lb)
Front brake disc bolt 40 N·m ( 4.0 kg-m, 29 ft-lb) Apply a locking agent to the threads.
Fork tube cap 23 N•m ( 2.3 kg-m, 17 ft-lb)
Fork bottom socket bolt 20 N·m ( 2.0 kg-m, 14 ft-lb) Apply a locking agent to the threads
Anti-dive case socket bolt 4 N·m ( 0.4 kg-m, 2.8 ft-lb)
Brake pipe clamp bolt 10 N·m ( 1.0 kg-m, 7 ft-lb)
Brake pipe three-way joint bolt 10 N•m ( 1 .0 kg-m, 7 ft-lb)
13-1
TOOLS
Special
Fork seal driver 07947-KA50100
Fork seal driver attachment 07947-KF00100
Steering stem socket 07916-3710100 rSteering stem driver 07946-3710601
Steering stem driver 07946 - MBOOOOO _LAttachment 07964- MB00200
Ball race remover 07953-MJ100001Ball race remover attachment 07953-MJ1000A
(U.S.A. only)
- driver attachment 07953-MJ10100 Attachment 07746-0010200
- driver handle 07953-MJ10200 Driver 07949-3710001
Ball race remover attachment 07946-3710500 -Adjustable bearing puller 07736-A01 OOOA
Common
Bearing remover head, 20 mm 07746-0050600 Equivalent commercially
Bearing remover shaft 07746-0050100 available in U.S.A.
Driver 07749-0010000
Attachment, 42 x 4 7 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Lock nut wrench, 30 x 32 mm 07716-0020400 Equivalent commercially
Extension bar 07716-0020500 available in U.S.A.
Attachment, 52 x 55 mm 07746-0010400
TROUBLESHOOT ING
Hard steering
• Steering bearing adjustment nut too tight
• Faulty steering stem bearings
• Damaged steering stem bearings
• Insufficient tire pressure
Steers to one side or does not track straight

• Bent fork
• Bent front axle
• Wheel installed incorrectly
Front wheel wobbling

• Bent rim
• Worn front wheel bearings
• Faulty tire
• Axle nut tightened improperly
Soft suspension
• Weak fork springs
• Insufficient fluid in fork
• Fork air pressure incorrect
Hard suspension
• Incorrect fluid weight in fork
• Fork air pressure incorrect
• Bent fork tubes
• Clogged fluid passage
• Clogged anti-dive orifice
Front suspension noise

• Worn slider or guide bushings
• Insufficient fluid in fork
• Loose fork fasteners
13-2
HANDLEBARS (1 l LEFT HANDLEBAR

SWITCH -
(2) CLUTCH MASTER
CYLINDER
REMOVAL
Remove the throttle housing mounting screws.

Remove the following components:
- left handlebar switch.
- front brake master cylinder.
- clutch master cylinder.
CAUTION
• Suspend the front brake master cylinder and clutch master cyl-
inder to the frame at their installed height so that air does not
get in the hydraulic system.
Remove the left handlebar weight, handlebar grip and choke

lever from the left handlebar.
Remove the left handlebar retainer ring and loosen the left
handlebar pinch bolt.
Remove the left handlebar from the fork tube.
Remove the right handlebar weight.
Remove the right handlebar retainer ring and loosen the right
handlebar pinch bolt.
Remove the right handlebar from the fork tube.

Remove the throttle housing and throttle grip from the right
handlebar.
(4) HANDLEBAR
WEIGHT
INSTALLATION
Install the left handlebar aligning the boss on the handlebar

with cut-out in the top bridge.
~3-3
Install the left handlebar retainer ring to the groove in the fork
tube.
Tighten the left handlebar pinch bolt.
TORQUE: 27 N·m 12. 7 kg-m, 20 ft-lb)
NOTE
• Tighten the pinch bolt while pushing the handlebar forward
until contacting the boss on the handlebar with the top
bridge.
Install the choke lever.
Apply Honda bond A to the inside surface of the grips and to

the clean surface of the left handlebar and throttle pipe. Wait
3-5 minutes and install the grips.
Rotate the grips for even application of the adhesive.
NOTE
• Allow the adhesive to dry for an hour before using.
Install the left handlebar grip and handle weight to the handle-
bars.
Connect the choke cable to the choke lever.

Install the left handlebar switch by aligning the locating pin
with the hole in the handlebar.
Tighten the front screw first, then tighten the rear screw.
I PUNCH MARK
Install the clutch master cylinder aligning the mating surface (3) CLUTCH
between master cylinder and holder with the punch mark on MASTER
the left handlebar. CYLINDER
Tighten the upper bolt first, then tighten the lower bolt.
NOTE
• Install the clutch master cylinder holder with the "UP"
mark on the holder faced up.
Apply grease to the throttle cable ends and connect the throt-
tle cables to the throttle pipe.
Apply grease to the right handlebar.

Install the right handlebar into the throttle pipe.
13-4
Install the right handlebar aligning the boss on the handlebar

with the cut-out in the top bridge.
Install the retainer ring to the groove in the fork tube.
Tighten the right handlebar pinch bolt.
TORQUE: 27 N•m (2. 7 kg-m, 20 ft-lb)
NOTE
• Tighten the pinch bolt while pushing the handlebar forward
until contacting the boss on the handlebar with the top
bridge.
t
(4) HANDLEBAR
Install the right handlebar weight. WEIGHT
Align the locating pin on the right handlebar switch with the
hole in the handlebar.
Install the right handlebar switch mounting screws.

Tighten the front screw first. then tighten the rear screw.
(11 SCREWS
Place the front brake master cylinder on the handlebar and in-
stall the master cylinder holder with the "UP" mark facing up.
Align the end of the holder with the punch mark on the handle-
bar. Tighten the upper holder bolt first, then tighten the lower
bolt.
Connect the front brake switch wires.
FRONT WHEEL ( 1 l FRONT FENDER
REMOVAL
Remove the brake hose holder bolts.

Remove the four front fender mounting bolts and front fender.
\
CAUTION
• Do not bend the brake pipe.
13-5
Raise the front wheel off the ground by placing a floor or other
support jack under the engine.
Disconnect the speedometer cable from the speedometer gear

box by removing the cable set screw.
Remove the right brake caliper bracket bolts and right brake
caliper.
CAUTION
• Support the caliper assembly so that it does not hang on the
brake hose. Do not twist the brake hose.
NOTE
• If you squeeze the front brake lever after the caliper is re-
moved, the caliper piston will move out and make assembly
difficult.
Remove the axle bolt.

Loosen the right and left front axle pinch bolts.
Withdraw the front axle and remove the front wheel.
AXLE INSPECTION
Set the axle in V block and measure the runout.
WHEEL INSPECTION
Check the rim runout by placing the wheel in a truing stand.

Spin the wheel slowly and read the runout using a dial indica-
tor.
SERVICE LIMITS:
Radial runout: 2.0 mm (0.08 in)
Axial runout: 2.0 mm (0.08 in)
NOTE
• The wheel cannot be repaired and must be replaced with a
new one if. the service limits are exceeded.
13-6
WHEEL BEARING INSPECTION
Turn the inner race of the each bearing with your finger. The
bearings should turn smoothly and quietly. Also check that the
outer race of the each bearing fits tightly in the hub.
Remove and discard the bearings if the races do not turn

smoothly, quietly, or if loosely in the hub.
NOTE
• Replace wheel bearings in pairs.
WHEEL BALANCE
CAUTION
Wheel balance directly affects the stability, handling and over-
all safety of the motorcycle. Always check balance when the
tire has been removed from the rim.
NOTE
• For optimum balance, the tire balance mark (a paint dot on
the side wall) must be located next to the valve stem.
Remount the tire if necessary.
(2) BALANCE MARK
Remove the dust seal and speedometer gearbox from the

wheel.
Mount the wheel, tire and brake disc assembly in an inspection
stand.
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) point of the wheel with chalk.
Do this two or three times to verify the heaviest area. If the
wheel is balanced, it will not stop consistently in the same po-
sition.
To balance the wheel, install wheel weights on the highest

side of the rim, the side opposite the chalk marks. Add just
enough weight so the wheel will no longer stop in the same po-
sition when it is spun. Do not add more than 70 grams to the
front wheel (rear wheel: 60 grams).
DISASSEMBLY
Remove the speedometer gear box from the left side.

Remove the dust seal and speedometer gear retainer.
Remove the socket bolts, left brake disc and brake disc shims.
NOTE
• Do not damage the socket bolts when remove them as lock-
ing agent is applying.
13-7
Remove the right side collar and dust seal.

Remove the socket bolts, right brake disc
shims.
NOTE
• Do not damage the socket bolts when removing them.
Remove the bearings and distance collar.
NOTE
• Never reinstall old bearings: once the bearings are removed,
they must be replaced with new ones.
TOOLS:
Bearing remover shaft 07746-0050100 or
available in U.S.A.
Bearing remover head, 20 mm 07746.- 0050600 or
available in U.S.A.
ASSEMBLY
(2) RIGHT SIDE
COLLAR
(1 l RIGHT BRAKE (3) BEARING
DISC-----//
(4) DUST SEAL

(3) BEARING
(6) SPEEDOMETER GEAR

BOX
(10) DISTANCE
COLLAR
(9) SPEEDOMETER
GEAR RETAINER
(8) BRAKE DISC
SHIM
13-8
Drive in the right bearing first, then install the distance collar
into place.
NOTE
• Be certain the distance collar is in position before installing
the left bearing.
Drive in the left bearing.
TOOLS:
Driver 07749-0010000
Attachment. 42 x 4 7 mm 07746-0010300
Pilot. 20 mm 07746-0040500
Clean the threads of the socket bolt holes. 111 SHIMS
Install the brake disc shims on the right side of the wheel.
I
Clean the threads of the socket bolts. "'7"i )BRAKE

Apply locking agent to the threads of the bolts. DISC •
Install the right brake disc and socket bolts.

f /
~ ~~
,. ,.,.,. 0
Tighten the bolts.
r
Install the dust seal and right side collar.
Install the brake disc shims on the left side of the wheel. 11 I SHIMS
13-9
Install the left brake disc and socket bolts.

Tighten the bolts. . - --
(3) -RETAINER I (4) GEAR BOX-
Install the speedometer gear retainer in the left side of the

wheel hub, aligning its tang with the slots in the hub.
Install the dust seal.
Fill the speedometer gear box with grease and install the drive
gear.
Install the speedometer gear box in the wheel hub, aligning the
tangs with the slots.
INSTALLATION
Position the front wheel between the fork legs and insert the
front axle from the left side.
CAUTION
• When installing the front wheel, fit the left brake disc carefully
between the brake pads to avoid damaging the pads.
Align the stoppers on the gear box and left fork leg.
Tighten the left axle pinch bolts aligning the index line on the
axle with fork slider outside end.
Tighten the right axle pinch bolts.
Install and tighten the front axle bolt.
Install the right caliper with the caliper bracket.

install the caliper bracket bolts and tighten the bolts.
Install the new o-ring to the speedometer cable.

Install the speedometer cable to the speedometer gear box and
tighten the screw.
13-10
Install the front fender to the fork sliders. ( 1) FRONT FENDER

Install the brake hose holder and tighten the three-way joint
bolts.
TORQUE:
Three-way joint bolt: 10 N·m (1.0 kg-m, 7 ft-lb)
\
Install and tighten the front fender mounting bolts.
Measure the clearance between each surface of the left brake

disc and the left caliper bracket with a 0. 7 mm (0.028 in)
feeler gauge.
Loosen the left axle pinch bolts if the feeler gauge cannot be
inserted easily. Pull the left fork out or push it in until the gauge
can be inserted.
Tighten the left axle pinch bolts.
After installing the wheel, apply the brake several times, then
recheck both discs for caliper bracket-to-disc clearance.
'itt.foflfr!d
• Failure to provide adequate disc to caliper holder clearance
may damage the brake disc and impair braking efficiency.
FORK
REMOVAL
Remove the front wheel (page 13-5).

Remove the front brake calipers (page 15-5).
CAUTION
• Support the caliper assembly so that it does not hang on the
brake hose or pipe. Do not twist the brake hose.
Do not bend the brake pipe.
Remove the right and left handlebar (page 13-3).
Remove the fork tube air valve cap and release the air pressure
in the fork.
Loosen the fork tube cap.
Loosen the steering top bridge pinch bolts. (1) PINCH BOLT
Loosen the steering bottom bridge pinch bolts and remove the
fork legs.
NOTE
• Be careful not to drop the fork legs when loosening the
steering bottom bridge pinch bolts.
13-11
FORK NEEDLE BEARING REPLACEMENT
Remove the pivot collar.

Check the needle bearing for wear or damage.
Replace it if necessary.
Remove the needle bearing using a hydraulic press with suita-
ble tools as shown.
Install a new needle bearing in the reverse order of removal.
r--
(2) SUITABLE TOOLS
DISASSEMBLY ( 1l FORK TUBE CAP
Remove the fork tube cap.

Check the fork tube cap a-ring for wear or damage.
Replace it if necessary.
\
''fMWM'
• The cap is also under spring pressure. Use care when removing
and wear eye and face protection.
Remove the spacer, spring seat and spring from the fork tube.
Drain the fork fluid by pumping the fork up and down several
times.
!
Remove the dust seal and snap ring.
NOTE
• When removing the snap ring, do not damage the fork tube.
13-12
Hold the fork slider in a vise with soft jaws or a shop towel. ( 11 SOCKET BOLT
Remove the socket bolt. I
I
I
I
I
NOTE I
I
I
• Temporarily install the spring and fork cap if difficulty is en-
countered in removing the socket bolt.
Pull the fork tube out until resistance from the slider bushing is
felt. Then move it in and out, tapping the bushing lightly until
the fork tube separates from the slider. The slider bushing will
be forced out by the fork tube bushing.
Remove the lower snap ring, oil lock valve, spring, spring seat (3) SLIDER (4) BACK UP
and upper snap ring from the left fork piston. BUSHING RING
Remove the fork piston from the left fork tube.
Remove the slider bushing, back up ring and oil seal from the
left fork tube. l I
NOTE
• Do not remove the fork tube bushing unless it is necessary
to replace.
(6) FORK
BUSHING
Remove the oil lock piece and snap ring from the right fork pis- (1) OIL LOCK (2) FORK (3) SLIDER
ton. PIECE BUSHING BUSHING
~i
Remove the fork piston from the right fork tube.
Remove the slider bushing, back up ring and oil seal from the
right fork tube.
NOTE
• Do not remove the fork tube bushing unless it is necessary
to replace it.
(6) SNAP RING (4) OIL SEAL
13-13
INSPECTION
Measure the fork spring free length.
SERVICE LIMIT: 464 mm 118.3 in)
Check the spacer and spring.seat for wear or damage. (1 I SPRING SEAT
I
121 SPACER
Check the fork tube and fork slider for bending or scratches. 121 FORK (31 REBOUND
Check the fork tube, fork slider and fork piston for score PISTON SPRING
marks, scr.atches or wear.
Replace any components which are worn or damaged.
t /
lt
Check the fork piston ring for wear or damage.

Check the rebound spring for fatigue or damage.
Place the fork tube in a set of V blocks and measure the run-
out.
SERVICE LIMIT: 0.2 mm 10.01 inl
13-14
Visually inspect the slider and fork tube bushing.

Replace the bushing if there is excessive scoring or scratching,
or if the teflon is worn so that the copper surface appears on
more than 3/4 of the entire surface. (1) BUSHING (2) BACK-UP RING
~
', (3) CHECK POINTS
~---..... (4) COPPER SURFACES
ANTI-DIVE CASE (2) STOPPER RING
Remove the four socket bolts and anti-dive case from the left
fork slider.
Remove the stopper ring from the collar and disassemble the
anti-dive case.
(3) COLLAR
Check the o-rings for wear or fatigue. (3) COLLAR .

Check the spring, piston, rubber boot and collar for wear, dete-
rioration or damage.
(5) SPRING (4) BOOT
Assemble the anti-dive case in the reverse order of dis- (1) PISTON
assembly.
Apply locking agent to the socket bolt threads and tighten the
socket bolts.
TORQUE: 4 N•m (0.4 kg-m. 2.8 ft-lb)
NOTE
• Apply ATF to the piston and piston 0-ring.
Check the operation of the piston.
(2) BOLTS
13-15
ASSEMBLY (5) AIR VALVE CAP

(4) PISTON RING \ (6) STOPPER (13) LEFT (14) PISTON
(3) RIGHT FORK RING FORK RINGS (15) LEFT FORK
n
PISTON / TUBE PISTON
~ (7) FORK TUBE
~_/CAP
e' (8) SPACER
cc
(12) OIL LOCK
ALVE
D
~
LEFT
~
PRING
SEAT
~
~
£ REBOUND
SPRING
7)
~DUST SEAL
~
~\~~8lP RING
(19)
OIL SEAL
BACK UP
RING
(21 l SLIDER
BUSHING
(23) RIGHT FORK
TUBE d)lllD
@ ~@
~@~'- v0~
13)
(26) OIL LOCK (24) FORK TUBE
PIECE BUSHING ! IJ
(25) SNAP (22) FORK SOCKET
RING BOLT
Insert the rebound spring and piston into the fork tube. (1 l LOWER
On the left fork, install the upper snap ring, spring seat, spring, SNAP RING
oil lock valve and lower snap ring.
t
(5) OIL LOCK
VALVE (4) SPRING SEAT
Install the slider bushing, back up ring and oil seal to the left (1 l FORK TUBE (2) SLIDER
fork tube. BUSHING BUSHING
NOTE
•
•
Install a new oil seal with the mark facing up.
Coat a new oil seal lips with A TF.
\ \
Insert the left fork tube into the left fork slider.
(4) OIL SEAL
13-16
Install the snap ring and oil lock piece on the right fork piston. (1 I OIL LOCK 131 BACK UP
PIECE RING
Install the slider bushing, back up ring and oil seal on the right
fork tube. \
NOTE
• Install a new oil seal with the mark facing up.
• Coat a new oil seal lips with ATF.
Insert the right fork tube into the right fork slider.
(6) FORK TUBE (51 SLIDER (4) OIL

BUSHING BUSHING SEAL
Place the fork slider in a vise with soft jaws or a shop towel.
Apply locking agent to the threads of the socket bolts. Tighten
socket bolts.
NOTE
Temporarily install the fork spring and fork cap bolt to tight-
en the socket bolt.
I
I
TORQUE: 20 N•m (2.0 kg-m, 14 ft-lb) I
I
I
I
I
I
( 1 I SOCKET BOL T__._""L_•
Drive the slider bushing, back-up ring and oil seal with the seal (1 I FORK SEAL DRIVER
driver.
TOOLS:
Fork seal driver 07947-KA50100
Fork seal driver attachment 0794 7 -KF00100
121 ATTACHMENT
Install the snap ring and dust seal. ( 1) SNAP RING
121 DUST SEAL
- 131 SNAP RING

I (4) OIL SEAL
(5) BACK-UP
RING
(6) BUSHING
(7) DUST SEAL
13-17
Fill the fork with ATF.
CAPACITY: +
(1) OIL
RIGHT FORK 485 cc (16.4 US oz, 17.0 Imp oz) LEVEL
LEFT FORK 495 cc 116.7 US oz. 17.4 Imp oz)
Pump the fork several times.
Compress the fork and measure the oil level from the top of the
tube after the level stabilizes.
SPECIFIELD LEVEL: 148 mm I 5.8 in)

_-_-.·1
- -
Wipe oil off the spring thoroughly using a clean cloth.

Install the fork spring with tapered end facing down.
I
I t
~ rDOWN
Install the spring seat and spacer. (1 I SPACER

Coat the 0-ring with A TF.
Install the fork tube cap with an a-ring and tighten it lightly.
INSTALLATION
Install the fork legs through the steering bottom bridge and top
bridge so that the grooves on the fork tubes align with the top
of the top bridge.
Tighten the steering top bridge pinch bolts.
13-18
Tighten the steering bottom bridge pinch bolts.
Tighten the fork tube caps.
Fill the left brake caliper pivot collar bearing with paste grease
with 40% or more molybdenum disulfide.
NOTE
• Some sources of MoS2 paste grease with 40% or more mo-
lybdenum are:
• Molykote® G-n Paste manufactured by Dow Corning,
U.S.A.
• Honda Moly 45 grease (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan.
Any other manufacture's paste grease equivalent to the above
may also be use.
Install the pivot collar.
Adjust the fork air pressure.
AIR PRESSURE: 0-40 kPa I0-0.4 kg/cm 2 , 0-6 psi)
Install the air valve cap.
Install the following components:

- front wheel (page 13-10).
- front brake calipers (page 15-6).
- right and left handlebars (page 13-3).
13-19
STEERING STEM (1) LOCK NUT WRENCH~ (2) EXTENSION BAR
REMOVAL
Remove following components:

- handlebars (page 13-3).
/-.
Remove the steering stem nut.
TOOLS:
Lock nut wrench. 30 x 32 mm 07716-0020400 or
available in U.S.A.
available in U.S.A. ( 1) BRAKE HOSE HOLDER
Remove the brake hose holder from the steering bottom

bridge.
Unlock the tabs of the lock washer and remove the lock nut
and lock washer.
Remove the bearing adjustment nut.
TOOLS:
Steering stem socket 07916-3710100
available in U.S.A.
13-20
Remove the dust seal, upper bearing inner race, upper bearing
and steering stem.
Remove the lower bearing from the steering stem.

Check the steering stem bearings, inner races and outer races
for damage or wear.
BEARING REPLACEMENT (1) INNER RACE (2) STEM NUT
NOTE
• Replace the bearing and bearing race as a set.
Remove the bearing inner race and dust seal from the steering
stem.
NOTE
• Temporarily install the steering stem nut onto the steering
stem so as not to damage steering stem threads when re-
moving the lower inner race.
Install a dust seal onto the steering stem and press the lower (1) STEM
bearing inner race over the stem with the special tool. DRIVER
TOOLS:
Steering stem driver 07946-MBOOOOO
or
Steering stem driver 07946-3710601
Attachment 07964-MB00200
Drive the upper outer race out of the steering head.
TOOLS:
Ball race remover 07953-MJ10000
- driver attachment 07953-MJ10100
- driver handle 07953-MJ10200
or
Ball race remover attachment 07953-MJ1000A
(U.S.A. only)
Driver 07949-3710001
Attachment, 37 x 40 mm 07746-0010200
13-21
Set the ball race remover attachment to the lower outer race.
Drive the lower outer race out of the steering head.
TOOL:
Steering stem driver 07946-MBOOOOO
Ball race remover attachment 07946-3710500
or
Adjustable bearing puller 07736-A010001
with commercially
available slide hammer.
Drive the outer races into the steering head.
TOOLS:
Upper:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Lower:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
INSTALLATION
Pack the bearing cavities with grease.
Install the lower bearing onto the steering stem, then insert the
steering stem into the steering head.
Install the upper bearing and upper bearing inner race.
Install the dust seal to the steering head.
141 LOWER
BEARING/ (31 S~ING STEM
Install and tighten the adjustment nut to the specified torque. (1) STEERING STEM
SOCKET
TORQUE: 25 N·m (2.5 kg-m, 18 ft-lb) / -,
TOOLS:
Steering stem socket 07916-3710100
available in U.S.A.
Turn the steering stem lock-to-lock 4- 5 times to seat the

bearings, then tighten the nut to the same torque.
13-22
Install a new bearing adjustment nut lock washer aligning the

tabs with the grooves in the nut. Bend two opposite tabs down
into the grooves.
NOTE
• Do not install a used bearing adjustment nut lock washer.
Finger tighten the lock nut all the way.

Hold the adjustment nut and further tighten the lock nut within
90 degrees enough to align its grooves with the lock washer
tabs.
Bend the lock washer tabs up into the lock nut grooves.
Install the brake hose holder to the steering bottom bridge and (1 I HOLDER (21 BOLT
tighten the bolt.
Install the fork top bridge and install the steering stern nut.
Temporarily install the fork legs.
Tighten the steering stern nut.
TOOLS:
Lock nut wrench, 30 x 32 mm 07716-0020400 or
available in U.S.A.
available in U.S.A.
Install the fork correctly (page 13-18).

Install the following components:
- handlebars (page 13-3).
STEERING HEAD BEARING PRELOAD
Remove the upper fairing (page 12-31

Place a stand under the engine and raise the front wheel off
the ground.
Position the steering stern in the straight ahead position.
Hook a spring scale to the fork tube and measure the steering
head bearing preload.
NOTE
• Make sure that there is no cable or wire harness interfer-
ence.
The preload should be within 1.1-1 .6 kg (2.43-3.53 lb) for

right and left turns.
If the readings do not fall within the range, lower the front
wheel and adjust the bearing adjustment nut.
13-23
REAR WHEEL/SUSPENSION
7
/
45
(4.5N•m
kg-m, 33 ft-lb)
45 N•m (4 . 5 kg-m,
33 ft-lb)
14-0
14. REAR WHEEL/SUSPENSION
SERVICE INFORMATION 14-1 SHOCK ABSORBER 14-7
TROUBLESHOOTING 14-2 SHOCK LINKAGE 14-13
REAR WHEEL 14-3 SWING ARM 14-15
SERVICE INFORMATION
GENERAL
'WMMIN
• The rear wheel uses a tubeless tire. For tubeless tire repairs, refer to the TUBELESS TIRE MANUAL.
• Refer to page 13- 7 for wheel balance inspection and adjustment procedure.
SPECIFICATIONS
unit: mm (in)
Axle runout -- 0.2 (0.01)

Rear wheel rim runout Radial -- 2.0 (0.08)
Axial -- 2.0 (0.08)
Shock absorber spring free length 137.4 (5.41) 134. 5 (5.30)
I Shock absorber damping compression 15.4-20.0 kg (33.95-44.09 lb) 15.39 kg (33.929 lb)
TORQUE VALUES
Shock absorber mounting bolt

Shock link-to-frame bolt
Shock arm-to-link bolt
45 N·m (4.5 kg-m, 33 ft-lb)
45 N·m (4.5 kg-m, 33 ft-lb)
45 N·m (4.5 kg-m, 33 ft-lb)
45 N·m (4.5 kg-m, 33 ft-lb)
m
Shock arm-to-swing arm bolt
Swing arm pivot nut 110 N·m ( 11 .0 kg-m, 80 ft-lb)
Rear brake torque rod nut 22 N·m (2.2 kg-m, 16 ft-lb)
Final driven sprocket nut 90 N·m (9.0 kg-m, 65 ft-lb) Apply grease to the seat of the nut
Rear brake disc bolt 40 N•m (4.0 kg-m, 29 ft-lb)
Rear axle nut 95 N•m (9.5 kg-m, 69 ft-lb)
TOOLS
Special
Bushing driver B 07HMF-MM90200
Spring compressor 07964-ME90000
Driver pin 07GMD-KT80100
Driver shaft 07946 - MJOOlOO~Attachment,
24 x 26 mm 07746-0010700
Bearing remover 07936-3710300 LDriver 07949-3710001
- bearing remover handle 07936-3710100
- bearing remover weight 07741-0010201--Remover weight 07936-3710200
Needle bearing remover 07GMD-KT70200
Attachment, 28x30 mm 07946-1870100
Common
Bearing remover head, 20 mm 07746-0050600::JEquivalent commercially available in U.S.A.
Bearing remover shaft 07746-0050100
Driver 07749-0010000
Attachment, 42 x 4 7 mm 07746-0010300
Pilot, 20 mm 07746-0040500
14-1
Attachment, 52 x 55 mm 07746-0010400
Attachment, 62 x 68 mm 07746-0010500
Pilot, 25 mm 07746-0040600
Attachment, 24 x 26 mm 07746-0010700
Pilot, 17 mm 07746-0040400
Attachment, 32 x 35 mm 07746-0010100
Pilot, 15 mm 07746-0040300
Pilot, 22 mm 07746-0041000
TROUBLESHOOTING
Oscillation
• Rim Bent
• Wheel bearings loose
• Wheel bearings worn
• Faulty tire
• Axle loose
• Tire pressure incorrect
• Swing arm bearings worn
• Tires worn
• Wheel out of balance
Soft suspension
• Spring weak
• Fluid in shock absorber insufficient-operating without rear damper heat shield in place may cause oil seal deterioratio
and oil leakage.
• Spring adjustment incorrect
• Air in damper
Hard suspension
• Shock absorber bent
• Spring adjustment incorrect
Suspension noise
• Shock case binding
• Fasteners loose
• Shock linkage pivots worn or lack of lubrication
14-2
REAR WHEEL
REMOVAL
Raise the rear wheel off the ground by supporting the motor-
Remove the rear axle nut.
Loosen the lock nut and adjusting nut, and push the rear
wheel forward, and remove the drive chain from the driven
sprocket.
Remove the rear axle and rear wheel.
Suspend the rear brake caliper bracket from the frame using a
string.
AXLE INSPECTION
Set the axle in V blocks and read the axle runout with a dial in-
dicator.
WHEEL RIM RUNOUT
Check the rim for runout by placing the wheel in a truing stand.
Spin the wheel slowly, and read the runout using a dial indica-
tor.
SERVICE LIMITS:
Radial runout: 2.0 mm (0.08 in)
Axial runout: 2.0 mm (0.08 in)
NOTE
• The wheel cannot be serviced and must be replaced if the
above limits are exceeded.
WHEEL BEARING INSPECTION
Turn the inner race of each bearing with your finger. The bear-
ings should turn smoothly and quietly. Also check that the
outer race of the each bearing fits tightly in the hub or driven
flange.
Remove and discard the bearings if the races do not turn

smoothly, quietly, or if they fit loosely in the hub or driver
flange.
NOTE
• Replace hub and driven flange bearings as a set.
For bearing replacement, see page 14-4.
14-3
FINAL DRIVEN SPROCKET
Check the condition of the final driven sprocket teeth. Replace

the sprocket if worn or distorted. (1) GOOD (2) REPLACE
NOTE
• The drive chain and drive sprocket must also be inspected if
the driven sprocket is worn or damaged. Never install a new
drive chain on worn sprockets or a worn chain on new
sprockets. Both chain and sprocket must be in good condi-
tion or the new replacement chain or sprockets will wear
rapidly.
WHEEL BALANCE
• Refer to page 1 3-7.
DISASSEMBLY
Remove the left side collar and dust seal.
Remove the right side collar and dust seal.

Remove the rear brake disc mounting bolts and brake disc.
(4) BOLTS
Remove the final driven sprocket and driven flange together.
NOTE
• Do not separate the driven sprocket and flange, unless re-
placement of the driven sprocket or flange is necessary.
Replace the damper rubbers if they are damaged or deteriorat-

ed.
Check the 0-ring for wear or damage. Replace if necessary.

Remove the damper rubbers.
(2) DRIVEN SPROCKET
.
DRIVEN FLANGE
14-4
Remove the axle sleeve from the driven flange. Drive out the (2) BEARING
flange bearing.
Remove the wheel bearings and distance collar from the wheel
hub.
TOOLS:
Bearing remover head. 20 mm 07746-0050600 or
available in U.S.A.
Bearing remover shaft 07746-0050100 or
available in U.S.A.
CAUTION
• Never reinstall old bearings: once the bearings have been re-
moved, they must be replaced by new ones.
ASSEMBLY
Gii.fodld'
• Do not get grease on the brake disc or stopping power will be
reduced.
(2) DISTANCE (5) FLANGE

COLLAR BEARING
iL
(6) DUST SEAL
(7) LEFT
SIDE
/ COLLAR
(11 l WHEEL
BEARING
(6) DUST
SEAL (9) DRIVEN
FLANGE
'
( 10) AXLE (8) DRIVEN
SLEEVE SPROCKET
14-5
Drive the left bearing first, then install the distance collar and
right bearing.
TOOLS:
Left side:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Right side:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 20 mm 07746-0040500
Drive in a new bearing into the final driven flange.
TOOLS:
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot,25 mm 07746-0040600
Install the axle sleeve onto the driven flange bearing. I 1 l AXLE SLEEVE
Apply grease to the 0-ring and install it in the groove in the

wheel hub.
Install the rubber dampers.
Install the final driven flange.
If the final driven sprocket is removed, install the washers and
apply oil to the driven sprocket mounting nuts and tighten the
nuts to the specified torque.
TORQUE: 90 N·m 19.0 kg-m, 65 ft-lbl
14-6
Apply grease to the dust seal lip and install the dust seal onto
the flange.
Install the left side collar.
NOTE
• Do not interchange the left and right dust seals.
Apply grease to the dust seal lip and install the dust seal onto
the wheel hub.
Install the right side collar.
Install the brake disc and mounting bolts.
INSTALLATION
Install the rear wheel, fitting the brake disc carefully between
the brake pads.
Install the drive chain over the drive sprocket.

Install the drive chain adjusters with the "UP" marks facing up
and install the rear axle from the left side.
Adjust the drive chain (page 3-12).
Tighten the rear axle nut.
SHOCK ABSORBER
REMOVAL
Raise the rear wheel off the ground by supporting the motor-
Remove the side covers (page 12-2).
Romove the shock absorber upper mounting bolt.
14-7
Remove the left muffler (page 12-7).

Remove the shock link (page 14-13).
Remove the shock absorber lower mounting bolt.
Raise the rear wheel enough to take any downward load off
the shock absorber.
(3) LOWER MOUNTING

BOLT ~ HOC~LINK
Remove the shock absorber from the frame as shown.
UPPER JOINT BUSHING REPLACEMENT (1 I COLLAR (2) BUSHING
Remove the collar from the shock absorber upper joint.

Check the collar for wear or damage, and replace it if neces-
sary.
Check the bushing for wear, damage or scratches.

Remove the dust seals and dust seal caps if replace the bush-
ing.
Remove the shock absorber upper joint bushing using a hy- 1
draulic press and bushing driver B.

Drive in the shock absorber upper joint bushing using a hydrau-
lic press and bushing driver B.
NOTE
• Drive in the bushing gradually so that both ends of the
bushing stick about 1 mm (0.04 in) out of both ends of the
upper joint hole.
TOOL:
Bushing driver B 07HMF-MM90200 (2) BUSHING
14-8
ADJUSTER INSPECTION
Check the adjuster for deterioration, leaks or damage.

Check that the adjusting knob moves freely between "LOW"
and "HIGH".
Turn the adjusting knob from "LOW" to "HIGH" fully and

measure the stroke of adjuster between the adjuster body and
spring.
ADJUSTER STROKE: 9.0 mm (0.35 in)
DISASSEMBLY (1) SCREW
•MMMMI
• The shock absorber is filled with nitorogen gas under high pres-
sure, do not try to disassemble.
Remove the lower spring seat screw.
Compress the spring until the stopper ring can be removed

(1 I SPRING
using a hydraulic press and spring compressor.
COMPRESSOR
TOOL:
Remove the stopper ring and disassemble the shock absorber.
INSPECTION
Measure the spring free length.
14-9
Check the rear damper for deformation, oil leaking, bending of (1 l DAMPER RUBBER
the rod or rough operation.
Check the damper rubber for wear or damage.
(3) DAMPER ROD
ASSEMBLY (1 l SPRING PRELOAD

ADJUSTER
(2) SPRING SEAT C
I'§>"~
(8) STOPPER----~
RING
(3) COLLAR
(11) SPRING SEAT

\@ o (5) DUST SEAL
(10) SPRING SEAT B
(7) DAMPER
(9) SPRING
(5) DUST SEAL~ ~(8) STOPPER

RING
Install the lower spring seat to the damper, aligning the holes
in the spring seat and damper.
(2) LOWER SPRING SEAT
14-10
Install the spring and upper spring seat to the damper, aligning
the screw with the groove in the upper joint.
NOTE
• Install the spring with the tightly wound coils facing down.
(31 UPPER SPRING SEAT
Mark the damper rod at the first 1 0 mm exposed from the

damper body.
Place the damper rod on a scale and measure the force re-
quired to compress the damper until the 10 mm (0.4 in) mark is
flush with the damper body.
COMPRESSION FORCE: 15.4-20.0 kg (33.95-44.09 lb)
If the force required is less than 15.4 kg (33.95 lb), gas is leak-
ing.
Examine the damper rod and replace the damper unit if it is
bent or scored.
SHOCK ABSORBER DISPOSAL PROCEDURE
Center punch the damper case to mark the drilling point, ap-
proximately 13 mm (0.5 in) from the lower surface.
Wrap the damper unit inside a plastic bag.
Support the damper unit upright in a vise as shown.
Through the open end of the bag, insert a drill motor with a (11 PLASTIC BAG
sharp 2-3 mm (5/64-1 /8 in) drill bit.
GMMl!fld
Do not use a dull drill bit which could cause a build-up of exces-
sive heat and pressure inside the damper, leading to explosion
and severe personal injury.
The shock absorber contains nitrogen gas and oil under high
pressure. Do not drill any farther down the damper case than
the measurement given above, or you may drill into the oil
chamber; oil escaping under high pressure may cause serious
personal injury.
Always wear eye protection to avoid getting metal shavings in
your eyes when the gas pressure is released. The plastic bag is
only intended to shield you from the escaping gas.
Hold the bag around the drill motor and briefly run the drill
motor inside the bag; this will inflate the bag with air from the
(31 DAMPER UNIT
motor and help keeping the bag from getting caught in the bit
·when you start.
14-1 ~
Compress the spring until the stopper ring can be installed

(1 l SPRING
using a hydraulic press and spring compressor.
COMPRESSOR
TOOL:
Install the stopper ring in the groove in the damper.
(2) STOPPER
~RING
Apply molybdenum disulfide paste (containing more than 40% (1) BUSHING
of molybdenum) to the upper bushing.
NOTE
• Use molybdenum disulfide paste (containing more than
40% of molybdenum) as follows:
* Honda Moly 45 Grease. (U.S.A. only)
* Molykote® G-n paste manufactured by Dow Corning,
U.S.A.
* Rocol ASP manufactured by Rocol limited, U.K.
* Rocol paste manufactured by Sumico Lubricant, Japan.
* Any other manufacturer's paste grease equivalent to the
above may also be used. (3) COLLAR
Install new dust seals and caps if the bushing was replaced.
Install the collar.
Install and tighten the lower spring seat screw.
INSTALLATION
Install the shock absorber to the frame with the spring preload
adjuster facing the right side.
Tighten the shock absorber upper mounting bolt.
14-12
Install and tighten the shock absorber lower mounting bolt.
TORQUE: 45 N•m 14.5 kg-m. 33 ft-lb)
Install the shock link (page 14-15).

Install the left muffler (page 12-8).
SHOCK LINKAGE
REMOVAL
Remove the left muffler (page 12-7).

Remove the shock link-to-shock arm bolt, shock link-to-frame
bolt and shock link.
Remove the shock absorber lower mounting bolt, shock arm-
to-swing arm bolt and shock arm.
Remove the dust seals and collars from the shock link and
shock arm.
Check the dust seals and collars for wear, damage or fatigue.
Check the needle bearings for damage or loose fit.
If the needle bearings are loose or damaged, replace them.
(21 COLLARS
NEEDLE BEARING REPLACEMENT (1 I DRIVER PIN
Remove the needle bearings from the shock arm using a hy-
draulic press.
TOOLS:
Swing arm joints:
Driver pin 07GMD-KT80100
Shock link joint:
Driver shaft 07946-MJ00100
or
Driver 07949- 3710001
Attachment, 24 x 26 mm 07746-0010700
14-13
Remove the shock link needle bearings using a bearing remov- (1) WEIGHT (2) REMOVER
er.
TOOLS:
Bearing remover 07936-3710300
- bearing remover handle 07936-3710100 'fl
- bearing remover weight 07741-0010201 or /
/
07936-3710200 /
/
/
I /'
I /
I /
I /
///
/I
(4) HANDLE (3) NEEDLE BEARINGS
Apply grease to the needle bearings of the shock arm.

Press the needle bearings into the the shock arm.
TOOLS:
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Pilot, 17 mm 07746-0040400
Apply grease to the needle bearings of the shock link. (2) ATTACHMENT
Press the bearings into the shock link.
TOOLS:
Driver 07749-0010000
Attachement, 24 x 26 mm 07746-0010700
Pilot, 17 mm 077 46-0040400
/
/
(3) PILOT,
BEARING
ASSEMBLY ( 1 l DUST SEALS/NEEDLE BEARINGS

/
/
/
Fill the needle bearings, collars and dust seal lips with grease. /
/
Install the collars and dust seals to the shock arm and shock /
/
link.
, I"
/
(2) COLLARS
14-14
INSTALLATION
Install the shock arm and tighten the shock arm-to-swing arm
bolt and shock absorber lower mounting bolt.
TORQUE:
Shock arm-to-swing arm bolt
45 N·m (4.5 kg-m. 33 ft-lb)
Shock absorber lower mounting bolt
45 N·m (4.5 kg-m. 33 ft-lb) (5) SHOCK LINK
-TO-SHOCK ARM
Install the shock link and tighten the shock link-to-frame bolt BOLT
and shock link-to-shock arm bolt.
TORQUE:
Shock link-to-frame bolt
45 N·m (4.5 kg-m. 33 ft-lb)
Shock link-to-shock arm bolt
45 N·m (4.5 kg-m. 33 ft-lb)
Install the left muffler (page 12-8).
SWING ARM
REMOVAL
Raise the rear wheel off the ground by supporting the motor
Remove the rear wheel (page 14-3).

Remove the rear fender B (page 12-7).
Remove the shock arm-to-swing arm bolt and shock absorber
lower mounting bolt (page 14-13).
Remove the cotter pin, bolt, nut and washer, and remove the
brake torque rod from the swing arm.
Remove the swing arm pivot nut, pivot bolt and swing arm.
DISASSEMBLY/INSPECTION (1) DISTANCE COLLAR (2) CHAIN SLIDER
Remove the drive chain slider from the swing arm.

Check the drive chain slider for wear or damage.
Remove the dust seal, left pivot collar and distance collar.
Check the dust seal, left pivot collar and distance collar for
damage or fatigue.
Check the needle bearing for damage.
' ..... (3) NEEDLE

BEARING
14-15
Remove the right pivot collar and dust seal, and check them
for damage or fatigue.
(2) PIVOT COLLAR
Check that the bearing turns smoothly and quietly and fits
tightly in the swing arm.
If the bearing must be replaced, remove the snap ring.
(2) SNAP RING
PIVOT BEARING REPLACEMENT
Press the right pivot bearing out of the swing arm using a hy-
draulic press and driver shaft.
TOOL:
(2) PIVOT
BEARING
Install the needle bearing remover to the left needle bearing. (1) DRIVER
SHAFT
TOOL:
Needle bearing remover 07GMD-KT70200
Set the driver shaft as shown and press the needle bearing out
of the swing arm.
TOOL:
14-16
Press the right pivot bearing into the swing arm using a hy-
draulic press.
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 15 mm 07746-0040300
Press the left needle bearing into the swing arm using a hy-
draulic press.
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 22 mm 07746-0041000
ASSEMBLY
Install the snap ring into the groove in the swing arm if the
right pivot bearing is replaced.
( 11 SNAP RING
Apply grease to the dust seal lips and install it in the right -~ ( 1 l DUST SEAL
swing arm pivot.
Install the right pivot collar.
(21 PIVOT COLLAR
14-17
Fill the left needle bearing with grease. (2) CHAIN SLIDER
Install the distance collar.
Apply grease to the dust seal lips and install it in the left swing
arm pivot.
Install the left pivot collar.
Install the drive chain slider onto the swing arm.
INSTALLATION
Install the swing arm to the frame.

Apply grease to the seat of the swing arm pivot nut.
Install the swing arm pivot bolt and nut, and tighten the swing
arm pivot nut.
Install the brake torque rod to the swing arm.

Install the. brake torque rod mounting bolt, washer and nut,
and tighten the nut.
Install a new cotter pin through the brake torque rod mounting
nut and bend the both cotter pin ends down.
Install the following components.

- rear fender B (page 12-7).
- rear wheel (page 14- 7).
- left muffler (page 12-8).
14-18
MEMO
HYDRAULIC BRAKE
1 2 N·m 9 ft-lb)
6 N•m
(0.6 kg-m, 4 . 3 ft-lb) ' l~}rn, @. /
30
(3.0N•m
kg-m, 22 ft-lb)
'(§)~
22
(2.2N·m
kg-m, 16 ft-lb)
15-0
15. HYDRAULIC BRAKE
SERVICE INFORMATION 15-1 REAR MASTER CYLINDER 15-12
TROUBLESHOOTING 15-2 FRONT BRAKE CALIPER 15-15
BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER 15-17
AIR BLEEDING 15-3
BRAKE PEDAL 15-19
BRAKE PAD/DISC 15-5
FRONT MASTER CYLINDER 15-9
SERVICE INFORMATION
GENERAL
'iMMMi
• The brake calipers can be removed without disconnecting the hydraulic system.
• Bleed the hydraulic system if it has been disassembled or if the brake feels spongy.
• Do not allow foreign material to enter the system when filling the reservoir.
• Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced.
• Always check brake operation before riding the motorcycle.
SPECIFICATIONS Unit: mm (in)
Brake disc Thickness Front 4.3-4.7 (0.17-0.19) 3.5 (0.14)

Rear 4.8-5.2 (0.19-0.20) 4.0 (0.16)
Runout -- 0.3 (0.01)
Master cylinder l.D. Front 15.870-15.913 (0.6248-0.6265) 15.93 (0.627)
Rear 12. 700-12. 743 (0.4999-0.5017) 12. 76 (0. 502)
Master piston O.D. Front 15.827-15.854 (0.6231-0.6242) 15.82 (0.623)
Rear 12.657-12.684 (0.4983-0.4994) 12.65 (0.498)
Caliper cylinder l.D. Front 30.230-30.280 (1.1900-1.1920) 30.29 ( 1. 193)
Rear 27.000-27.050 (1.0630-1.0650) 27 .06 ( 1.065)
Caliper piston 0. D. Front 30.165-30.198 (1.1879-1.1889) 30. 16 ( 1. 187)
Rear 26.918-26.968 (1.0598-1.0617) 26.91 ( 1 .059)
Brake fluid DOT4 --
TORQUE VALUES
Front brake caliper bracket bolt 27 N·m (2. 7 kg-m, 20 ft-lb)
Anti-dive piston bolt 12 N•m ( 1.2 kg-m, 9 ft-lb)
Bleed valve 6 N·m (0.6 kg-m, 4.3 ft-lb)
Brake hose bolt 30 N·m (3.0 kg-m, 22 ft-lb)
Rear brake caliper mounting bolt 23 N·m (2.3 kg-m, 17 ft-lb)
Front brake pad pin 18 N·m ( 1.8 kg-m, 13 ft-lb)
Front brake pad pin plug 2. 5 N•m (0.25 kg-m, 1.8 ft-lb)
Rear brake pad pin retainer bolt 11 N·m ( 1 .1 kg-m, 8 ft-lb)
Front brake lever pivot nut 6 N·m (0.6 kg-m, 4.3 ft-lb)
Front master cylinder holder bolt 12 N·m ( 1 .2 kg-m, 9 ft-lb)
Right footpeg bracket bolt 27 N·m (2. 7 kg-m, 20 ft-lb)
Brake lever adjuster pivot screw 4 N·m (0.4 kg-m, 2.9 ft-lb) Apply a locking agent to the threads
Front brake light switch screw 1.2 N•m (0.12 kg-m, 0.9 ft-lb)
15-1
HYDRAULIC BRAKE
TOOL
Special
Snap ring pliers 07914-3230001-equivalent commercially available in U.S.A.
TROUBLESHOOTING
Brake lever/pedal soft or spongy Brakes grab
• Air in hydraulic system • Pads contaminated
• Low fluid level • Disc or wheel misaligned
• Hydraulic system leaking
Brake chatter or squeal
Brake lever/pedal too hard • Pads contaminated
• Sticking piston(s) • Excessive disc runout
• Clogged hydraulic system • Caliper installed incorrectly
• Pads glazed or worn excessively • Disc or wheel misaligned
Brake drag
• Hydraulic system sticking
• Sticking piston(s)
• Clogged hydraulic system
• Caliper slide pins sticking
• Disc or wheel misaligned
15-2
HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/

Al R BLEE DI NG
GMMl!fli
• A contaminated brake disc or pad reduces stopping power. Dis-
card contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
CAUTION
• Do not allow foreign material to enter the system when filling
the reservoir.
• A void spilling fluid on painted, plastic or rubber parts. place a
• Use only DOT 4 brake fluid from a sealed container.
• Do not mix brake fluid types and never reuse drained fluid. ~ <(1) FRONT>
BRAKE FLUID DRAINING
Connect a bleed hose to the bleed valve.

Remove the reservoir cover.
NOTE
• Be sure the fluid reservoir is parallel to the ground before re-
moving the cover and diaphragm.
Loosen the caliper bleed valve and slowly pump the brake lever
or pedal.
Stop operating the lever or pedal when fluid stops flowing out
of the bleed valve.
BRAKE FLUID FILLING
NOTE
• Check the fluid level often while bleeding the brakes to pre-
vent air from being pumped into the system.
• When using the Brake Bleeder, follow the manufacturer's
instructions.
• Do not mix brake fluid types and never reuse the fluid which
has been pumped out during brake bleeding, because it may
impair the efficiency of the brake system.
Close the bleeder valve, fill the reservoir with DOT 4 brake
fluid to the upper level.
Install the diaphragm and reservoir cover.
15-3
HYDRAULIC BRAKE
Connect a Brake Bleeder or equivalent to the bleed valve. <(1) FRONT>
Pump the brake bleeder and loosen the bleed valve. Add fluid
when the fluid level in the master cylinder reservoir is low.
Repeat above procedures until no air bubbles appear in the
plastic hose.
NOTE
If air is entering the bleed from around the bleed valve
threads, seal the threads with teflon tape.
'
If a brake bleeder is not available, fill the system as follows:
Pump up the system pressure with the lever or pedal until

there are no air bubbles in the fluid flowing out of the reservoir
hole and lever or pedal resistance is felt.
AIR BLEEDING
Bleed the system as follows:

1 I Connect a bleed hose to the bleed valve.
2) Squeeze the brake lever (or depress the brake pedal), then
open the bleed valve 1/2 turn and close the valve.
NOTE
• Do not release the brake lever (or pedal) until the bleed
valve has been closed.
3) Release the brake lever (or pedal) slowly and wait several
seconds after it reaches the end of its travel.
Repeat steps 2 and 3 until bubbles cease to appear in the fluid

at the end of the hose.
Tighten the bleed valve.
TORQUE: 6 N·m (0.6 kg-m, 4.3 ft-lb)
Close the bleed valve, fill the reservoir with DOT 4 brake fluid
to the upper level.
Reinstall the diaphragm and reservoir cover.
15-4
HYDRAULIC BRAKE
BRAKE PAD/DISC
FRONT PAD REPLACEMENT
CAUTION
• Always replace the brake pads in pairs to assure even disc pres-
sure.
• Leave the brake hose as it is.
Right front caliper:

Remove the pad pin plugs and loosen the pad pins.
Remove the caliper bracket bolts, then remove the right front
brake caliper and bracket.
Left front caliper: <IITTEFT FRONT CALIPER> (2) BRACKET BOLT

Remove the pad pin plugs and loosen the pad pins. (5) (3) PINS
Remove the caliper bracket bolt and anti-dive piston bolt, then ANTI-DIVE
remove the left front brake caliper and bracket. PISTON BOLT
Pry one old pad against the caliper with a screwdriver to push
the pistons into the caliper.
Pull the pad pins out of the caliper.

Remove the brake pads.
15-5
HYDRAULIC BRAKE
Position the pad spring in the caliper as shown.
Apply silicone grease to the caliper bracket pins.
Install the new pads in the caliper.
Install the pad pins, first one pin, then the other, by pushing
the pads against the caliper to depress the pad spring.
Left front caliper:

Install the left front brake caliper, making sure not to damage
the pads, tighten the caliper bracket bolt and anti-dive piston '<( ITTEFT FRONT CALIPER>
bolt.
TORQUE:
Caliper bracket bolt 27 N•m (2. 7 kg-m, 20 ft-lbl
Anti-dive piston bolt 12 N·m (1.2 kg-m, 9 ft-lbl
Tighten the pad pins.
TORQUE: 18 N·m (1.8 kg-m, 13 ft-lbl
Tighten the pad pin plugs.
TORQUE: 2.5 N·m (0.25 kg-m, 1.8 ft-lbl
15-6
HYDRAULIC BRAKE

Install the right front brake caliper, making sure not to damage
the pads, then tighten the caliper bracket bolts.
TORQUE: 27 N·m (2. 7 kg-m, 20 ft-lb)
TORQUE: 2.5 N•m (0.25 kg-m, 1.8 ft-lb)
NOTE
• Operate the brake lever to seat the caliper pistons against
the pads.
REAR BRAKE PAD REPLACEMENT
NOTE
• Always replace the brake pads in pairs to assure even disc
pressure.
Remove the pad pin retainer bolt and retainer.

Remove the caliper mounting bolt.
Remove the rear caliper from the bracket.
Pry one old pad against the caliper with a screwdriver to push
the pistons into the caliper.
Pull the pad pins out of the caliper.

Remove the brake pads.
15-7
HYDRAULIC BRAKE
Position the pad spring in the caliper as shown.
Install the new pads in the caliper. (2)

Install the pad pins, first one pin, then the other, by pushing PINS
the pads against the caliper to depress the pad spring.
Apply silicone grease to the caliper bracket pin.
Install the caliper, making sure not to damage the pads, then
tighten the caliper mounting bolt applied silicone grease.
'
TORQUE: 23 N•m (2.3 kg-m, 17 ft-lbl
Install the pad pin retainer to the pad pins securely and tighten
the retainer bolt.
TORQUE: 11 N•m (1.1 kg-m. 8 ft-lbl
NOTE
• Operate brake pedal to seat the caliper pistons against the
pads.
DISC THICKNESS
Measure the thickness of each disc.
SERVICE LIMITS: Front: 3.5 mm (0.14 inl

Rear: 4.0 mm (0.16 in)
15-8
HYDRAULIC BRAKE
BRAKE DISC WARPAGE
Measure brake disc for warpage.
FRONT MASTER CYLINDER

REMOVAL
CAUTION
• A void spilling brake fluid on painted, plastic or rubber parts.
Place a rag over these parts whenever the system is serviced.
NOTE
• When removing the fluid hose, cover the end of the hose to
prevent contamination. Secure the hose to prevent fluid
from leaking out.
Drain the brake fluid from the front brake system (page 1 5-3). 111 (21 BRAKE LIGHT SWITCH
Disconnect the brake hose. BRAKE LEVER 131 PISTON BOOT
Disconnect the front brake switch wires.
Remove the master cylinder holder bolts and master cylinder.
Remove the brake lever pivot nut, bolt and adjuster arm pivot
screw.
Remove the brake lever and adjuster arm from the master cyl-
inder body.
Remove the front brake light switch.

Remove the piston boot.
141 PIVOT SCREW
NOTE
• Be careful not to damage the piston boot when removing it.
111 SNAP RING
DISASSEMBLY
Remove the snap ring from the master cylinder body.
TOOL:
available in U.S.A.
15-9
HYDRAULIC BRAKE
Remove the secondary cup and piston, then remove the pri-
mary cup and spring.
Clean the inside of the master cylinder and reservoir with clean
brake fluid.
NOTE
• Clean the disassembled parts with brake fluid and make
sure air can go through the master cylinder port by applying
compressed air.
(6) PRIMARY CUP (5) PISTON
INSPECTION
Check the master cylinder for scores, scratches or nicks .

Measure the master cylinder l.D .
Measure the master piston O.D.
Check the primary and secondary cups for damage before as-
sembly.
ASSEMBLY
NOTE
.(2)
• The master cylinder piston, cups and spring must be in-
PRIMARY CUP
stalled as a set.
~ / ~~~TON
/.)~NDA?v
Dip the piston cups in clean brake fluid before assembly .
Install the spring and primary cup together . Install the master
cylinder piston .
1
CAUTION
• When installing the cups, do not allow the lips to turn inside (6) SPRING CUP
,,:>
out. (4) SNAP RING
15-10
HYDRAULIC BRAKE
Install the snap ring to the master cylinder body.
TOOL:
available in U.S.A.
CAUTION
• Be certain the snap ring is firmly seated in the groove.
Install the piston boot.
Install the joint pin, adjuster and adjuster rod to the brake (2) BRAKE LEVER
lever.
Apply silicone grease to the adjuster rod.
CAUTION
• Align the index mark on the adjuster with the arrow on the
brake lever.
Install the adjuster arm to the brake lever.

Apply a locking agent to the pivot screw and tighten it.
TORQUE: 4 N•m (0.4 kg-m. 2.9 ft-lb)
Apply grease to the brake lever pivots. (1) NUT

Install the lever and adjuster arm in the master cylinder.
Tighten the nuts to the specified torque.
TORQUE: 6 N·m (0.6 kg-m. 4.3 ft-lb)
Install the brake light switch.

Tighten the screw to the specified torgue.
TORQUE: 1.2 N•m (0.12 kg-m, 0.9 ft-lb)
(2)
BRAKE LIGHT .
(3) SCREW SWITCH
INSTALLATION
Place the front master cylinder on the handlebar and install the
holder with its "UP" mark facing up.
Align the end of the holder with the punch mark on the handle-
bar. Tighten the upper bolt first, then tighten the lower bolt.
Connect the brake hose with new sealing washers and tighten
the bolt.
Connect the front brake switch wires.

Fill and bleed the front brake system (page 15-3).
15-11
HYDRAULIC BRAKE
REAR MASTER CYLINDER

REMOVAL
CAUTION
• A void spilling brake fluid on painted, plastic or rubber parts.
Place a rag over these parts whenever the system is serviced.
NOTE
• When removing the fluid hose bolt, cover the end of the
hose to prevent contamination. Secure the hose to prevent
fluid from leaking out.

Drain the rear brake system (page 1 5-3).
Loosen the rear master cylinder mounting bolts.

Remove the brake hose bolt and disconnect the brake hose.
Remove the reservoir.
Remove the right footpeg bracket.
Disconnect the push rod joint from the rear brake pedal.
Remove the master cylinder from the right footpeg bracket.
DISASSEMBLY
Remove the reservoir hose from the master cylinder by remov-

ing the screw.
'
'
(2) SCREW
Move away the dust boot . (1) BOOT

Remove the snap ring and push rod from the master cylinder
body.
CAUTION
• 'Beware that piston rod will pop out when removing the snap
ring.
TOOL:
available in U.S.A.
I (3) SNAP RING PLIERS
15-12
HYDRAULIC BRAKE
Remove the piston and spring. (3) CUPS (4) ROD
NOTE
Clean the disassembled parts with brake fluid and make
sure air can go through the master cylinder port by applying
compressed air.
Check the push rod for bending or damage.
(1) MASTER
CYLINDER (5) PISTON
INSPECTION
Check the master cylinder for scores, scratches or nicks.

Measure the master cylinder bore.
SERVICE LIMIT: 12. 76 mm (0.502 in)
Check the piston and piston cups for damage, wear or deterio-
ration.
Measure the master piston 0.D.
ASSEMBLY
Dip the piston cups in clean brake fluid before assembly.

Coat the inside of the master cylinder with brake fluid.
Install the spring and piston together. (4) ROD
NOTE
• The master cylinder piston, cups and spring must be in-
stalled as a set.
Apply grease to the push rod attached to piston contact sur-

faces.
CAUTION (1) MASTER

CYLINDER
When installing the cups, do not allow the lips to turn inside
out.
15-13
HYDRAULIC BRAKE
Install the push rod into the master cylinder. (1) WASHER
Install the washer, snap ring and dust boot.
TOOL:
available in U.S.A.
CAUTION
• Be certain the snap ring is seated firmly in the groove.
(4) SNAP RING PLIERS (3) SNAP RING
Check the 0-ring of reservoir hose for fatigue. (1) MASTER CYLINDER (2) HOSE
Install the reservoir hose to the master cylinder with the

screw.
(4) 0-RING ., ( 3 ) SCREW
INSTALLATION
Temporarily install the master cylinder to right footpeg brack-

et.
Connect the push rod joint to the rear brake pedal with joint pin
and secure the joint pin with the washer and a new cotter pin.
Install the right footpeg bracket with two bolts and tighten
them.
TORQUE: 27 N•m (2. 7 kg-m, 22 ft-lb)
Tighten the master cylinder mouting bolts.
Connect the rear brake hose with the bolt and new sealing
washers.
15-14
HYDRAULIC BRAKE
Install the reservoir with its mounting bolt.
Fill and bleed the rear brake system (page 1 5-3).

Install the right side cover.
FRONT BRAKE CALI PER

REMOVAL
Place a clean container under the caliper and disconnect the

brake hose from caliper.
9 <(2) LEFT>
CAUTION
• A void spilling brake fluid on painted surfaces.
Loosen the pad pins (page 15-5).

Remove the caliper bracket bolts and anti-dive piston bolt from
the left front brake caliper.
Remove the caliper bracket bolts from the right front brake cal-
iper.
Remove the calipers.

- pad pins and pads
- caliper bracket
- pad spring
- pivot boots
DISASSEMBLY
Position the caliper with the pistons down and apply short
bursts of air pressure to the fluid inlet.
GMMl!flN
• Do not use high pressure air or bring the nozzle too close to the
inlet.
• Place a shop towel over the pistons to prevent them from flying
out.
Examine the pistons and cylinders for scoring, scratches or

other damage and replace if necessary.
Push the piston and dust seals in, lift them out and discard
them.
CAUTION
• Be careful not to damage the piston sliding surfaces when re-
moving the seals.
Clean the caliper cylinders, seal grooves and caliper pistons

with clean brake fluid.
15-15
HYDRAULIC BRAKE
INSPECTION
Check the pistons for scoring, scratches or other damage.

Measure the piston O.D.
Check the caliper cylinder for scoring, scratches or other dam-

age . Measure the caliper cylinder bore.
SERVICE LIMIT: 30. 16 mm ( 1 .187 in)
ASSEMBLY/INSTALLATION (1) PISTON SEALS (21 DUST SEALS
The piston and dust seals must be replaced with new ones
whenever they are removed.
Coat the seals with brake fluid before assembly.
Install new seals .

Install the pistons with the insulated ends toward the pads.
If the boots are hardened or deteriorated, replace them .
Install the boots. (31 PISTONS

Apply silicone grease to the caliper pin and caliper bracket pin.
Install the pad spring and caliper bracket.
Install the pads and pad pins (page 1 5-5).
CAUTION
• Be careful not to damage the pads.
Install the caliper bracket on the fork leg .

Left front caliper:
Tighten the caliper bracket bolt and anti-dive piston bolt .
TORQUE:
Caliper bracket bolt 27 N•m (2. 7 kg-m, 20 ft-lb)
Anti-dive piston bolt 12 N·m ( 1.2 kg-m, 9 ft-lb)
Connect the brake hose to the caliper with new sealing wash-
ers and the hose bolt.
Tighten the hose bolt.
TORQUE: 2.5 N·m (0.25 kg-m, 1.8 ft-lb)
15-16
HYDRAULIC BRAKE

Tighten the caliper bracket bolts.
TORQUE: 27 N·m (2. 7 kg-m, 20 ft-lb)
TORQUE: 2.5 N·m (0.25 kg-m, 1.8 ft-lb)
Connect the brake hose to the caliper with new sealing wash-
ers and the hose bolt.
Fill and bleed the front brake system (page 15-3).
REAR BRAKE CALI PER

REMOVAL
Drain the brake fluid from the rear brake system (page 1 5-3).
Disconnect the brake hose from the caliper.
Remove the rear caliper mounting bolt and remove the rear cal-
iper.
Remove the rear brake pads (page 15-7).
Remove the caliper from the bracket.
DISASSEMBLY
Remove the pad spring, boots and pivot collar from the rear
brake caliper.
If the boots are hardened or deteriorated, replace them.
Position the caliper with the pistons down and apply short
bursts of air pressure to the fluid inlet.
1%1&.M@ld
• Do not use high pressure air or bring the nozzle too close to the
inlet.
• Place a shop towel over the pistons to prevent them from flying
out.
15-17
HYDRAULIC BRAKE
Push the dust and piston seals in, lift them out and discard
them.
CAUTION
• Be careful not to damage the piston sliding surfaces.
Clean the caliper cylinders, seal grooves and caliper pistons

with clean brake fluid.
(2) DUST SEALS
INSPECTION
Check the caliper cylinder for scratches, scoring or other dam-

age.
Measure the caliper cylinder bore.
Check the pistons for scoring, scratches or other damage.

Measure the piston O.D ..
ASSEMBLY ( 1) PISTON SEALS
The piston and dust seals must be replaced whenever they are
removed.
Coat the seals with brake fluid before assembly.
Install new seals.

Install the pistons with the opened ends toward the pads.
Apply silicone grease to the pivot collar, pin and the insides of
the boots and install them into the caliper.
(2) COLLAR
----1
CAUTION
• Make sure that boots are seated in the caliper grooves.
Install the pad spring.
15-18
HYDRAULIC BRAKE
INSTALLATION
Install the rear brake pads (page 1 5-8).
CAUTION
• Be careful not to damage brake pads.
Apply the silicone grease to the caliper mounting bolt and

tighten it.
TORQUE: 23 N•m ( 2.3 kg-m, 17 ft-lb)
Install the pad pin retainer and tighten the bolt.
TORQUE: 11 N•m ( 1.1 kg-m, 8 ft-lb)
Install the brake hose with the bolt and new sealing washers.
Tighten the hose bolt.
Fill and bleed the rear brake system (page 15-3).
BRAKE PEDAL
REMOVAL

Remove the right footpeg bracket bolts.
Remove the brake pedal return spring and stop light switch
spring from the brake pedal.
Disconnect the brake pedal from the brake rod by removing

cotter pin.
Remove the snap ring and brake pedal.
15-19
HYDRAULIC BRAKE
INSTALLATION
Apply grease to the brake pedal pivot and install the brake
pedal to the footpeg.
(2) PEDAL
Install the snap ring on the brake pedal pivot securely.
Hook the push rod and brake pedal using the joint pin with the
washer and a new cotter pin.
Install the rear brake pedal return spring and rear stop light
switch spring on the brake pedal.
Install the right footpeg bracket and tighten the bolts.
Install the right side cover.
15-20
MEMO
BATTERY/CHARGING SYSTEM
( 1) IGNITION (3) MAIN

SWITCH FUSE 30 A
(2) BATTERY
12 V 14 AH
(6) SUB
FUSE
10 A
(5) ALTERNATOR (4) REGULATOR/

RECTIFIER
(6) SUB
(1) IGNITION
FUSE
-ol
SWITCH
10 A
Cf\.P- R/BI
y
I
Bl
R
R/W
y
L---y
(4) G
L-----Y
1
REGULATOR/
RECTIFIER (3) MAIN FUSE
- --Bl 30 A
(2) BATTERY
w 12 V 14 AH
Y: yellow
Bl: black
W: white
R: red
G: green
16-0
16. BATTERY/CHARGING SYSTEM
SERVICE INFORMATION 16-1 CHARGING SYSTEM 16-4
TROUBLESHOOTING 16-2 REGULATOR/RECTIFIER 16-5
BATTERY 16-3 ALTERNATOR 16-5
SERVICE INFORMATION
GENERAL
• Do not smoke or allow }lames near a charging battery. The gas produced by a battery will explode if }lames or sparks are brought
near.
• When inspect the charging system, check the system components and lines step-by-step according to troubleshooting on next page.
• The battery fluid level should be checked regularly. Fill with distilled water after removing the battery from the frame when
necessary.
• Quick charge a battery only in an emergency; slow-charging is preferred.
• Remove the battery from the motorcycle for charging. If the battery must be charged on the motorcycle, disconnect the
battery cables.
CAUTION
• For battery charging, do not exceed the charging current and time. Use of excessive current or charging time may damage the bat-
tery.
• The alternator shaft can not be removed when the engine is installed in frame, see section 11 for starter clutch/alternator shaft re-
moval.
• The following color codes are used throughout the electrical system.
Bu = Blue G = Green Lg = Light Green R = Red
Bl = Black Gr = Gray 0 = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow
• All charging system components can be tested on the motorcycle.
SPECIFICATIONS
ITEM STANDARD
Battery Capacity 12 V-14 AH

Specific gravity Fully charged 1.280
at 20°C (68°FJ Normal charge 1.260
' Needs charging 1.200
Charging rate 1 .4 amperes max.
Alternator Type Three-phase AC with field coil
Output 350 W/5,000 rpm
Resistance Bl-W 2.0:_2.6 {}
at 20°C (68°FJ Y-Y 0.4-0.6 {}
Regulator/rectifier Type Three-phase/full-wave rectify,
field coil current regulate
Regulated voltage 13.5-15.5 v
TORQUE VALUE
Alternator shaft nut 50 N•m (5.0 kg-m, 36 ft-lb)
16-1
TROUBLESHOOTING
Battery discharged
Probable cause
1 . Perform the leakage inspection (page 16-4) L E A K - - - - - - - • Loose, broken or shorted wire or connec-
tion
NOT LEAK
•
2. Start the engine and perform the regulated
voltage inspection (page 16-4)
REGULATED----• Faulty battery
LOW VOLTAGE
(SAME AS BATTERY VOLTAGE)
t
3. Check the alternator stator coil and field coil OUT OF ORDER---· Faulty stator coil
continuity (page 16-5) • Faulty field coil
NORMAL
4. Measure the feed back voltage and out put BATTERY VOLTAGE-· Open or shorted black, or green wires or
line voltage (page 16-5) DOES NOT COME their connections
• Loose or poorly contact connectors
BATTERY VOLTAGE COMES
5. Measure the feild coil voltage (page 16-5) VOLTAGE APPLIED-· Faulty alternator
NO VOLTAGE
'----------------------------- • Faulty regulator/rectifier
Battery overcharged
1 . Disconnect the alternator connector and CONTINUITY----· Faulty alternator field coil
check continuity between the white and
body ground at the alternator connector
I
NO CONTINUITY
'-----------------------------~· Faulty regulator/rectifier
16-2
BATTERY /CHARGING SYSTEM
BATTERY
BATTERY VOLT AGE
Remove the seat and battery cover.

Set the meter to the D\:V-Scale. Connect the Red lead to the
battery (+)terminal and the Black lead to the battery (-) termi-
nal.
Fully Charged: 12-13 volts

Normal Reading: 11 -12 volts
Needs Charging: Below 11 volts
REMOVAL (1) NEGATIVE/

CABLE
Disconnect the negative cable at the battery, then disconnect
the positive cable.
Remove the battery.
INSPECTON
Check for cracked or broken case or plates. Check the plates

for sulfation.
Replace the battery if damaged or sulfated.
Check each cell's electrolyte level. If low, add distilled water (1 l BATTERY TEMPERATURE VS SPECIFIC GRAVITY
1 31
to bring the level to the upper mark. · 1.304
>-
I-
NOTE >
<(
1.29
• In order to obtain accurate test readings when checking the a:

(.'.)
charging system, the battery must be fully charged and in u 1.27
good condition. Perform the following inspections and tests u:::
before attempting to troubleshoot charging system prob- u
w
a.. 1.25
lems. C/l
1.256
0 (32) 10 (50) 20 (68) 30 (86) 40 (1041

(2) ELECTROLYTE TEMPERATURE °C (°F)
SPECIFIC GRAVITY (4) Specific gravity changes by 0.007 for every 10°C
The specific gravity must be checked with a hydrometer. Test

each cell by drawing electrolyte into the hydrometer.
Fully Charged: 1.280 at 20°C (68°F)

Normal Reading: 1.260 at 20°C (68°F)
Needs Charging: 1.200 at 20°C (68°F)
Make sure the variation between the high and low cells is less
than 0.05.
W4Mlfl'
The battery electrolyte contains sulfuric acid. A void contact
with skin, eyes, or clothing. If electrolyte gets in your eyes;
flush them thoroughly with water get prompt medical atten-
tion.
16-3
CHARGING
Remove the battery cell caps. Fill the cells with distilled water
to the upper level line, if necessary.
Connect the charger positive (+) cable to the battery positive
(+)terminal.
Connect the charger negative (-) cable to the battery negative
(-) terminal.
Charging current: 1.4 amperes max.
Charge the battery until specific gravity is 1.270-1.290 at
20°C (68°F).
IJMfo.111.lld
• Before charging a battery, remove the cap from each cell.
• Keep flames and sparks away from a charging battery.
• Turn power ON/OFF at the charger, not at the battery termi-
nals, to prevent sparks.
• Discontinue charging {f the electrolyte temperature exceeds
45°C (ll3°F)
CAUTION
PIPING AS SHOWN BELOW.
CAUTION BATT ELBOW
• Quick-charging should only be done in an emergency; slow- BATTERY
BREATHER
charging is preferred.
• Route the breather tube as shown on the battery caution label.
After installing the battery, coat the terminals with clean

grease.
CHARGING SYSTEM
NOTE
• Check the system components and lines step-by-step ac-
cording to troubleshooting described on page 16-2.
LEAKAGE INSPECTION
Check the battery for voltage leakage before making a charg-
ing output inspection.
Turn the ignition switch OFF. Remove the ground cable from
the battery.
Disconnect the regulator/rectifier connectors.
Connect the voltmeter between the ground cable and battery
(-) terminal.
The voltmeter should indicate OV with the ignition switch
OFF.
CHARGING OUTPUT INSPECTION

Start the engine and warm it up to operating temperature.
Remove the seat.
Connect the voltmeter between the positive and negative ter-
minals of the battery.
CAUTION
• Be careful not to let the battery positive cable contact the frame
while testing.
Start the engine and take the readings on the voltmeter.

Gradually increase the engine speed and check that the volt-
age is regulated.
REGULATED VOLTAGE: 13.5-15.5 V/5,000 rpm
16-4
REGULATOR/RECTIFIER
REMOVAL/INST ALLA Tl ON
Remove the seat, left side cover and fairing.

Disconnect the connectors of the regulator/rectifier and
remove the regulator/rectifier.
Installation is the reverse order of removal.
INSPECTION IGNITION ENGINE

WIRE COLOR OF THE SWITCH STOP SWITCH
ITEM
REGULATOR/RECTIFIER
ON OFF ON OFF
Check the terminals of each connector for loose or poor con-
FEEDBACK BLACK f+I
tact before inspection. VOLTAGE
Inspect the regulator/rectifier wires by measuring the voltage. YES NO YES NO
GREEN 1-1
OUT PUT RED/WHITE f+I
VOLTAGE
YES YES YES YES
GREEN 1-1
FIELD COIL WHITE f+I
VOLTAGE
GREEN 1-1
YES NO YES NO
BLACK f+I
GREEN 1-1
ALTERNATOR
ST ATOR COIL INSPECTION
Remove the left side cover, left side fairing and seat.
Disconnect the alternator connector.
Check for continuity between the alternator yellow wire leads
and between the leads and ground.
RESISTANCE IV-VI: 0.4-0.6 n (20°C/68°F)

Replace the stator if there is no continuity between the yellow
wires or if there is continuity between the yellow wire and
ground.
FIELD COIL INSPECTION
Measure the resistance between the Black and white wires of

the connector.
RESISTANCE (81-WI: 2.0-2.6 n (20°C/68°F)

Replace the field coil if there is no continuity between the
Black and White wires.
16-5
STATOR REMOVAL
Disconnect the alternator connector.
Remove the alternator cover and remove the clip and grommet
from the cover.
Remove the bearing with a commercially available bearing pull-

er.
Shift the transmission into gear and apply rear brake.
Remove the alternator shaft nut, rotor and stator.
16-6
STATOR INSTALLATION
Install the stator.

Install the rotor, aligning the hole on the rotor and pin on the
shaft.
Tighten the shaft nut to the specified torque.
Install the new shaft bearing onto the shaft driving inner race
of the bearing.
NOTE
• Face the spring side out.
Install the cover after attaching the grommet and clip.
16-7
IGNITION SYSTEM
(61 SPARK UNIT
(8) SUB
FUSE
10A
(71 PULSE
GENERATORS
(2) ENGINE (8) SUB
r
STOP FUSE (1) IGNITION
SWITCH 10A SWITCH
0-- Bl -J'\.J>- R/BI ---0--o- R _ ___JV'-..J:>--·f<:t:I
Bl/W
(31 BATTERY
12V 14AH -:-
Bu/Y Bl/W Y/Bu G

Y /Bu Bl/W Bu/Y Bl/W
(4) IGNITION
COILS
(61 SPARK UNIT
""
(71 (71 PULSE
(91 CYLINDER PULSE GENERATOR II
L-~~~~~~~~~~---'GENERATORI
IlII
NUMBER
Bl: black
W: white
-:"' -:"' ~ ":" R: red
Y: yellow
Bu: blue
G: green
17-0
17. IGNITION SYSTEM
SERVICE INFORMATION 17-1 IGNITION COIL 17-3
TROUBLESHOOTING 17-2 PULSE GENERATOR 17-4
SPARK UNIT IGNITION TIMING 17-6
SYSTEM INSPECTION 17-3
SERVICE INFORMATION
GENERAL
• Ignition timing cannot be adjusted since the spark unit is non-adjustable. If ignition timing is incorrect, check the system
components and replace the faulty parts.
• For spark plug gap inspection and adjustment procedure, see page 3-6.
• When inspecting the ignition system, check the system components and lines step-by-step according to the troubleshoot-
ing information on the next page.
• Be sure the battery is fully charged before diagnosing the ignition system.
• Each pair of spark plugs (No. 1 -4 and No. 2-3) has its own ignition circuit.
SPECIFICAITONS
ITEM SPECIFICATION
I Spark plug NGK I ND

DPR9EA-9 I X27EPR-U9 I
Spark plug gap 0.8-0.9 mm I0.03-0.04 in) I
J 1gnition system Type Transisterized digital control ignition system
Ignition timing Initial IF mark) 10° BTDC/1,000 ± 100 rpm
Full advance 38° BTDC/5,000 rpm I
Ignition coil Primary 2.6-3.2 n 120°C/68°F)
resistance Secondary With plug wire 17-23k!l120°C/68°F)
Without plug wire 13-17k!l120°C/68°F)
Pluse generator Coil resistance 460-580 n 120°C/68°F)
Firing order
TORQUE VALVE
1-2-4-3
ID
Pulse rotor bolt 50 N•m (5.0 kg-m, 36 ft-lb)
17-1
IGNITION SYSTEM
TROUBLESHOOTING
No spark at one spark plug
• Faulty spark plug
• Faulty spark plug wire
No spark at all plugs
1 . Check the spark unit connectors for loose ABNORMAL

• Loose or poor contact at the connectors.
or poor contact.
NORMAL
2. Measure voltage between the Bl/W (+) and

G (-)/between the Bu/Y (+) and G (-) of the ABNORMAL
Spark unit 6P connector. Battery voltage • Faulty ignition or engine stop switches
should appear with the ignition switch ON • Open or short circuit in wire harness
and the engine stop switch "RUN".
NORMAL
3-1 . Check the pulse generator resistances at ABNORMAL

3-2. Check the pulse generator (page 1°7-4).
the spark unit 4P connector (page 17-3).
NORMAL
NORMAL
•
i
Open or short circuit •
ABNORMAL
Faulty pulse gener-
in wire harness ator
• Loose or poor con-
tact connectors
• Faulty spark unit
No spark at either group (No. 1-4 or 2-31-ICHECK WRONG SPARK GROUP)
1 . Check the ignition secondary coil resistance ABNORMAL

(page 1 7-4). - • Faulty ignition coil
Faulty spark plug wire
NORMAL
2-1 . Check the ignition primary coil resistance

at the spark unit 6P connector (page 1 7- ABNORMAL
- 2-2. Check the ignition coil (page 17-3).
3).
NORMAL ABNORMAL
• Loose or poor con- • Faulty ignition coil
NORMAL tact connectors
• Open or short circuit
in wire harness
'
3-1 . Check the pulse generator resistances at ABNORMAL

-
3-2. Check the pulse generator (page 17-4).
the spark unit 4P connector (page 17-3).
NORMAL ABNORMAL
• Open or short circuit • Faulty pulse gener-
NORMAL in wire harness ator
• Loose or poor con-
tact connectors
4. Exchange the ignition coil and try the spark GOOD JUMP
• Faulty ignition coil
test.
DO NOT JUMP
~------------------------.. • Faulty spark unit
17-2
IGNITION SYSTEM
SPARK UN IT SYSTEM INSPECTION

NOTE
• Check the system components and lines step-by-step ac-
cording to troubleshooting described on page 17-2.
Disconnect the spark unit connectors and check them for

loose contact or corroded terminals.
Measure the resistance between connector terminals of the

following chart.
<6P CONNECTOR>
ITEM TERMINALS STANDARD

I
Ignition primary coil Y/Bu and Bl/W (No. 1-4) Bu/Y and Bl/W (No. 2-3) 2.6-3.2 !l (20°C/68°F) I
Power supply system Bl/W (+) and G (-)
Battery voltage should come
(Ignition switch "ON" and engine stop switch "RUN") I
<4P engine stop switch "RUN")CONNECTOR>
ITEM TERMINALS STANDARD
Pulse generator coil W/Y and Y (No. 1) W/Bu and Bu (No. 2) 460-580 !l (20°C/68°F)
each terminal and body ground NO CONTINUITY
IGNITION COIL
INSPECTION
Remove the fuel tank front mounting bolts and support the
tank by the support rod.
<
Disconnect the black/white wires from the ignition coil.
Set the meter to the DCV-Scale.
Measure the voltage between the black/white (+) and yellow/
blue (No. 1-4) or blue/yellow (No. 2-3) terminals.
The battery voltage sould appear when the ignition switch is
"ON" and the engine stop switch is "RUN".
If there is no battery voltage, check the wire harness for short

or opened circuit.
If the battery voltage does come on, perform the following in-
spection.
Measure the primary coil resistance by checking for continuity

between the primary terminals.
STANDARD: 2.6-3.2 n (20°C/68°F)
17-3
IGNITION SYSTEM
Measure the secondary coil resistance with the spark plug cap
in place by checking for continuity between the plug cap and
green terminal.
STANDARD: 17-23 kO (20°C/68°F)
If the resistance is out of standard, remove the spark plug wire

and measure the resistance between the secondary terminals ..
STANDARD: 13-17 kO (20°C/68°F)
REPLACEMENT

Disconnect the primary terminals from the coil.
Remove the spark plug cap from the spark plug.
Remove the ignition coil mounting bolts and coil.
Install the new ignition coil in the reverse order of removal.
NOTE
• Connect the primary wire terminals properly.
No. 1 -4 coil: black terminal-black/white wire
green terminal-yellow/blue wire
No. 2-3 coil: black terminal-black/white wire
green terminal-blue/yellow wire
PULSE GENERATOR
INSPECTION
NOTE
• It is not necessary to remove the pulse generator to make
this inspection.
Remove the seat, left side cover and fairing.
Disconnect the pulse generator 4P mini connector (BLACK).
Measure the resistances between the white/yellow and yellow

wires (No. 1 pulse generator) and the white/blue and blue
wires (No. 2 pulse generator).
STANDARD: 460-580 a (20°C/68°F)
REPLACEMENT
Remove the pulse generator cover and heat protector.
Remove the gasket.
17-4
IGNITION SYSTEM
Remove the pulse rotor and pulse generators.
Install the pulse generators and tighten the bolts securely.

Install the grommet correctly.
Install the pulse rotor aligning the projections on the rotor with
the cut-out and hole on the crankshaft.
Apply a locking agent to the threads of rotor bolt.

Tighten the rotor bolt to the specified torque.
TORQUE: 5,0 N·m (5.0 kg-m, 36 ft-lb)
Install the cover and heat protector and tighten the bolts se-
curely.
IGNITION SYSTEM
IGNITION TIMING
NOTE
• Ignition timing seems incorrectly by the cause of variety of
the timing light or how to connect it in spite of ignition
timing is correct. Ignition timing seems correctly by con-
necting the timing light to the other spark plug wire of same
ignition coil or exchanging primary coil wire terminals if igni-
tion timing seems incorrectly.
• The spark unit system is factory pre-set and cannot be ad-
justed. Ignition timing inspection procedures are given to in-
spect the function of the spark unit components.
(1) TIMING LIGHT
Warm up the engine to operating temperature.
Remove the crankshaft hole cap on the pulse generator cover.
Connect the timing light to the No. 1 or No. 4 spark plug wire.
The timing is correct if the "F" mark on the crankcase aligns

with the index mark on the pulse rotor at idle ( 1 ,000 ± 100
rpm).
17-6
MEMO
ELECTRIC ST ARTER
(4) MAIN (5) DIODE

FUSE
30A
(3) STARTER
MOTOR
(7) BATTERY
12V 14AH
(6) STARTER
RELAY
SWITCH (4) MAIN FUSE 30A
(10) NEUTRAL
(7) - (5) DIODE SWITCH
BATTERY ; ~
(3) STARTER
12V14AH
l
"'-+----- G/R _ _ _ _........_(9-)CLUTCH SWITCH
er~
--,
G G
I
MOTOR
- - - - - - - - Y/R .J_ _j_
R----o-"'-
( 1) IGNITION
R/BI~
(8) SUB FUSE
Bl J
-----Q"""'
(2) STARTER
SWITCH 10A SWITCH
18-0
18. ELECTRIC STARTER
SERVICE INFORMATION 18-1 STARTER RELAY SWITCH 18-6
TROUBLESHOOTING 18-2 CLUTCH DIODE 18-6
STARTER MOTOR 18-3
SERVICE INFORMATION
GENERAL
NOTE
• This motorcycle uses a mechanical damper in the starting system. If the engine won't start by the starter motor, and there
is excessive noise while cranking, bad igniton timing may be causing the crankshaft to turn backwards. The mechanical
damper is absorbing the backward motion, to prevent damage to the alternator drive.
Recheck the ignition timing components.
• The starter motor and pulse generator can be removed with the engine in the frame.
SPECIFICATIONS
Unit: mm (in)
Starter motor brush length 12.0-13.0 (0.47-0.51) 6.5 (0.26)
TORQUE VALUE
Starter motor case screw 4.5 N•m (0.45 kg-m, 3.3 ft-lb)
18-1
ELECTRIC ST ARTER
TROUBLESHOOTING
NOTE
• The starter motor could turn when the transmission is in neutral or the clutch disengaged.
• Check the following items before troubleshooting the system.
- Main (30 A) and sub ( 1 0 A) fuses for burn.
- Battery and starter motor cables for loose connection.
- Battery discharged.
Starter motor do not turn
1-1 . Check the starter relay switch for opera- 1-2. Apply battery voltage to the starter motor
tion. 'CLICK' HEARD _ directly and check the operation.
You should hear the relay 'CLICK' when
the starter switch button is depressed. TURN DO NOT TURN
• Loose or poor con- • Faulty starter motor

'CLICK' NOT HEARD
tact cables (page 18-3)
• Faulty starter relay
switch (page 18-6)
ABNORMAL
I 2. Check the neutral indicator for function. 1
i ---------- • Faulty neutral switch (page 19-11)
~--.-----------------~ • Loose or poor contact connectors of the neu-
NORMAL tral switch
• Faulty ignition switch (page 19-5)
3. Check the starter relay switch voltage (page 11--_ _N_o_v_o_LT_A_G_E--1~

• Loose or poor contact connector of the clutch
1 18-6) I diode
• Faulty starter switch (page 19-7)
BATTERY
• Faulty clutch diode (page 18-6)
VOLTAGE COMES
• Open or short circuit in wire harness
I
4 . Check the starter relay switch for operation l __A_B_N_O_R_M_A_L___- •

t-
Faulty starter relay switch
1 (page 18-6) I
NORMAL
'--------------------------- • Loose or poor contact connector of the starter
relay switch
Starter motor turns engine slowly

• Low specific gravity
• Excessive resistance in circuit
• Binding in starter motor
Starter motor turns, but engine does not turn

• Faulty starter clutch
• Faulty starter motor gears
• Faulty starter motor or idle gear
Starter motor and engine turns, but engine dose not start
• Faulty ignition system
• Engine problems
- Low compression
- Fouled spark plugs
18-2
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
MMJiidN
• With the ignition switch OFF, remove the negative cable at the
battery before servicing the starter motor.
Remove the right side fairing (page 12-2).
NOTE
• Starter motor should remove easily, after removing the car-
buretor (page 4-5).
Disconnect the starter motor cable.

Remove the motor mounting bolts and motor.
DISASSEMBLY
Remove the following components:

- motor case screws.
- front cover and rear cover.
- armature.
NOTE
• Record the location and number of shims. (1 l SCREWS
INSPECTION
Check for continuity from the cable terminal to the body and
from the cable terminal to the brush wire (black).
CABLE TERMINAL-BODY
NO CONTINUITY: NORMAL
CABLE TERMINAL-BRUSH (BLACK WIRE)

CONTINUITY: NORMAL
Measure the brush length. ---\ \ - ( 1l BRUSH
.............
18-3
ELECTRIC STARTER
Check the needle bearing for wear, damage or excessive free (1 l NEEDLE
play. BEARING
Check the dust seal for wear or damage and apply a small
amount of grease to the dust seal.
(2) DUST SEAL
Inspect the commutator bars for discoloration.

The bars discolored in pairs indicate grounded armature coils.
Check for continuity between pairs of commutator bars.
There should be continuity.
Check for continuity between individual commutator bars and

the armature shaft.
There should be no continuity.
ASSEMBLY
(1) BODY
(6) BRUSH HOLDER

(7)
SPRING
~
0 (3) 0 -RING
(4) SHIMS
131 0 -RING / , (8) REAR COVER
(12) /
FRONT
COVER
( 11)
LOCK
WASHER
(2) INSULATED
(3) 0-RING
WASHER
(4) SHIMS
18-4
ELECTRIC STARTER
Install the brush holder on the body aligning the tab on the
holder with the groove on the body.
Install the 0-ring.
Install the armature.

Set the brushes on the holder by securing springs.
Install the shims to the armature shaft.

Apply grease to the shaft and its journal of the cover, and in-
stall the rear cover aligning the tab on the brush holder with
the groove on the cover.
(3) SHIMS
Install the shims and lock washer to the shaft.

Install the 0-ring on the body.
Install the front cover, taking care not to damage the dust seal
on the cover.
161 DUST (5) INSULATED

SEAL WASHER (4) SHIMS 131 0 -RING
(l) ALIGN
Align the index marks of the front and rear covers.
Install and tighten the 0-rings, washers and screws.
TORQUE: 4.5 N•m (0.45 kg-m. 3.3 ft-lb)
Apply oil to the 0-ring of the front cover.

I
I
,,
I
I
I
I
I
I
I
I
I • (2) SCREWS AND
(3) 0-RING WASHERS
18-5
ELECTRIC ST ARTER
INSTALLATION
Install the starter motor to the engine.

Install and tighten the motor mounting bolts securely.
Connect the motor cable to the motor terminal.

Install the rubber cap to the terminal.
Connect the battery negative cable.
STARTER RELAY SWITCH

Depress the starter switch button with the ignition ON. The
coil is normal if the starter relay switch clicks.
STARTER RELAY VOLTAGE INSPECTION
If the switch 'click' is heard, measure the voltage between the

yellow/red wire (+) and green/red (-).
The battery voltage should appear when the starter switch is
depressed with ignition switch ON and the transmission is in
the neutral position.
Perform the following inspection if the battery voltage
appeared between the yellow/red wire and green/red.
SWITCH INSPECTION
Disconnect the starter relay switch coupler.

Disconnect the battery and starter motor cables.
Remove the starter relay switch.
Connect an ohmmeter to the starter relay switch large termi-

nals.
Connect a fully charged 1 2 V battery positive wire to the start-

er relay switch Yellow/Red wire terminal and battery negative
wire to the Green/Red wire terminal.
Check for continuity between the starter relay switch termi-

nals.
~ ~ (1) CLUTCH
~- DIODE
There should be continuity while 1 2 V battery is connected to
the starter relay switch terminals and should be no continuity
when the battery is disconnected.
CLUTCH DIODE
REMOVAL
Remove the right side cover (page 1 2-2).

Remove the clutch diode from the wire harness.
18-6
ELECTRIC STARTER
INSPECTION
Check for continuity with an ohmmeter.
NORMAL DIRECTION: CONTINUITY

REVERSE DIRECTION: NO CONTINUITY
18-7
MEMO
19. LIGHTS/SWITCHES
SERVICE INFORMATION 19-1 TEMPERATURE SENSOR 19-8
HEADLIGHT 19-2 THERMOSTATIC SWITCH 19-9
TURN SIGNAL 19-2 FUEL PUMP RELAY 19-9
TAILLIGHT /STOPLIGHT 19-3 FUEL SENSOR/METER 19-9
LICENSE LIGHT 19-3 TACHOMETER 19-10
INSTRUMENTS 19-4 NEUTRAL SWITCH 19-11
IGNITION SWITCH 19-5 BRAKE LIGHT SWITCH 19-11
HANDLEBAR SWITCH 19-7 CLUTCH SWITCH 19-12
OIL PRESSURE SWITCH 19-7 HORN 19-12
TEMPERATURE GAUGE 19-8
SERVICE INFORMATION
GENERAL
• Some wires have different colored bands around them near the connector. These are connected to other wires which cor-
respond to the band color.
• All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
• To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals or connections.
• A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two
points. An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance in-
volved, or when checking for high resistance caused by corroded connections.
• The following color codes are indicated throughout this section and on the wiring diagram.
Bu = Blue G = Green Lg = Light Green R = Red
Bl = Black Gr = Gray 0 = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow
SPECIFICATION
Headlight (high/low) 12 v 60/55 w

Position light 12 V 2 cp x 2
Tail/stoplight 12 V 32/2 cp (SAE TRADE No. 11 57) x 2
Front turn signal/running light 12 V 32/2 cp (SAE TRADE No. 1034) x 2
Rear turn signal light 12 V 32 cp (SAE TRADE No. 1073) x 2
License light 12 V 3 cp
Pilot light: turn signal 12 v 3.4 w x 2
oil pressure 12 v 3.4 w
neutral 12 v 3.4 w
high beam 12 v 3.4 w
Instrument light 12 v 3.4 w x 4
Main fuse 30 A
Sub fuse (turn signal, stoplight, horn
passing) 15 A
Sub fuse 10 Ax 6
TORQUE VALUE
Ignition switch 25 N•m (2.5 kg-m, 18 ft-lb)
19-1
LIGHTS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
Remove the upper fairing lower right inner cover (page 1 2-3).
Disconnect the headlight connector and remove the seal rub-
ber.
Remove the bulb retainer and replace the bulb with a new one.
CAUTION
Wear gloves when installing the halogen bulb.
If you touch the bulb with your bare hands, clean it with a cloth
moistened with alcohol to prevent its early failure.
Install the bulb retainer and seal rubber with the "TOP" mark
on the seal rubber facing up.
Connect the headlight connector and check operation.

Install the upper fairing lower right inner cover (page 1 2-4).
REMOVAL/INSTALLATION
Remove the upper fairing (page 12-3).

Remove the four screws attaching the headlight to the upper
fairing.
Install the headlight in the reverse order of removal.
NOTE
• Adjust the headlight aim after installation (page 3-16).
TURN SIGNAL
BULB REPLACEMENT
Front:
Remove the upper fairing lower inner cover (page 12-3).
Remove the bulb socket and bulb, rotating the socket to re-
lease its tabs.
(1 l BULB
19-2
LIGHTS/SWITCHES
Rear:
Remove the rubber, screw and lens.
(1 I BULB -
Remove the bulb and replace it with a new one.
(21 RUBBER AND

SCREW
TAILLIGHT/STOPLIGHT
REPLACEMENT
Remove the seat.
Remove the bulb socket, rotating the socket to release its

tabs.
Replace the bulb with a new one.
LICENSE LIGHT
BULB REPLACEMENT
Remove the license light/license plate stay mounting bolts and

stay.
Replace the bulb with a new one.
19-3
LIGHTS/SWITCHES
Install the lincese light/license plate stay to the rear fender A

with the holes in the stay aligning with the bosses on the rear
fender A and tighten the mounting bolts.
INSTRUMENTS
BULB REPLACEMENT
Remove the upper fairing inner covers (page 12-3).

Remove the instruments mounting bolts.
Disconnect the instruments 9P mini (black) and 4P mini (black)

connectors.
Disconnect the speedometer cable.
Remove the instruments.
Pull the bulb sockets from the instruments and replace the
bulbs with new ones.
19-4
LIGHTS/SWITCHES
DISASSEMBLY
Remove the instruments mounting screws and disassemble

them.
)
II
ASSEMBLY
Assemble and install the instruments in the reverse order of re-

moval and disassembly.
NOTE
• Match the color codes on the instrument case with the wire
colors, when installing.
SB = Light blue
L Blue
B Black
GR= Green
BR = Brown
IGNITION SWITCH
INSPECTION
Disconnect the ignition switch 6P (BLACKI connector.

Check for continuity between the ignition switch connector
terminals in each switch position.
Continuity should exsist between the color coded wires in

each chart at page 1 9-1 .
ON ~ ~ ~ ~ ~
OFF
P.LOCK ~
-
LOCK
Color R R/BI Bu/0 Br/W Br Y/BI
19-5
LIGHTS/SWITCHES
REMOVAL
Disconnect the ignition switch 6P connector.

Remove the ignition switch mounting bolts and ignition,
switch.
DISASSEMBLY (1 l SCREWS
Cut the wire clamp.

Remove the three screws, pull the contact base out of the cyl-
inder.
Replace the contact base with a new one.
(2) CLAMP
ASSEMBLY
Install the contact base, aligning the hole of the base with the
shaft of the cylinder.
Install and tighten the three screws.

Clamp the wire.
INSTALLATION
Install the ignition switch in the reverse order of removal.
Inspect the ignition switch after installation (page 19-5).
(2) SCREWS
19-6
LIGHTS/SWITCHES
HANDLEBAR SWITCH
The handlebar switches (turn signals, horn, starter, engine
stop and dimmer) must be replaced as assemblies.
Remove the upper fairing inner covers (page 12-3) and discon-
nect the handlebar switch connectors from the coupler holder.
Continuity checks for the components of the handlebar cluster

switches are as follows.
Continuity should exsist between the color coded wires in
each chart below.
ENGINE STOP HORN SWITCH

SWITCH
BAT2 IG Ho BATJ
OFF FREE
RUN
COLOR
- -
Bl Bl/W
PUSH
COLOR
- -
Lg WIG
DIMMER SWITCH ST ARTER SWITCH
HL Lo Hi ST BAT2 HL BA To
Lo - - FREE - -
(Nl
- - - PUSH - -
Hi - - COLOR Y/R Bl Bu/W Bl/R
COLOR Bu/W w Bu
TURN SIGNAL SWITCH
w R L BAT. PR PL
R
- - - -
N - -0- -
I
COLOR
L
-
Gr Lb
-0 -
Br/W Lb/W
-
O/W
OIL PRESSURE SWITCH ( 1 l OIL PRESSURE INDICATOR
Make sure that the oil pressure warning indicator come on

with the ignition switch "ON".
~
19-7
LIGHTS/SWITCHES
If the light does not come on, inspect as folow:

Remove the lower fairing (page 12-2).
Disconnect the oil pressure switch wire from the switch by re-
moving the terminal screw. Turn the ignition switch ON.
Ground the oil pressure switch wire to the engine.
The oil pressure warning light should come on.
If the light does not come on, check the wires for a loose con-
nection, sub fuse or an open circuit.
Check also for a burnt out bulb, and replace or repair if neces-
sary.
If the oil pressure and warning systems are normal and the
warning light comes on, replace the oil pressure switch.
Apply a sealing agent to the new switch threads when replac-
ing the switch (See page 1-5).
TEMPERATURE GAUGE (i")TEMPERATURE~

SENSOR
Disconnect the sensor wire from the thermosensor and short it
to ground using a jumper wire.
Turn the ignition switch ON.

Temperature gauge should move all the way to the (H).
CAUTION
• Do not leave the thermosensor wire grounded for longer than a
few seconds, or the temperature gauge will be damaged.
If the gauge needle does not move, check the sub fuse (10 A) ( 1) TEMPERATURE METER
and wires for a loose connection or an open circuit; if normal,
replace the gauge with a new one (page 19-5).
TEMPERATURE SENSOR
Drain the coolant (page 5-2) and remove the temperature sen-
sor.
Suspend the unit in oil over a burner and measure the resis-
tance through the unit as the oil heats up.
Tempera- 60°C 85°C 110°C 120°c

tu re 140°F 185°F 230°F 248°F
Resistance 104.o n 43.9 n 20.3 n 1 s.1 n
( 1) TEMPERATURE SENSOR
l@AM@IN
Wear gloves ancf eye protection.
• Heated oil is highly flammable. Keep it away from open
flames.
NOTE
• Oil must be used as the heated liquid to check operation
above 100°C (212°F).
• You'll get false readings if either the thermometer or tem-
perature unit touches the pan. (2) THERMOMETER
19-8
LIGHTS/SWITCHES
THERMOSTATIC SWITCH
The cooling fan motor is actuated by the thermostatic switch

located in the radiator.
If the fan motor does not start, disconnect the switch wires
from the thermostatic switch and short the wires togheter
with a jumper wire as shown.
Turn the ignition switch on. The cooling fan motor should start
running.
If it does not run, check for a blown or faulty fuse, loose termi-
nals or connectors, or an open circuit.
If the motor runs, inspect the fan thermostatic switch as fol-
lows:
Suspend the switch in a pan of coolant (50-50 mixture) and
check the temperatures at which the switch opens and closes.
Make sure that there is no switch continuity with room tem- (1) THERMOMETER
perature and gradually raise the coolant temperature. The
switch should show continuity (close) at 98-102 °C (208-
2160F).
NOTE
Keep temperature constant for 3 minutes before testing
continuity. A sudden change of temperature will cause an
error of the temperature reading between the thermometer
and the switch.
• Do not let the thermometer or switch touch the pan as it will
(2) THERMOSTATIC SWITCH
cause a false reading.
• Suspend the switch in coolant up to its threads.
FUEL PUMP RELAY

l§H;fo!fr!d
• Gasoline is extremely flammable and is explosive under certain
conditions. Work in a well ventilated area. Do not smoke or
allow flames or sparks in the work area.
Check for a burnt sub-fuse.

Remove the left side cover (page 12-2).
Remove the fuel pump relay from the mount bracket.

Check the relay connectors for improper contact and loose-
ness.
Measure the voltage between the relay black wire and a body
ground. The battery voltage should appear with the ignition
switch ON.
Disconnect the fuel out let wire and make sure that the fuel
pump operates while the relay connector black and brown/red
wires are shorted and the ignition switch is ON.
If the pump does not operate, check the fuel pump connectors
for improper contact and the fuel pump (page 4-16).
Check the Yellow/blue and Blue/yellow wires for continuity be-

tween the spark unit and fuel pump relay. If there are
continuities, replace the fuel pump relay. If there are no
continuities, check for a loose or poor contact, replace the
wire harness.
19-9
LIGHTS/SWITCHES
FUEL SENSOR/METER
Remove the fuel tank.
Remove the fuel sensor nuts and remove the sensor and 0-
ring.
NOTE
• Be careful not to bend the float arm.
FUEL SENSOR INSPECTION
Connect the ohmmeter to the fuel sensor connector.
Inspect the resistance of the float at the top and bottom posi-
tions.
FLOAT POSITION RESISTANCE

TOP (FULL) n
4-10
BOTTOM (EMPTY) 90-100 n
FUEL METER INSPECTION
Connect the fuel sensor connector to the wire harness and

move the float from empty to full to check the fuel meter indi-
cation.
If the fuel meter does not indicate properly, check the wiring
for an open or short circuit.
If the wiring is good, replace the fuel meter with a new one
(page 19-5) and retest.
( 1 l FUEL METER
TACHOMETER
If the tachometer does not work properly, inspect as follows:
Turn the ignition switch ON, and check the voltage between
black/brown (+) and green (-) wire terminals.
There should be battery voltage.
If the voltage does not come on, check the sub fuse ( 10 Al and
wire for a loose connection or an open circuit.
If in good condition, check the yellow/blue wire for an open cir-

cuit.
- between tachometer and instruments 4P connector.
- between instruments connector and spark unit.
19-10
LIGHTS/SWITCHES
If the problem still exists, replace the tachometer with a new

one (page 19-5).
NEUTRAL SWITCH
INSPECTION

Check the neutral switch for continuity between the light
green/red connector and body ground.
There should be continuity when the transmission is in neutral

and there should be no continuity with the transmission in any
gear.
BRAKE LIGHT SWITCH

FRONT INSPECTION
Disconnect the front brake light switch connectors and check

for continuity between the switch terminals.
There should be continuity with the front brake applied, and

should be no continuity when the brake is released.
Replace the switch if necessary.
REAR INSPECTION
Disconnect the rear brake light switch connector and check for
continuity between the terminals.
There should be continuity with the rear brake applied and

should be no continuity with rear brake released.
Replace the rear brake light switch, if necessary.
19-11
LIGHTS/SWITCHES
CLUTCH SWITCH
INSPECTION
Disconnect the clutch switch wire connectors.
Check for continuity between the switch terminals.
There should be continuity with the clutch applied and should

no continuity with the clutch released.
Replace the clutch switch with a new one if necessary.
HORN
INSPECTION
Disconnect the horn wire connectors and connect a fully

charged 1 2 V battery to the horn terminals.
The horn is normal if it sounds when the battery is connected

across the terminals.
19-12
21. TROUBLESHOOTING
·~·
ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW AND

HARD TO START 21-1 IDLE SPEED 21-3
ENGINE LACKS POWER 21-2 POOR PERFORMANCE AT HIGH SPEED 21-4
ENGINE DOES NOT START OR IS HARD TO START

Possible cause
1. Check fuel flow to carburetor NOT REACHING CARBURETOR - - - • Clogged fuel valve
• Fuel tank empty
REACHING CARBUTRETOR • Clogged fuel line or fuel filter
• Sticking float valve
• Faulty fuel pump
• Faulty fuel pump relay
• Clogged fuel tank vent hole
• Loose or disconnected fuel pump
relay wire
2. Check spark plug condition FOULED, DISCOLORED OR WET--... • Too rich mixture
• Carburetor flooded
NORMAL • Carburetor choke excessively
closed
• Cylinder flooded
• Air cleaner dirty
• Spark plugs not serviced frequently
enough
• Spark plug with incorrect heat
range
3. Perform spark test WEAK OR NO S P A R K - - - - - - • GO TO PAGE 17-2
GOOD SPARK
+
4. Test cylinder compression LOW COMPRESSION - - - - - - • • Low battery charge
• Improper valve clearance (too
NORMAL small)
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
5. Start by following normal procedure ENGINE ST ARTS BUT STOPS---.,. • Improper choke operation
• Carburetor incorrectly adjusted
ENGINE DOES NOT FIRE • Insulator leaking
• Improper ignition timing
!
6. Start with choke applied
• Fuel contaminated
fD
21-1
TROUBLESHOOTING
ENGINE LACKS POWER

Possible cause
1. Raise wheels off ground and WHEELS DO NOT SPIN FREELY--.- • Brake dragging
spin by hand • Worn or damaged wheel bearings
• Drive chain too tight
WHEELS SPIN FREELY • Rear axle nut excessively tight
2. Chetk tire pressure PRESSURE L O W - - - - - - - - · • Punctured tire

• Faulty tire valve
PRESSURE NORMAL
3. Chetk clutch slipping CLUTCH S L I P S - - - - - - - - - • Faulty clutch lifter system

• Worn clutch disc/plate
CLUTCH ENGAGED PROPERLY • Warped clutch disc/plate
~
4. Accelerate lightly ENGINE SPEED DOES NOT INCREASE.,..• Carburetor choke closed
• Clogged air cleaner
ENGINE SPEED INCREASES • Restricated fuel flow
j
• Clogged muffler
• Clogged fuel tank vent hole
5. Check oil level and condition INCORRECT---------- • Oil level too high
• Oil level too low
CORRECT • Contaminated oil
6. +
Check ignition timing INCORRECT--------- • GO TO PAGE 17-2
CORRECT
7. +
Check spark plug condition FOULED, DISCOLORED OR WET----<~• Spark plugs not serviced frequently
enough
NORMAL • Spark plug with incoreect heat
range
• Too rich mixture
• Carburetor flooded
• Carburetor choke excessively
closed
• Cylinder flooded
• Air cleaner dirty
8. Test cylinder compression LOW COMPRESSION------- • Valve stuck open

• Worn cylinder and piston rings
NORMAL • Damaged cylinder head gasket
• Improper valve timing
• Low battery charge
j •
•
Improper valve clearance (too small)
Seized valve
9. Remove cylinder head cover and VALVE TRAIN NOT LUBRICATED- • Clogged oil passage
inspect lubrication PROPERLY • Clogged oil control orifice
VALVE TRAIN LUBRICATED

PROPERLY
+
10. Check valve clearance INCORRECT----------· • Improper valve adjustment
• Worn valve seat
CORRECT
i
21-2
TROUBLESHOOTING
11 . Check carburetor for clogging CLOGGED---------- • Carburetor not serviced frequently

enough
NOT CLOGGED
+
12. Check for engine overheating OVERHEATING-------- • Coolant level low
• Fan motor not working
(thermostatic switch)
NOT OVERHEATING • Thermostat stuck closed
• Excessive carbon build-up in com-
bustion chamber
1
13. Accelerate or run at high speed ENGINE KNOCKS--------~•
• Use of poor quality fuel
Worn piston and cylinder

• Wrong type of fuel
ENGINE DOES NOT KNOCK • Excessive carbon build-up in com-
bustion chamber
• Ignition timing too advanced
POOR PERFORMANCE AT LOW AND IDLE SPEEDS

Possible cause
1. Perform spark test WEAK OR INTERMITTENT SPARK - • GO TO PAGE 17-2
GOOD SPARK
2. +
Check for leaking carburetor LEAKING-----------• • Loose carburetor
insulator • Damaged insulator
NO LEAK
3.
t
Check carburetor pilot screw I N C O R R E C T - - - - - - - - - • GO TO PAGE 4-2
adjustment
CORRECT
4. +
Check ignition timing INCORRECT---------• GO TO PAGE 17-2
CORRECT
5. +
Check valve clearance INCORRECT----------~ • Improper valve adjustment
• Worn valve seat
CORRECT
21-3
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED

NOTE: Ignition to the No. 2 and No. 3 cylinder is cut-off at 10,800-11,000 rpm to prevent engine damage.
Possible cause
1. Check ignition timing INCORRECT---------• GO TO PAGE 17-2
CORRECT
2.
t
Check fuel flow to carburetor NOT REACHING CARBURETOR - - - - • Fuel tank empty
• Clogged fuel line or fuel filter
REACHING CARBURETOR • Clogged fuel tank vent hole
• Clogged fuel valve
• Faulty fuel pump relay
• Faulty fuel pump
• Sticking float valve
• Loose or disconnected fuel pump
relay wire
3. Check valve timing INCORRECT _ _ _ _ _ _ _ _ ___,_ • Camshaft not installed properly
CORRECT
+
4. Check valve clearance INCORRECT----------• • Improper valve adjustment
• Worn valve seat
CORRECT
t
5. Check valve spring tension W E A K - - - - - - - - - - - - - Faulty spring
NOT WEAKENED
•
6. Remove carburetors and check for
clogged jets
C L O G G E D - - - - - - - - - - Clean
JETS OK
21-4
22. INDEX
Air Cleaner . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Fairing Installation ........................................... . 12-4
Case ..................................................... 4-4 Removal ............................................... . 12-2
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-5 Fork .............................................................. . 1 3-11
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-8 Front Wheel/Suspension .................................. . 1 3-1
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-1 Brake Caliper ......................................... . 1 5-15
Battery .................................................... 3-1 3, 1 6-3 Master Cylinder ..................................... . 15-9
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Wheel .................................................. . 13-5
Replacement/Air Bleeding . . . . . . . . . . . . . . . . . . . . .. . . 1 5-3 Fuel System ................................................... . 4-1
Light Switch .................................. 3-1 5, 19-11 Filter .................................................... . 3-4
Pad Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 4 Line ........................................ .. ....... .. .. . 3-4
Pad/Disc ............................................... . 1 5-5 Fuel Pump Inspection ...................................... . 4-16
Pedal ................................................... . 1 5-19 Relay ................................................... . 19-9
System ................................................ . 3-15 Fuel Sensor/Meter .......................................... . 19-10
Cable & Harness Routing ................................. . 1-10 Tank .................................................... . 4-3
Carburetor Choke ........................... ......... ....... . 3-5 Gearshift Linkage/Balancer ............................... . 10-1
Camshaft Installation ...................................... . 7-19 Linkage ................................................ . 10-2
Removal .............. ......... ... ....... ... ....... .. .. . 7-3 General Information ........................................ . 1 -1
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Safety .................................................. . 1 -1
Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Handlebar Switch ........................................... . 19-7
Carburetor-idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 0 Handlebars .................................................... . 13-3
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-4 Headlight ....................................................... . 19-2
Clutch ............................... ............................. 9-1 Aim ..................................................... . 3-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 2 High Altitude Adjustment (U.S.A. only) ............. . 4-18
Diode ............................ .. ....... ............... 18-6 Horn ............................................................. . 19-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Hydraulic Brake .... .. ............................... .. ....... . 1 5-1
Fluid ..................................................... 3-16 Ignition System .............................................. . 17-1
Replacement/Air Bleeding ........................ 9-3 Coil ...................................................... . 17-3
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Switch ................................................. . 19-5
Slave Cylinder . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . 9-7 Timing ................................................. . 17-6
Switch .................................................. 1 9-1 2 Instruments ................................................... . 19-4
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 6 License Light .................................................. . 19-3
Connecting Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Lights/Switches .............................................. . 1 9-1
Control Cable Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Limiter Cap Installation .................................... . 4-17
Coolant Replacement .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Lubrication ..................................................... . 2-1
Cooling System .......................................... 3-1 0, 5-1 Point .................................................... . 2-10
Crankcase Assembly ........................................ 11 -1 9 Maintenance .................................................. . 3-1
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Schedule .............................................. . 3-3
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -3 Model Identification ........................................ . 1-2
Crankshaft Installation ...................................... 11 -1 4 Neutral Switch ............................... .. .............. . 1 9-11
Removal ............................................... . 11 -11 Nuts, Bolts, Fasteners ..................................... . 3-18
Cylinder Head/Valve ........................................ . 7-1 Oil Cooler ...................................................... . 2-9
Cylinder/Piston ............................................... . 8-1 Pass Pipe Plate/Alternator Drive Chain
Compression ......................................... . 3-11 Tensioner Installation ............................. . 11-16
Cylinder Head Assembly .................................. . 7-1 5 Pass Pipe Plate/Alternator Drive Chain
Disassembly .......................................... . 7-10 Tensioner Removal ................................ . 11-5
Installation ............................................ . 7-17 Pressure Check ..................................... . 2-4
Removal ............................................... . 7-7 Switch ................................................. . 19-7
Cylinder Installation ........................................ . 8-6 Pump ................................................... . 2-5
Removal ................................ ............... . 8-3 Strainer/Pressure Relief Valve .................. . 2-4
Drive Chain .................................................... . 3-12 Pilot Screw Adjustment ................................... . 4-17
Electric Starter ............................................... . 1 8-1 Piston Installation ........................................... . 8-5
Emission Control Information Labels .................. . 1-18 Removal ............................................... . 8-4
Systems ............................................... . 1-1 5
Engine Removal/Installation .............................. .
Installation ...... : ..................................... .
6-1
6-5
Pulse Generator .............................................. .
Radiator Coolant ............................................. .
Radiator/Cooling Fan ....................................... .
17-4
3-10
5-4
fl.I
Engine Oil & Filter Change ............................... . 2-3 Rear Wheel/Suspension ................................... . 14-1
Level .................................................... . 2-3 Brake Caliper ......................................... . 1 5-17
Engine Removal .............................................. . 6-2 Master Cylinder ..................................... . 15-12
Evaporative Emission Control System ................ . 3-11 Wheel .................................................. . 14-3
(California model only) ............................ . 4-19 Regulator/Rectifier .......................................... . 16-5
Exhaust System ............................................. . 12-7 Reserve Tank ................................................. . 5-7
Fairing/Exhaust System ................................... . 1 2-1 Seat Cowling/Rear Fenders 12-6
22-1
INDEX
Secondary Air Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Rear Wheel/Suspension .......................... . 14-2

(California model only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 8 Transmission/Crankshaft ........................ . 11-2
Service Information Turn Signal ............... , .................................... . 19-2
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 Valve Clearance ............................................. . 3-7
Clutch ................................................... 9-1 Guide Replacement ................................ . 7-12
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Seat Inspection/Refacing ........................ . 7-13
Cylinder Head/Valve . .. .. .. ... .. .. ... .. .. ... .. .. ... . 7-1 Water Pump ................................................... . 5-5
Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Wheels/Tires .................................................. . 3-18
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 Windshield ..................................................... . 12-5
Engine Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 6-1 . Wiring Diagram .............................................. . 20-1
Fairing/Exhaust System . .. .. ... .. ... .. .. ... .. .. ... 12-1
Front Wheel/Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Gearshift Linkage/Balancer . . . . . . . . . . . . . . . . . . . . . . . 1 0-1
Hydraulic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-1
Ignition System ...................................... 17-1
Lights/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Rear Wheel/Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Transmission/Crankshaft . .. .. ... .. .. .. ... .. .. ... . 11-1
· Service Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Linkage ................................................. 14-1 3
Side Stand . .. .. ... .. .. .. .. . ... .. .. .. .. .. ... .. .. .. .. ... .. .. ... .. . 3-16
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Unit System Inspection . . .. .. ... .. .. .. .. ... ... ... . 17-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Starter Clutch/ Alternator Shaft Installation .......... 11-1 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Motor.................................................... 18-3
Relay Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-6
Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 9
Stem ..................................................... 13-20
Suspension .................................................... . 3-17
Swing Arm .................................................... . 14-15
System Testing .............................................. . 5-2
Tachometer ................................................... . 19-10
Taillight/Stoplight ........................................... . 19-3
Temperature Gauge ........................................ . 19-8
Sensor ................................................. . 19-8
Thermostat .................................................... . 5-3
Thermostatic Switch ....................................... . 19-9
Throttle Operation .......................................... . 3-4
Tools ............................................................ . 1-8
Torque Values ........ .. ..... ...... ..... ........... ............ 1-5
Transmission/Crankshaft .. .. .. .. .. ... .. . . ... ... . ... .. . . . .. 11-1
Assembly .............................................. 11-1 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Troubleshooting
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-2
Clutch ................................................... 9-2
Cooling System ..................................... . 5-1
Cylinder Head/Valve ............................... . 7-2
Cylinder/Piston ...................................... . 8-2
Electric Starter ...................................... . 18-2
Front Wheel/Suspension ......................... . 13-2
Fuel System .......................................... . 4-2
Gearshift Linkage/Balancer ...................... . 10-1
Hydraulic Brake ..................................... . 15-2
Ignition System ..................................... . 17-2
Lubrication ............................................ . 2-2
22-2 (292)

1987 CBR1000F Factory Service Manual

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1987 CBR1000F Factory Service Manual

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HOW TO USE THIS MANUAL CONTENTS

Sections 1 through 3 apply to the whol~

Most sections start with an assembly or

Date of Issue: Feb., 1 987

(1 l VEHICLE IDENTIFICATION NUMBER

The vehicle identification number (VIN) is on the left side

(2) FRAME SERIAL NUMBER (3) ENGINE SERIAL NUMBER

(4) CARBURETOR IDENTIFICATION NUMBER (5) COLOR LABEL

DIMENSIONS Overall length 2,200 mm (86.6 in)

ENGINE Intake valve Opens 15° [0°] BTDC

CARBURETION Carburetor type/throttle bore KEIHIN VG/38. 5 mm (1. 52 in)

DRIV E TRAIN Clutch Wet, multi-plate

ELECTRICAL Ignition Full transistor ignition

DPR 9EA-9 X27 EPR-U9

Spark plug gap 0.8-0.9 mm (0.031-0.035 in)

LIGHTS Head light (high/low beam) 12 V-60/55 W

5.5- 7.5 mm (0.22-0.30 in)

NOTE 2: Do not apply locking agent as shown.

Engine hanger bolt (12 mm) 2 12 60 (6.0, 43)

Clutch switch screw 1 4 1.2 (0.12, 0.9)

STANDARD TORQUE VALUES

Torque Values Torque Values

5 mm bolt and nut 5 (0.5, 3.5) 5 mm screw 4 (0.4, 3)

Snap ring pliers 07914 - 3230001 - ,_ Equivalent commercial- 9, 15

Float level gauge 07401-0010000 4

DESCRIPTION TOOL NUMBER REMARKS

Valve seat cutter, 45° 07780-0010800 Intake, 33 mm

CABLE & HARNESS ROUTING

• Protect wires and harnesses with electrical tape or a tube if

• Do not use wires or harness with broken insulator. Repair

• Route wire harnesses to avoid sharp edges, corners or the

• Keep wire harnesses away from the exhaust pipes and

• Be sure grommets are seated in their grooves properly.

• After clamping, check each harness to be certain that it is

• Wire harnesses routed along the handlebars should not be

• Do not bend or twist control cables. Damaged control

(2) LEFT HANDLE BAR

11) IGNITION (3) RIGHT HANDLE BAR

(18) VIEW A (12) RIGHT HANDLE SWITCH

(7) FRONT BRAKE

(1) THROTTLE (2) INSTRUMENT

(9) VIEW A (10) BATTERY

(11) GROUND CABLE

(3) ALTERNATOR (4) FUEL PUMP (5) FUEL PUMP

(1) TEMPERATURE SENSOR WIRE

(3) FAN MOTOR

(6) DRAIN TUBE (5) STARTER

(1) NEUTRAL/OIL PRESSURE (2) DRAIN TUBE

(4) REAR BRAKE LIGHT (3) STARTER MOTOR CABLE

(5) RIGHT TURN SIGNAL

(6) LEFT TURN SIGNAL

~MISSION CONTROL SYSTEMS

CRANKCASE EMISSION CONTROL SYSTEM

Q : (3) FRESH AIR

EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM)

(Except California model)

(1 l AIR INJECTION CONTROL VALVE (AICVl

(2) AIR CLEANER

EVAOPRATIVE EMISSION CONTROL SYSTEM !California model only)

. _ (4) FUEL VAPOR

~ (7) AIR VENT

NOISE EMISSION CONTROL SYSTEM

2. Removal, of, or puncturing of any part of the intake system.

3. Lack of proper maintenance.