Honda Nithawk

1(
lm~ortantSafetv Notice
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
L. .- .
Indicates a possibility of equipment damage if instructions are not followed.
NOTE:
Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It
is importantto note that this manualcontains some warnings and cautions against somespecific service methodswhich
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please
understand that those warnings could not cover all conceivable ways in which service, whether or not recommended
by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda
investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must
sat~sfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods
or tools selected
'
This servlce manual describes the servlce procedures for

theCB750.
This Model Specific Manual includes every service
procedure that is of a specific nature to this particular
model. Basic service procedures that are common to
other Honda Motorcycle/Motor Scooter/ATVs are
covered in the Common Service Manual. This Model
Specific Service Manualshouldbe used togetherwith the
Common Sew~ceManual in order to ~rovidecom~lete
service information on all aspects of this motorcycle.
CODE
AREA (TYPE)
A
America
California
AC
,.
1.
I
k.
,
Contents
Introduction
General Information
F r a m e / B o d y Panels/Exhaust S y s t e m
Maintenance
Lubrication S y s t e m
I
I
-w ,
m
a
Fuel S y s t e m
C y l i n d e r Head/Cylinder/Piston
LY
Crankshaft/Transmission
.-ww
Sections 1 and 3 apply to the whole motorcycle. Section

2 illustrates procedures for removal/installation of
components that may be required to perform service
described in the following sections.
Sections 4 through 17 describe pans of the motorcycle,
grouped according to location.
Front Wheel/Suspension/Steering
Rear Wheel/Suspension
Brake System
Charging S y s t e m / A l t e r n a t o r
8
5
Find the section you want on this page, then turn to the
table of contents on the first page of the section.
-::
Ignition S y s t e m
Electric Starter/Starter C l u t c h
ers/Switches
gram
Troubleshooting
Index
All information, illustrations, directions and specifications included in this publication are based on
the latest product information available at the time
of approval for printing. Honda Motor Co., Ltd.
reserves the right to make changes at any time
without notice and without incurring any obligation
whatever. No palt of this publication may be repraduced without written permission. This manual
is written for persons who have acquired basic
knowledge of maintenance on Honda motorcycles,
motor scooters or A N s .
HONDA MOTOR CO., LTD.
Service Publications Office
Date of Issue: December, 1990

GHONDA MOTOR CO., LTD.
.i
Clutch/Gearshift L i n k a g e
E
Follow the Maintenance Schedule (Section 3)

recommendations to ensure that the vehicle is in peak
operating condition and the emission levelsarewithin the
standards set by the U.S. Environmental Protection
Ageney and the California Air Resources Board.
Performing the first scheduled maintenance is very
imponant. It compensatesforthe initial wear that occurs
during the break-in period.
If you don't know the source of the trouble, go to section

18 Troubleshooting.
.= 1
Engine R e m o v a l / l n s t a l l a t i o n
AREA (TYPE)
CODE
CM Canada
Most sections describe the service procedure through a

system illustration. Refer to the next page for detail on
how to use this manual.
How to Use Thi
ual
Finding Fhe Information You Need
This manual is divided into sections which cover each of

the major components of the motorcycle.
To quickly find the section you are interested in, the first
page of each section is marked with a black tab that lines
up with Qne of the thumb index tabs before this page.
The first page of each section lists the table of contents
within the section.
Read the service information and troubleshooting related
t o the section before you begin working.
An index of the entire book is provided in the last chapter
t o directly locate the information you need.
Understanding The Instructions

2-
The removal and installation of parts are for the most part illustrated by large and clear illustrations that should provide the
reader with visual aid in understanding the major point for servicing.
The system illustrations are augmented by callouts whose numbers or letters indicate the order in which the parts should
be removed or installed.
The sequence of steps represented numerically are differentiated from the ones represented alphabetically t o notify the
reader that they must perform these steps seperately.
For example, if the steps prior and up t o camshaft removal are performed with the engine installed, but the subsequent
Steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders.
The illustrations may contain symbols t o indicate necessary service procedures and precautions that need t o be taken.
Refer to the next page for the meaning of each symbol.
Also in the illustration is a chart that lists information such as the order in which the part is removed/installed, the name of
the pan. and some extra notes that may be needed.
Step by step instructions are provided t o supplement the illustrations when detailed explanation of the procedure is necessary or illustrations alone would not suffice.
Service procedures required before or after the procedure described on that particular page, or inspection/adjustment procedures required following the installation of pans, are described under the title Requisite Service.
Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual.
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining t o these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the partlsl with new one(s1 before assembly.
Use special tool.
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of engine oil and molybdenum grease in a ratio of 1 : 1).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide. NLGl X2 or
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
Apply sealant.
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
Use Fork or Suspension Fluid.
1. General lnformation
I
1
Model Identification
Specifications
Lubrication & Seal Points
1-19
Cable & Harness Routing
1-21
Emission Control System
1-27
Emission Control Information Labels

(U.S.A. Only)
1-30
General Safety
Carbon Monoxide
If the engine must be running to do some work, make sure
the area is well ventilated. Never run the engine in an
enclosed area.
Used Engine/Transmission Oil
kesl may cause skin cancer if repeatedly left i n

contact with the skin for prolonged periods.
Althogh this is unlikely unless you handle used oil
on a daily basis. it is still advisable to throughly
wash your hands with soap and water as soon as
possible after handling used oil. KEEP OUT OF
REACH OF CHILDREN.
gas that can cause loss of consciousness and may

laed to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
Gasoline
Work in a well ventilated area. Keep cigarettes, flames or
sparksaway from the work area orwhere gasoline isstored.
Brake Dust
Never use an air hose or dly brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the
hazard caused by airborne asbestos fibers.
II
Gasoline is extremely flammable and is explosive

under certain conditions. KEEP OUT OF REACH
OF CHILDREN.
Hot Components
II
asbestos fibers have been found to cause

respiratory disease and cancer.
I
I
Brake Fluid
CAUTION
and remain hot forsome timeaftertheengine is run.

Wear insulated gloves or wait until the engine and
exhaust system have cooled before handling these
1
Spilling fluid on painted, plastic or rubber parts w i l l
damage them. Place a cleanshop towel over these
parts wheneverthe system is serviced. KEEP OUT
OF REACH OF CHILDREN.
General Information
Coolant
Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. I f the ethylene glycol does ignite, you will not see any flame, but you
can be burned.
.
.
Avoid spilling engine coolant on the exhaust

system or engine parts. They may be hot enough
and burn without a
to cause the coolant to ignite
visible flame.
Coolant (ethylene glycol) can cause some skin
irritation and is poisonous if swallowed. KEEP OUT
OF REACH OF CHILDREN.
Do not remove the radiator cap when the engine is
hot. The coolant is under pressure and could scald
Keep hands and clothing away from the cooling
fan, as it starts automatically.
If it contacts your skin, wash the affected areas immediately with soap and water. If it contacts your eyes, flush
them thoroughly with fresh water and get immediate medical attention. If it is swallowed, the victim must be forced
tovomitthen rinse mouthand throatwithfresh waterbefore
obtaining medical attention. Because of these dangers,
always store coolant in a safe place, away from the reach
of children.
Nitrogen Pressure
For shock absorbers with a gas-filled
reservoir:
-
.
.
.
Use only nitrogen to pressurizethe shock absorber.

The useof an unstable gas can causea fireor explosion resulting in serious injury.
The shock absorber contains nitrogen under high
pressure. Allowing fire or heat near the shock absorber could lead to an explosion that could result
in serious injury.
Failure to release the pressure from a shock
absorber before disposing of it may lead to a
possible explosion end serious injury if it is heated
or pierced.
To prevent the possibility of an explosion, release the nitrogen by pressing the valve core. Then removethe valve stem
from the shock absorber reservoir. Dispose of the oil in a
manner acceptable to the Environmental Protection Agency
(EPA).
Before disposal of the shock absorber, release the nltrogen
by pressing the valve core. Then remove the valve stem
from the shock absorber.
Banery Hydrogen Gas & Electrolyte
The battery gives off explosivegases; kaepsparks.

flames and cigerenes away. Provide adequate
ventilation when charging.
The banery contains sulfuric acid (electrolyte).
Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.
- If electrolytegetson yourskin, flush with water.
- If electrolyte gets i n your eyes, flush with water
for at least 15 minutes and call a physician.
Electrolyte is poisonous.
-If swallowed, drink large quantities of water or
milk and follow with milk of magnesia or
vegetableoilandcall a physician. KEEP OUTOF
REACH OF CHILDTEN.
General Information
Model ldentification
(1) FRAME SERIAL NUMBER
( 1 ) The frame serial number is stamped on the right side of

the steering head.
(3)VEHICLE IDENTIFICATION NUMBER

(3) The Vehicle ldentification Number WIN) is located on
(2)The engine serial number is stamped on the upper right
the Safety Certification Label on the left side of the

steerino head.
of the crankcase.
I
(4) COLOR CODE LABEL
(4) The color label is attached as shown. When ordering

color-coded parts. always specify the designated color
code.
(5)CARBURETOR
IDLNTIFICATIONNUMBER
15) The carburetor identification number is stamped on the

left side of the carburetor body.
General Information
Specifications
- -.
-ueneral
Specifications
Item
Dimensions Overall length

Overall width
Overall height
Wheel base
Seat height
Footpeg height
Ground clearance
Dry weight tAC model)
Curb weight (AC model)
Maximum weight capacity (CM model)
Frame
Engine
2,185 mm ( 8 6 . 0 in)
8 0 0 mm (31.5 in)
1,135 m m (44.7 in)
1,505 mm (59.3 in )
7 8 0 m m (30.7 in)
3 2 0 mm ( 1 2 . 6 in)
1 4 0 m m (5.5 in)
2 1 0 kg (463 lbs) (212 kg (467 lbs))
226 kg (498 lbs) (228 kg (503 lbs))
161 kg (355 lbs) (165 kg ( 3 6 4 lbs))
Frame type
Front suspension
Front wheel travel
Rear suspension
Rear wheel travel
Rear damper
Front tire size
Rear tire size
Tire brand (Bridgestone) FrontIRear
Tire brand (Dunlop) Front/Rear
Tire brand (Yokohama) Front/Rear
Tire brand (IRC) FrontIRear
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity
Double cradle
Telescopic fork
1 4 0 mm (5.5 in)
Swingarm
1 1 0 m m (4.3 in)
Double effect type
110/80-18 5BH
1 4 0 / 7 0 1 7 66H
Bore and stroke

Displacement
Compression ratio
Valve train
Intake valve opens (at l m m lift)
Intake valve closes (at 1m m lift)
Exhaust valve opens (at 1mm lift)
Exhaust valve closes (at 1mm lift)
Lubrication system
Oil pump type
Cooling system
Air filtration
Crankshaft type
Engine weight tAC model)
Firing order
Cylinder arrangement
Cylinder number
6 7 . 0 x 5 3 . 0 m m ( 2 . 6 x 2 . 1 in)
747 cc ( 4 5 . 6 cu-in)
9.3: 1
Silent multi link chain drive and DOHC with rocker arm
0 BTDC
3 5 ABDC
30" BBDC
-6' ATDC
Forced pressure and wet sump
Trochoid
Air cooled
Paper filter
Unit-type
81.3 kg (179.2 lbs) (82 kg (180.7 Ibs))
1-2-4-3
In line four
4 Front
K505F/K505
-
Hydraulic brake
Internal expanding shoe
29"
117 mm (4.6 in)
1 8 . 0 lit. (4.76 US gal. 3.96 Imp gal)
3.0 lit. ( 0 . 7 9 US gal, 0 . 6 6 Imp gal)
General Information
- General (Cont'd)
Specifications
Item
Carburetor
Carburetor type
Throttle bore
Constant vacuum 4 carburetors

3 4 mm (1.3 in)
Drive Train
Clutch system
Clutch operation system
Transmission
Primaw reduction
Secondary reduction
Third reduction
Final reduction
Gear ratio lsr
Gear ratio 2nd
Gear ratio 3rd
Gear ratio 4th
Gear ratio 5th
Gear ratio 6th
Gear ratio reverse
Gearshift pattern
Multi-plate, wet
Mechanical type
5-speed
1.780(73/41)
Electrical
Ignition system
Starting system
Charging system
Regulator/rectifier type
Lighting system
AC regulator type
2.533(38/15)
3.000(42/14)
2.056(37/18)
1.545(34/22)
1.240(31/251
1.074(29/27)
Left foot operated, return system, 1-N-2-3-4-5

Full transistor ignition
Starter motor
Triple phase output alternator
Field control/triple phase full-wave rectification
Battery
General I n f o r m a t i o n
Lubrication
Item
Standard
Engine oil capacity at draining

at disassembly
at oil filter change
Recommended engine oil
OIL VISCOSITIES
I
I .. I
2.7 lit. (2.8 USqt, 2.4 Imp qt)

3.6 lit. (3.8 US qt, 3.2 Imp qt)
2.9 lit. (3.0 US qt, 2.6 Imp qt)
Use Honda 4-stroke Oil or equivalent
API Service Classification: SF or SG
Viscosity: SAE 1OW-40
I
b
Unit:mm(ir
Service Limit
I Other viscosities shown in the chart may I
be used when the average temperature

in your riding area is within the indicated
range.
0
-ZU
20
-10
60
40
10
80
20
30
100
F'
40 .C
Oil pressure (80'C/176'F)
630 kPa (6.3 kg/cm2, 90 psi) at 6,000

rpm
0.15 (0.006)
0.1 5-0.22 (0.006-0.009)
0.02-0.07 (0.001 -0.003)
Oil pump rotor tip clearance@)

body clearanceQ
end clearance
Fuel System
Carburetor identification number
Main jet
Slow jet
Jet needle clip position
Pilot screw initial opening
(A model)
(AC model)
(CM model)
(A model)
(AC model)
(CM model)
(High altitude)
(2. 3)
(1. 4)
(Front)
(Rear)
(A model)
(AC model)
(CM model)
Pilot screw high altitude adjustment (A model)
(AC model)
Pilot screw final opening
(A model)
(AC model)
(CM model)
Air screw initial opening
Air screw high altitude adjustment
Float level
Carburetor vacuum difference
Base carburetor (For carburetor synchronization)
Idle speed
Trottle grip free play
Accelerator pump clearance
Secondan/ air supply system
PAIR control valve vacuum pressure
VE66B
VE77C
VE66C
Bll2
BllO
#I10
$35
See page 5-1 2

See page 5-1 2
2-3/8 turns out
See page 5- 13
See page 5-1 3
See page 5-1 2
See page 5-12
1/2 turn out
18.5 (0.73)
Within 30 mmHg (1.2 inHg)
No.2 carburetor
1,000+ 100 rpm
2-6 (0.08-0.24)
PAIR check valvesand PAIR control valve 270 mmHg (10.63 inHg)
-
General Information
-Cylinder
Unit:mm(i~
Head
Item
Standard
981 -1 373kPa(142-199ps1,10-14kg/cm) 250/rpm

392kPa(57ps1
4kg/cnm)
Cylinder compression
Cylinder compression synchronization difference

Valve clearance
IN
EX
Cylinder head warpage
Cam lobe height(1 IN
IN(California model)
EX
EXICalifornia model)
Camshaft runout (2
Camshaft oil clearance A
B
32.252-32.41 Z(1.2697-1.2760)
32.252-32.412(1.2697-1.2760)
32.136-32.296(1.2651-1.2714)
32.136-32.296(1.2651-1.2714)
0.020-0.062(0.0007-0.0024)
0.055-0.097(0.0021 -0.0038)
Camshaft journal 0.0. (A)

(B)
Camshaft holder I.D. (A)
(B)
Valvestem O.D. IN
EX
Valve guide I . D . IN
EX
Stem-to-guide clearance IN
EX
Valve guide projection above cylinder head IN
EX
Before guide installation:
1. Chill the valve guides in the freezer section of a
refrigerator for about an hour.
2 . Heat the cylinder head to 100-1 50.C (212-300F)
Valve seat width
Valve spring free length IN
EX
inner IN
inner EX
outer IN
outer EX
Rocker arm I.D. IN
EX
Sub-rocker arm I.D. IN
EX
Rocker arm shaft O.D. IN
EX
Sub-rocker arm shaft O.D. IN
EX
Rocker arm-to-rocker arm shaft clearance
Sub-rocker arm-to-rocker arm shaft clearance
Valve lifter O.D.
Valve lifter bore I.D
Hydraulic lash adjuster assist spring free length
Hydraulic lash adjuster compression stroke with kerosene
service ~ i m i t
25.959-25.980 (1.0220-1.0228)
25.929-25.950 (1.0208-1.0216)
26.0-26.033 (1.0236-1.0249)
26.010-26.031 (1.0240-1.0248)
4.975-4.990 (0.1959-0.1965)
4.955-4.970 (0.1951-0.1957)
5 . 0 0 0 - 5 . 0 1 2 (0.1969-0.1973)
5.000-5.012 (0.1969-0.1973)
0.010-0.037 (0.0006-0.0017)
0.030-0.057 (0.0012-0.0022)
0.9-1.1
4 3 . 7 (1.720)
43.7 (1.720)
c210-0008)
0 . 1 0 (0.004)
32.17 (1.266)
32.17 (1.266)
32.05 (0.907)
32.05 (0.907)
0 . 1 0 (0.004)
0.09 (0.003)
0.1 2 (0.004)
General Information
Unit:mm(~n)
CyIinderlPiston
Item
Standard
Cylinder I .O.
Cylinder out of round
Cylinder taper
Cylinder warpage
Piston mark direction
Piston O.D. (0)
Piston O.D. measurement point (H)
Piston pin hole I.D. (d)
"IN" mark facing toward the intake side

66.96-66.99 (2.636-2.637)
14mm (0.55 in) from the bottom
17.002-17.008 (0.6694-0.6696)
Cylinder-to-piston clearance
Piston pin O.D.
Piston-to-piston pin clearance
Connecting rod-to-piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Second ring end gap
Oil ringlside rail) end gap
Top ring mark
Second ring mark
0.01 -0.050 (0.0003-0.001 9)

16.994-17.000 (0.6691 -0.6693)
0.002-0.014 ( 0 0 0 0 1 -0.0006)
0.016-0.040 (0.0004-0.0020)
0.015-0.045 (0.0006-0.0018)
0.015-0.045 (0.0006-0.0018)
0.15-0.30 (0.006-0.012)
0.30-0.45 (0.012-0.018)
0.20-0.70 (0.008-0.028)
"R" Mark side facing up
"RN" Mark side facing up
Service Limit
67.0-67.01 0 (2.638-2.6381)
Crankshaft
Connecting rod small end 1.0.
Connecting rod big end side clearance
radial clearance
Crankshaft r u n o u t a
Crankpin oil clearance

Connecting rod bearing selection
Main journal oil clearance
Main journal bearing selection
0.024-0.057 (0.0009-0.0022)
See page 9- 15
0.020-0.054 (0.0007-0.0021 )
See page 9-14
17.016-17.034 (0.6699-0.6706)
0.05-0.20 (0.002-0.008)
17.07 (0.672)
0 . 3 (0.01)
0 . 0 5 (0.002)
0.06 (0.002)
0.06 (0.002)
General Information
Transmission
Standard
Item
Service Limit
-
28.000-28.021 (1.1024-1.1032)
24.000-24.021 (0.9449-0.9457)
31.000-31.025 (1.2205-1.221 5)
27.959-27.980 (1.1007-1.1016)
30.950-30.975 (1.2185-1.2195)
24.985-25.006 (0.9837-0.9845)
27.985-28.006 (1.1018-1.1026)
0.020-0.062 (0.0008-0.0024)
0.025-0.075 (0.0010-0.0030)
24.959-24.980 (0.9826-0.9835)
28.04 (1.104)
24.04 (0.946)
31.04 (1.222)
27.94 (1.100)
30.93 (1.222)
25.03 (0.985)
28.03 (1.104)
0.10 (0.004)
0.1 1 (0.004)
24.94 (0.982)
Countershaft O.D. at C1 gear

C2 gear
19.987-20.000 (0.7869-0.7874)
27.967-27.980 (1.1011-1.1016)
19.97 (0.786)
27.94 (1.100)
Gear-to-shaft clearance
Gear bushing-to-shaft clearance at M5 gear
C2
Shift fork claw thickness (Lj
(Cl
0.005-0.047 (0.0002-0.0019)
0.005-0.039 (0.0002-0.0015)
6.43-6.50 (0.253-0.256)
6.43-6.50 (0.253-0.256)
6.43-6.50 (0.253-0.256)
14.000-14.021 (0.5512-0.5520)
0.08 (0.003)
0.08 (0.003)
6.1 (0.24)
6.1 (0.24)
6.1 (0.24)
14.04 (0.553)
Transmission gear I.D. M5

C1
C2.3.4
Transmission gear bushing O.D. M5
C2.3.4
Transmission gear bushing I.D. M5
C2
Gear-to-bushing clearance at M5 gear
C2.3.4
Mainshaft O D . at M5 gear
M5
(R)
Shift fork I. D. (L)

(C)
(R)
Shift fork shaft O.D.
14.000-14.021 (0.5512-0.5520)
13.966-13.984 (0.5498-0.5505)
14.04 (0.553)
13.90 (0.547)
General Information
Unit: mm (in)
'Iutch System
Item
Standard
Service Limit
Clutch lever free play

Recommended clutch fluid
Clutch master cylinder I.D.
Clutch master piston 0. D.
Clutch outer I.D.
Clutch outer guide O.D.
I.D.
Mainshaft O.D. at clutch outer guide
Clutch spring free height
Clutch spring free lenght
Clutch disc thickness
Clutch disc thickness (A)
(B)
(C)
Clutch plate warpage
Centrifugal clutch
drum I.D.
bushing O.D.
Centrifugal clutch center guide I.D.
O.D.
Centrifugal clutch center guide collar height
Centrifugal clutch weight lining thickness
Centrifugal clutch spring free lenght
Clutch lining thickness
Crankshaft O.D. at clutch center
voollng system
Coolant capacity (Radiator and engine)
(Reserve tank)
Radiator cap relief pressure
Thermostat begins to open
Thermostat fully open
Thermostat valve lift
urtvw Iram
Recommended final drive oil
Final drive gear oil capacity at disassembly
at draining
Final drive gear backlash
Final drive gear backlash difference between
measurement
Ring gear-to-stop pin clearance (A)
Stop pin shim
Ring gear spacer
Pinton spacer
Final drive gear assembly preload
Output gear backlash
Output gear I. D.
Output gear bushing O.D.
I.D.
Output drive shaft O.D.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim
General Information
- Wheels/Tires
Unit: mm (in)
Item
Minimum tire tread depth (FR)

(RR)
Cold tire pressure Up to 90 kg (200 lb) load (FR)
Up to 9 0 kg (200 lb) load (RR)
Up to maximum weight capacity (FR)
Up to maximum weight capacity (RR)
Front and rear axle runout
Front and rear wheel rim runout (Radial)
(Axial)
Front wheel hub-to-rim distance
Front wheel hub standard surface
Rear wheel hub-to-rim distance
Rear wheel hub standard surface
Wheel balance weight (Front)
(Rear)
Drive chain slack
Drive chain size/link (DID)
(RK)
Standard
-
225
225
225
280
kPa
kPa
kPa
kPa
(2.25
(2.25
(2.25
(2.80
Service Limit
1.5 (0.06)
2.0 (0.08)
kg/cm2, 33 psi)
kg/cm2, 33 psi)
kg/cm2, 33 psi)
kg/cmZ, 41 psi)
0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
-
6 0 g (2.1 02)
60 g (2.1 02)
20-30 (3/4-1.3/16)
DID 525 V9/110
PK 525 SM4/110
402.0 (15.82)
-
394.0 (15.51)
Front suspension
Fork spring free length
Fork spring free length ( A )
(01
Fork spring direction
Fork tube runout
Recommended fork oil
Fork oil level
Fork oil level (R)
( L)
Fork oil capacity
Fork oil capacity (R)
(L)
Fork air pressure
Steering bearing preload
Tightly wound coil facing down
Fork fluid
137 (5.4)
0.2 (0.01)
-
472cc (15.96 USoz, 16.57 Imp oz)
1.0-1.6 kg
Rear Suspension
Shock absorber spring free length
Shock absorber spring free length (A)
(0)
Damper gas pressure
Damper compressed gas
Damper rod compressed force at 1 0 mm compressed
Damper drilling point
Shock absorber spring installed length (Standard)
(Adjustable range)
Shock absorber spring adjuster standard position
Shock absorber spring direction
Recommended shock absorber oil
Shock absorber oil capacity
air pressure
248.7 (9.79)
243.7 (9.59)
2nd groove
Tapered coil facing down
-
General Information
Unit: mm (in)
Brakes
Front
Rear
Item
brake fluid
brake lever free olav,
brake pad wear indicator @
brake disc thickness

brake disc runout
master cylinder I.D.
master piston 0.D
caliper cylinder I.D.
caliper cylinder I.D. (Upper)
(Lower)
caliper piston O.D.
caliper piston O.D. (Upper)
(Lower)
brake drum I.D.
brake lining tickness
brake fluid
brake pedal height
brake pedal free play
brake pad wear indicator
brake disc thickness
brake disc runout
master cylinder I.D.
master piston 0.D.
caliper cylinder I.D.
caliper piston O.D.
brake drum I.D.
brake lining thickness
Alternator/charging coil resistance (at 2 0 C / 6 8 F )

Regulator/rectifier regulated voltage/amperage
Battery capacity
Battery specific gravity (Fully charging)
(Needs charging)
Battery charging rate (Normal)
(Quick)
Battery voltage (fully charged 20;C/68'F)
(needs charging 2 0 C/68F)
Alternator field coil resistance (at 20'C/68'F)
AC regulator regulated voltage (with analogue type)
(with digital type)
Standard
DOT 4
-
1-
5.0 (0.20)
11 .O-11.043 (0.4331 -0.4348)
10.957- 10.984 (0.4314-0.4324)
2 7 . 0 0 0 - 2 7 . 0 5 0 (1.0630- 1.0650)
2 6 . 9 3 5 - 2 6 . 9 6 8 (1.0604- 1.0617)
Service Limit
I
I To the groove I
4 . 0 (0.16)
0.25 (0.01)
11.055 (0.4352
10.945 (0.4309
27.06 (1.065)
-
2 0 - 3 0 (0.8-1.2)
-
26.93 (1.060
-
160.0-160.3 ( 6 . 2 9 9 - 6 . 3 1 1)
5.0 (0.2)
161 .O (6.33)
2 . 0 (0.08)
0.4-0.6 R
13.0-15.OV/below0.5A/2,000rpm
12 V - 1 4 A h
1.270- 1.290
Below 1.260
1.4 A/lOh
--
2.1-2.6 R
-
General Information
. ..
Unit: mm linl
. ~
Ignition system
Item
Spark plug
(Standard NGK)
(Standaed NIPPONDENSO)
(For extended high speed riding NGK)
(For extended high speed riding NIPPONDENSO)
Spark plug gap
Ignition timing "F- mark
Advance start
stop
Full advance
Alternator exciter coil resistance (at 2OC/68'F)
Ignition coil resistance
(Primaly: at 2OC/68'F)
(Secondan/: with plug cap)
(Secondan/: without plug cap)
Ignition pulse generator resistance (at 20C/68'F)
Standard
DPR 8EA-9
X24EPR-U9
OPR 9EA-9
X27EPR-U9
0.8-0.9 mm (0.03-0.04 in)
10' BTDC
10'/1,50Orprn
33'/4,00Orpm
33'/4,00Orpm
2.6-3.2 Q
18-22 k R
13-1 7 k n
297-363 Q
Lights/Meters/Switches
Main fuse
Fuse
Headlight (high/low beam)
Tail/brake light
License light
Position light
Front turn signalhunning light
Front turn signal light
Rear turn signal light
Instrument lights
Oil pressure warning indicator
Tail/brake light warning indicator
Side stand warning indicator
Low fuel indicator
Coolant temperature indicator
Oil temperature indicator
High beam indicator
Turn signal indicator
Neutral indicator
Reverse indicator
Overdrive indicator
Oil temperature sensor resistance
Fuel unit resistance (at full level)
(at low level)
Fuel pump flow capacity (min./minute)
Coolant temperature sensor resistance (at 5OC)
- stanlng system
Starter driven gear 0.D.

Starter clutch outer I.D.
Starter motor
brush spring tension
brush length
30 A
lOAX2. 15AX1
12V60/55 W
12 V 3/32 CP
12 V 32/3 CP
12V32CP
12V1.7Wx3
12V3W
12V3W
-
12V3W
12V3.4W
12V3W
~~~~
~~~~~~
Sewice Limit
42.1 75-42.200 (1.660-1.661)
9209
12.5 (0.49)
8.5 (0.33)
~ ~
General Information
Torque Values
- standard
Torque
N .m (kg-m, ft-lb)
ltem
5 mm hex bolt and nut
5 (0.5,
10 (1 .O,
22 (2.2,
35 (3.5,
55 (5.5,
Torque
N m , (kg-m, ft-lb)
ltem
5 mm screw
6 mm screw
6 mm flange
6 mm flange
8 rnm flange
10 rnm flange
3.5)
7.2)
16)
25)
40)
bolt
bolt
bolt
bolt
(8 mm head)
(10 mm head) and nut
and nut
and nut
4 (0.4,
9 (0.9,
10 (1 .O,
12 (1.2,
27 (2.7,
40 (4.0.
3)
7)
7.2)
9)
20)
29)
Torque specifications listed below are for important fasteners. Others should be tightened to standard torque values listed
above.
Notes:
1. Apply sealant to the threads.

2. Apply a locking agent to the threads.
3. Apply molybdenum disulfide oil to the threads and flange surface.
4. Left hand threads.
5. Stake.
6. Apply oil to the threads and flange surface.
7. Apply clean engine oil to the O-ring.
8. Torque wrench scale reading using a special tool.
9. Apply grease to the threads and flange surface.
10. ues bolt.
11. U-nut.
tnglne
Thread
dia. (mm)
Torque
N.m (kg-m, ft-lb)
1
1
1
2
3
2
6
1
1
2
12
20
6
8
10
10
20
9
PT 1/8
6
35 (3.5, 25)
10 (1.O, 7.2)
12 (1.2, 9)
14 (1.4, 10)
31 (3.1, 22)
12 (1.2, 9)
30 (3.0, 22)
28 (2.8, 20)
12 (1.2, 9)
7 (0.7, 5.1)
4
12
20
8
3
4
4
4
7
9
6
6
5
6
12
6
19 (1.9, 14)
28 (2.8, 20)
14 (1.4, 10)
10 (1.0. 7.2)
6 (0.6, 4.3)
12 (1.2, 9)
15(1.5, 11)
12 (1.2, 9)
1
1
1
1
1
24
22
6
8
6
8 (0.8, 5.8)
llO(11.80)
12 (1.2, 9)
23 (2.3, 17)
14 (1.4, 10)
ltem
Lubrication:
Oil drain bolt
Oil filter
Oil pump driven sprocket bolt
Oil pipe bolt
Oil pipe bolt
Oil chamber cover bolt
Sealing bolt
Air separator cover bolt
Oil pressure switch
Oil cooler mounting bolt
Cylinder Head/Cylinder:
Cam sprocket bolt
Cylinder head cap nut
Camshaft holder bolt
Cylinder head cover bolt
Head cover breather plate bolt
Cam chain tensioner mounting bolt
Spark plug
De-foarning chamber cover bolt
Clutch/Gearshift Linkage
Change cover cap
Clutch center lock nut
Shift drum stopper arm bolt
Shift return spring pin bolt
Gear shift spindle joint bolt
Remarks
Note 2
Note 1
Note 1
Note2. 10
Note 3
Note 2
Note 2
Note5
General Information
-~~
~ ~ : ~ - .
cnglne
ltem
Crankcase/Crankshaft
Crankcase bolt
Crankcase bolt
Alternator rotor bolt
Alternator cover bolt
Crankcase breather separator bolt
Connecting rod nut
Countershaft bearing cover bolt
Shift fork bolt (M)
Alternator shaft nut
Ignition pulse generator rotor bolt
Alternator drive chain tensioner bolt
Alternator drive chain slipper bolt
Alternator drive chain slipper pin bolt
Drive spvocket bolt
a'w
Thread
dia. (mm)
Toque
N.m (kg-m, ft-lb)
14
16
1
3
3
8
3
1
1
1
3
1
1
1
8
6
10
6
6
8
8
7
10
10
6
6
6
10
23 (2.3. 17)
12 (1.2, 9)
34 (3.4, 25)
11 (1.1, 8)
12 (1.2, 9)
32 (3.2. 23)
23 (2.3, 17)
18 (1.8, 13)
34 (3.4, 25)
35 (3.5, 25)
12 (1.2, 9)
12 (1.2, 9)
12(1.2,9)
40 (4.0, 29)
Q'w
Thread
dia. (mm)
Torque
N.m (kg-m, ft-lb)
2
1
4
20
3 (0.3, 2.2)
23 (2.3, 17)
1
1
2
2
2
2
2
2
24
26
8
10
37
8
10
6
105 (10.5, 76)

25 (2.5. 18)
23 (2.3, 17)
50 (5.0, 36)
23 (2.3, 17)
20 (2.0, 14)
40 (4.0. 29)
7.5 (0.75, 5.4)
1
2
2
2
14
10
10
8
90 (9.0,
35 (3.5,
35 (3.5,
22 (2.2,
1
4
1
5
14
8
16
12
60 (6.0, 43)
22 (2.2, 16)
90 (9.0, 65)
100 (10. 72)
1
2
2
1
1
1
1
2
6
1
1
1
2
8
8
10
10
10
8
8
6
8
6
6
4
4
27 (2.7, 20)
31 (3.1. 22)
35 (3.5, 25)
2.5 (0.25, 1.8)
18 (1.8, 13)
23(2.3.17)
13 (1.3, 9)
12 (1.2, 9)
43 (4.3, 31)
1 (0.1. 0.7)
6 (0.6. 4.3)
1.2 (0.12, 0.9)
1.5 (0.15, 1.1)
Remarks
Note 2
Note 3
Note 2
Note 2
Note 2
Note2
rratrle
ltem
Fuel systems:
Tank cap screw
Fuel valve nut
Front Suspention:
Steering stem nut
Steering head bearing adjusting nut
Fork pinch bolt (upper)
Fork pinch bolt (lower)
Fork cap bolt
Fork socket bolt
Handlebar holder nut
Fork drain bolt
Rear Suspension:
Swingarm pivot nut
Shock mounting bolt (upper)
Shock mounting bolt (lower)
Drive chain adjuster lock nut
Wheels:
Front axle bolt
Fmnt axle pinch bolt
Rear axle nut
Driven sprocket nut
Brake:
Brake arm pinch bolt
Caliper bracket bolt
Brake hose bolt
Pad pin plug
Pad pin
Caliper pin bolt
Bracket pin bolt
Master cylinder holder bolt
Brake disc bolt
Brake lever pivot bolt
Brake lever pivot nut
Front brake light switch screw
Reservoir cover screw
65)
25)
25)
16)
Remarks
Note 2
Note 11
Note 9, 11
Note 11
Note 6
Note2
Note2
Note 2
General Information
- Frame
Item
FramdExhaust systems:
Rear fender A mounting bolt
Ignition switch mounting bolt
Exhaust pipe joint nut
Rear fairing screw
Side stand pivot bolt
Side stand pivot nut
Engine front bracket bolt
Engine lower bracket bolt (right)
Engine lower mounting bolt (left)
Engine rear mounting nut
Engine front mounting nut
Engine lower mounting bolt (right)
Engine rear bracket bolt
Q'w
Thread
dia. (mm)
Torque
N.m (kg-m, ft-lb)
2
2
8
2
1
1
4
2
1
1
1
1
2
8
8
7
12 (1.2, 9)
25 (2.5, 18)
20 (2.0, 14)
12 (1.2, 9)
10 (1 .O. 7.2)
3 0 (3.0, 22)
4 0 (4.0, 29)
4 0 (4.0, 29)
50 (5.0, 36)
50 (5.0, 36)
50 (5.0, 36)
50 (5.0, 36)
4 0 (4.0, 29)
8
10
10
8
8
10
10
10
10
8
Remarks
Note 11
General Information
Tools
Description
Maintenance:
Pilot screw wrench
Oil filter wrench
Lubrication:
Oil pressure gauge
Oil pressure gauge attachment
Fuel System:
Float level gauge
Cylinder HeadlCylinderlPiston:
Valve spring compressor
Valve spring compressor attachment
Valve guide driver, 5.0 mm
Valve guide reamer, 5.0 mm
Valve seat cutter
seat cutter, 24.5 mm (45" EX)
27.5 mm (45" IN)
flat cutter, 25 mm (32" EX)
28 mm (3Z0IN)
interiorcutter, 22 mm (60" EX)
26 mm (60" IN)
cutter hoider, 5 mm
Piston ring compressor
Piston base
Hydraulic tappet bleeder
ClutchlGearshii Linkage:
Clutch center holder
Lock nut wrench, 26 x 30 mm
Extension bar
Crankrhaft/Transmission:
Universal holder
Bearing remover. 17 mm
Handle
Sliding weight
Attachment, 37 x 40 mm
Attachment, 42 x 47 mm
Pilot, 20 mm
Pilot. 17 mm
Driver
Driver
Driver, 22 mm I.D.
Driver, 40 mm I.D.
Attachment, 20 mm I.D.
Front WhedlSuspensionlSteering:
Ball race remover
Ball race remover
-attachment
-driver handle
Steering stem driver
Driver
Attachment. 42 x 47 mm
Attachment. 52 x 55 mm
Steering st& socket wrench
Bearing remover head, 20 mm
Bearing remover shah
Pilot, 20 mm
Fork seal driver body
Fork seal driver attachment, 41 mm I.D.
Tool Number
+
I
Applicability
07908-4730001
07HAA-PJ70100
equivalent commercially
available in U.S.A. (Cal Van 466
07506-3000000
0751&MJ10100
available in U.S.A.
07401-0010000
07757-0010000
07959-KM30101
07942-MA60000
07986MA60001
or 07984-MA60M)C (U.S.A. only
07780010100
07780010200
07780012000
07780012100
07780014202
07780014500
07781-0010400
07954-3690000
07958-3000000
0797>MJ00000
available in U.S.A.
-or
--or
07HG&001000A (U.S.A. only

equivalent commerciall!
available in U.S.A.
available in U.S.A.
General Information
Description
Rear Wheel/Suspension:
Shock absorber compressor
Spring compressor attachment
Spring compressor holder base
Driver
Attachment, 2 8 x 30 mm
Attachment, 4 2 x 47 rnm
Pilot, 17 mm
Attachment, 32 x 35 rnrn
Pilot, 15 mm
Pilot, 2 0 mm
Pilot, 22 rnrn
Bearing remover head, 17 mm
Bearing remover shaft
Driver shaft
Needle bearing remover attachment
Bearing remover, 15 mm
-remover shaft, 15 rnrn
-remover head, 15 mm
-sliding weight
Brake System:
Snap ring pliers
Charging System/Alternator:
Flywheel puller
Lights/Meten/Switches:
T o n bit (T40)
Electrical Equipment:
Digital multimeter (KOWA)
Analogue tester
Applicability
Tool Number
07GME-0010000
07959- ME10000
07967-KC10100
07749 -001 0000
07946- 1870100
07746-001 0300
07746 -0040400
07746-0010100
07746 -0040300
07746-0040500
07746-0041 0 0 0
07746 -0050500
07746-0050100
07946-MJ00100
O7GMD-KT70200
07936-KC10000
07936-KClOl0007936-KC10200
07741 -0010201
-'
available in U.S.A.
or 07936-KC10500
or 079363710200
07914-3230001
07933 - 2 160000
07703-0010100
0741 1 -0020000
KS-AHM-32-003
(U.S.A. only)
07308 -0020001
(SANWA)
or TH-5H (KOWA)
or equivalent commercially
available in U.S.A.
General Information
Lubrication & Seal Points

- tnglne
Material
Location
Hydraulic tappet hole
Camshaft holder de-foaming chamber
Cam chaidalternator chain
Transmission gear teeth and bushings
Piston pin hole and outer surface
Piston pin outer surface
Each bearings
Piston ring sliding surface
Piston ring and ring groove
Cylinder sliding surface
Alternator shaft damper cam
Clutch lifter
Shift fork claw and pivot inner surface
Shift drum
O-rings
Clutch discs
Engine oil
Rocker arm slipper surface and pivot inner surface

Camshaft lobe and journal
Connecting rod small end
Valve stem (valve guide sliding surface)
Valve guide (valve stern sliding surface)
Transmission gear shift fork grooves
Crankshaft bearing sliding surface
Connecting rod bearing sliding surface
Crankshaft thrust sliding surface
Primary driven gear
Molybdenum disulfide oil

(amixture of 1/ 2 engine oil and
1/2 molybdenum disulfide grease)
Hydraulic tappet
Kerosene
Upper crankcase mating surface

-countershaft bearing cover mating surface
c l u t c h cover mating surface
Cylinder head/cylinder head cover gasket surface
Liquid sealant
Remarks
DO not apply sealant t o the

main journal bearings.
General Information
Frame
Material
Location
Steering stem bearing

Wheel bearing dust seal lips
Wheel axle outer surface
Handlebar (throttle grip sliding surface)
Throttle cable ends
Brake pedal pivot shaft
Side stand pivot bolt outer surface
Dust seal lips
Speedometer gear
Seat locking tab
Swingarm pivot bearings
Swingarm pivot bearing dust seal lips
Rear brake cam
Multi-purpose grease
Side reflector threads

Caliper bracket pin bolt threads
Caliper pin bolt threads
Seat catch hook mounting bolt threads
Locking agent
Fork cap O-ring

Fork oil seal lips
Honda Suspension Fluid SS-7
Handlebar grip
Honda Bond A or
Honda Hand Grip Cement
(U.S.A. only)
Brake caliper seals

Caliper-piston sliding surface
Master cylinder piston caps
Master cylinder-piston sliding surface
DOT 4 Brake fluid
Steering stem lock nut threads

Steering head bearing adjustment nut
Engine oil
Remarks
Apply thin coat of grease
General Information
Cable & Harness Routing
I
: Indicates the clamping wire
(2) CLUTCH CABLE
(3) CHOKE CABLE
(7) RIGHT HANDLEBAR
(4) LEFT HANDLEBAR

SWITCH WIRE
(6) BRAKE HOSE
(5) TURN SIGNAL WIRES
(9) 6P-RED CONNECTOR

(STARTER SWITCH,
ENGINE STOP SWITCH)
10) 9P-WHITE CONNECTOR

(TURN SIGNAL SWITCH)
(1 1) 2P-BLACK CONNECTOR
(IGNITION SWITCH)
General Information
THROlTLE CABLES
(1) CHOKE CAB
(6) BLACK/WHITE
WlRE
(3) BRAKE HOSE

(B)YELLOW/BLUE
WlRE
(7) CLUTCH CABLE

(4) MAIN WlRE HARNESS
General Information
(7) REGULATOR/
RECTIFIER
(8) CLUTCH CABLE
( 1 1) ~GNITIONPULSE
GENERATOR WIRE
\
(10) ALTERNATOR
WIRE
(1) TURN
SIGNAL
(3)IGN~TION
CONTROL
MODULE
(4) MAlN WlRE HARNESS
(2)TURN SIGNAL RELAY
General Information
(1) IGNITION PULSE

GENERATOR
WlRE
(5) SIDE STAND SWITCH

WlRE
(4) OIL PRESSURE SWITCH
WlRE
(2) WHITE TAPE
General Information
(3) No.11 TUBE

(7) PULSE SECONDARY
AIR INJECTION CONTROL
VALVE (PAIR CONTROL VALUE)
RATIVE EMISSION
RETOR AIR VENT CONTROL VALVE
TO AIR CLEANER
~
VALVE
(1 1) TO F U E AUTO
General Information
Emission Control System
The U .S. Environmental Protection Agency and California Air Resources Board (CARE) require manufacturers to certify that
the~rmotorcycles comply with applicable exhaust emissions standard during their useful life, when operated and maintained
according totheinstructionsprovided, and that motorcyclesbuilt afterJanuary 1. 1983complyw1thapplicableno1seemission
standardsfor 1 yearor 6,000 km (3.730 miles) afterthe timeof sale tothe ultimate purchaser. when operated and maintained
according to the instructions provided. Compliance with the terms of the Distributor's Warranties for Honda Motorcycle
Emission Control Systems is necessary in order to keep the emissions system warranty in effect.
Source Of Emissions
The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because,
under certain conditions, they reactto form photochemicalsmog when subjected to sunlight. Carbon monoxide does not react
in the same way, but it is toxic.
Honda Motor Co., Ltd
hydrocarbons.
. utilizes lean carburetor settings as well
as other systems, to reduce carbon monoxide and
Crankcase Emission Control System

The crankcase emission control system routes crankcase emission through the air cleaner and into the combustion chamber.
Condensed crankcase vapors are accumulated in the drain tube which must be emptied periodically. Refer to the Maintenance
Schedule (page 3-4). The drain tube needs to be checked for oil accumlation more frequently if the machine has been
consistently ridden at high speeds or in rain.
AIR CLEANER
*(3) : BLOW-BY GAS

*(4) : FRESH AIR
General Information
Exhaust Emission Control 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 moddl
The exhaust emission control system consists of a pulse secondary air supply system which introducesfiltered 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 vapor.
A pulse secondary air injection check valve (PAIR check valve) prevents reverse air flow through the system. The pulse
secondary air injection control valve (PAIR control valve) reacts to high intake manifold vacuum and will cut off the supply
of fresh air during engine deceleration, thereby preventing afterburn i n the exhaust system.
No adjustments t o the pulse secondary air supply system should be made, although periodic inspection of the
components is recommended.
(California Model Only)
(2) CARBURETOR
(1)INTAKE PORT
CONTROL VALVE
(4) PAIR CHECK VALVE
: (6):FRESH AIR
General Information
Evaporative Emission Control System(Ca1ifornia Model Only)
This vehicle complies with the California Air Resources Board requirements for evaporative emission regulations
Fuel vapor from the fuel tank and carburetor is routed into the evaporative emission canister (EVAP canister) where it is
absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission purge control
diaphragm valve (EVAP purge control valve) is open fuel vapor in the EVAP canister is drawn into the engine through the
carburetor. At the same time, the evaporative emission carburetor air vent control valve (EVAP CAV control valve) is open
and air is drawn into the carburetor through the valve.
(1) EVAP PURGE
@ (3) FRESH AIR
a (5)
:
EXHAUST PORT
: (6):FRESH AIR
'(7)EVAP CAV
CONTROL
VALVE
Noise Emission Control Svstem

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person, other than for purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for 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 parts of the intake system.
3.Lack of proper maintenance.
4.Replacing any moving parts of the vehicle, or pans of the exhaust or intake system, with parts other than those specified by the manufacturer.
General lnformation
Emission Control Information Labels

(U.S.A. Only)
An Emission Information Label is located on the rear fender as
shown. The seat must be removed to view it.
It gives basic tune-up specifications.
(1) EMISSION INFORMATION

LABEL
Vehicle Emission Control lnformation Update Label

After making a high altitude carburetor adjustment, attach an
update label on the rear fender as shown.
After re-adjusting the carburetor back to standard settings
for low altitude, remove the update label.
(3)VACUUM HOSE ROUTING

DIAGARM LABEL
(California model only)
(21 UPDATE LABEL
Vacuum Hose Routing Diagram Label (California Model

Only1
Thevacuum Hose Routing Diagram Label is on the rear fender
as shown.
The seat must be removed to view it.
Route the vacuum hoses as shown on this label.
ENGINE FAMILY - X X X X X X X X X X X
EVAPORATIVE FAMILY - X X X X X X X
CALIFORNIA VEHICLE
PAIR
CONTROL
2. Frame/ Body Panels/ Exhaust System
a
I
Service Information
2-1
Side Cover Removal/lnstallation
Troubseshooting
2-1
Rear Fairing Removal/lnstallation
Exhaust System Removal/lnstallation
2-2
Fuel Tank Removal/lnstallation
Seat Removal/lnstallation
2-3
2-3
2-4
Service lnformation
. Gasoline is extremely flammable and is explosive under certain conditions.

I
--
KEEP OUT OF REACH OF

CHILDREN.
Serious burns may result if the exhaust system is not allowed t o cool before components are removed or
serviced.
Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can
cause a fire or explosion.
This section covers removal and installation of the frame body panels, fuel tank and exhaust system.
Always replace the exhaust pipe gaskets when removing the exhaust pipe from the engine.
When installing the exhaust pipe, first install all the fasteners loosely. Next, tighten the exhaust clampsfirst, then tighten
the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe not seat properly.
Always inspect the exhaust system for leaks after installation.
Troubleshootinn
-
Excessive Exhaust Noise

Broken exhaust system
Exhaust gas leak
Poor Performance
Deformed exhaust system
Exhaust gas leak
Clogged muffler
.
.
.
FrameIBody PanelsIExhaust System
Exhaust System Removal/lnstallation
service the exhaust system while it is hot.

NnTC
,.-,-
When installing the exhaust pipelmuffler, always tighten the exhaust pipe joint nuts first, then tighten the mounting
Pmcedure
Removal Order
(1) Brake pedal pinch bolt
(2) Brake pedal
(3) Exhaust pipe joint nut
('4) Muffler center mounting bolt
(5) Spring washer
(6) Washer
(7) Muffler mounting boltlnut
( 8 ) Muffler assembly
(9) Gasket
Q'ty
Remarks
Installation is in the reverse order.of removal.

1
1
Align the punch mark on theshafl with the brake pedal slot.
installation, install all fasteners loosely and tighten the
8--At
2exhaust pipe joint nuts first.
2
With the "OUT" mark facing down.
2
21
4
FrameIBodv PanelsIExhaust Svstem
Removal
Insert the ignition key into the seat lock.

Turn the ignition key clockwise until it stops then remove
the seat by sliding it backward.
(1) HOOKS
A&
Installation
Apply grease to the hook of the seat.
Align the seat hooks with the frame hooks and push the seat
forward.
Push the seat down until it locks.
CAUTION
Be careful not to pinch the wire harness between the
seat and the frame.
(31 SEAT
Side Cover Removal/lnstallation

Remove the seat (see above).
Release the cover front bosses from the grommets.
Release the tabs from the rear fairing grooves and remove
the side cover.
CAUTION
/-
Be careful not t o damage the tabs and upper fairing]

grooves.
Install the side cover in the reverse order of removal.
( 2 ) SIDE'COVER
(1) BOSSES
FrameIBody PanelsIExhaust System
Rear Fairing Removal/lnstallation

Remove the seat (page 2-3).
Remove the shock absorber upper mounting bolts, collars
and washers.
Remove the fairing mounting screws, collars and washers.
Raise the rear fairing and remove the taillight mounting nuts
and washers.
Remove the rear fairing.
Install the rear fairing in the reverse order of removal

Install the seat (page 2-31
19) REAR FAIRING
Fuel Tank Removal/lnstallation
Gasoline is extremely flammable and is explosive

under certain conditions.
I
(1) FUELTANK
( 2 ) BOLT

Turn the fuel valve OFF.
Remove the fuel tank mounting bolt and lift the fuel tank up,
Disconnect the tubes, and remove the fuel tank.
Install the fuel tank in the reverse order of removal.
After installation, turn the fuel valve ON and check the fuel
line for leakage.
Install the seat (page 2-3)
.(5)VACUUM TUBE
(4) FUELTUBE N O . TUBE

~
(CALIFORNIA
MODEL ONLY)
3. Maintenance
Service Information
Service Access Guide
3-1
3-2
Maintenance Schedule
3-4
Air Cleaner
Carburetor Synchronization
Service Information
. Refer to Common Service Manual for items not included in this manual
. Refer to Specifications (Section 11 for maintenance data.
3-5
Maintenance

The following shows the locations of the parts that must be removed for the maintenance items listed below. Refer to
the Common Service Manual for items not included in this manual.
Refer to section 2 (Frame/Body Panels/Exhaust System), for the parts that must be removed for service.
For example: AIR CLEANER (Contamination, clogging, replacement): Pans
Side cover
The part required to be removed for service.
(5) THROTTLE GRIP (Operation, free play)

(4) EVAP PURGE CONTROL VALUE
(Damage, faulty hose)
I
( 6 ) BRAKE LEVER (Air bubbles in system)
( 7 ) BRAKE MASTER CYLINDER
(8)STEERING HEAD BEAR1

(1) BRAKE DRUM
(10) SUSPENSION
1) TIRE (Wear,
(15) LEVEL GAUGE

(Level check, replacement)
(14) ENGINE OIL DRAIN BOLT (Replacement)
II I
(13) OIL FILTER (Replacement)
Maintenance
(5) FUEL LINE (Damage, leakage)
(4) IGNITION TIMING (page 14-9)
(6) PAIR CONTROL VALVE and

EVAP CAV CONTROL VALVE
(Damage, faulty hose). Fuel tank
(7) AIR CLEANER (Contamination, clog,

replacement page 3-51 .Side cover
a
11) SIDE STAND
(10) SYNCHRONIZATION ADJUSTING

SCREW (Synchronization page 3-5)
.Fuel tank
I
(8) DRIVE CHAIN
(9) THROTTLE STOP SCREW (Idle speed adjustment)
Maintenance
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I:Inspect and clean, Adjust, Lubricate, or Replace if necessaw.
R: Replace, C: Clean. L: Lubricate. A: Adjust
The following items require some mechanical knowledge, Certain items (particularly those marked * and " ) may require more
technical information and tools. Consult your authorized Honda dealer.
"
Should be serviced by an authorized Honda dealer. unless the owner has the proper tools and service data, and is
mechanically qualified. Refer to the official Honda service Manual.
In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. California model only.
5. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replace requires mechanical
skill.
6. Refer to the Common Service Manual.
7. Use the specifications in section one and refer t o the Common Service Manual
Maintenance
Air Cleaner
Remove the left side cover.
Remove the air cleaner housing cover.
Pull the air cleaner retainer out and remove the air cleaner.
Discard the air cleaner according t o the maintenance
schedule.
Install the air cleaner with the

Install the retainer.
mark forward.
Install the removed Darts in the reverse order of removal.
Carburetor Synchronization
NOTE
For detailed instructions, refer to section 2 of the Common Service Manual. The information here only indicates
locations of the plugs for the adapters and the synchronization adjusting screws.
Before inspection, remove the fuel tank mounting bolts
(page 2-4) and move the tank rearward without disconnecting the fuel tube.
Carburetor Vacuum Difference:
Within 30 mmHg (1.2 inHg)
Base Carburetor: No.2 Carburetor
(1) PLUGS
(1) No.4
(2)
No.1
SCREW
MEMO
Lubrication System
.
Service Information
4-1
Oil Pump Disassembly/Assembly
4-4
Troubleshooting
4-1
Oil Cooler Removal/lnstallation
4-5
Lubrication System Diagram
4-2
Oil Pressure Check
4-6
Oil P u m ~
Removal/lnstallation
4-3
Service Information
If the engine must be running to do some work. make sure the area is well ventilated. Never run engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and
may lead to death. Run the engine in an open area or with an exhaust evacuation sysem in an enclosed area.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although
this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands
with soar, and water as soon as ~ossibleafter handling used oil.
The oil pump can be serviced with the engine installed in the frame.
For oil pressure check, refer to section 4 of the Common Service Manual; for the switch location, see page 16-2 of this
manual.
The service procedures in this section be performed after the engine oil is drained.
When removing and installing the oil pump, use care not to allow dust or din to enter the engine.
If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
Troubleshooting
Oil Level Low
Oil consumption
External oil leak
Worn piston ring or incorrect piston ring installation
Worn valve guide or seal
--
Or No Oil Pressure
-LowClogged
oil orifice
- lncorrect oil being used
No Oil Pressure
Oil level to low
Oil pump drive sprocket broken
Oil pump damaged (pump shaft)
Internal oil leaks
Low Oil Pressure
-- Clogged oil strainer screen

pump worn or damaged
- Oil
Internal oil leak
- lncorrect oil being used
- Low oil level
High Oil Pressure
- Pressure relief valve stuck closed
- Plugged oil filter, gallery, or metering orifice
lncorrect oil being used
Oil Pressure Warning Light Does Not Work Well
Refer to section 25 of the Common Service Manual
Lubrication Svstem
(11)
6~RELIEF VALVE
Lubrication Svstem
Oil Pump Removal/lnstallation
NOTE
Use care to prevent dust and dirt from entering the engine.
After installation, check that there are no oil leaks.
Requisite Service
Engine oil draininglrefill

Clutch rernoval/installation (page 8-41
Procedure
Removal Order
Oil pump driven sprocket bolt
Washer
Oil pump driven sprocket
Oil hose
O-ring
(6) Oil pan bolt
(7) Oil pan
( 8 ) Gasket
(9) Oil strainer
(10) O-ring
(1 11 Pressure relief valve
(12) O-ring
(13) Oil pipe
(14) O-ring
(15) Oil pump mounting bolt
(16 ) Oil pump assembly
(17) Dowel pin
(18) Oil orifice
(19) O-ring
(1)
(2)
(3)
(4)
(5)
Exhaust system rernovallinstallation (page 2-2)
Q'W
Remarks
Installation is in the reverse order of removal.
1
1
1
2
2
12
1
1
1
1
1
1
2
4
3
1
2
1
1
Clean with a non-flammable or high flash polnt solvent.
I
I
Lubrication Svstem
Oil Pump Disassembly/Assembly
PUNCH
PUNCH
MARK
NOTE
. If any portion of the oil pump is worn beyond the specified service limit, replace the oil pump as an assembly.
- Before assembling them, clean all disassembled parts thoroughly with clean engine oil.
to section 4 of the Common Service Manual for inspection information.
- Refer
Refer to oaoe 1-6 for soecifications.
Requisite Service
Oil pump removal/installation (page 4-3)
Procedure
Disassembly Order
Oil
pump cover attaching bolt
(1)
Oil
pump cover
(2)
(3) Dowel pin
(4) Cooler pump outer rotor
(5) Cooler pump inner rotor
(6) Drive pin

(7) Oil pump body
(8) Dowel pin

(9) Feed pump outer rotor
(10)Feed pump inner rotor
1 i
(1 1 ) Drive pin
11 2) P U ~ shaft
D
(13)washer
(14) Cotter pin
(15) Spring seat
(16)Spring
(1 7) Relief valve
Remarks
Q'W
Assembly is in the reverse order of disassembly.
3
1
2
1
1
1
1
1
1
1
lnstall with its punch mark facing the pump cover.

lnstall aligning the cut out with the drive pin.
lnstall with its punch mark facing the pump body.
.
.
Install with its punch mark facing the pump body.

lnstall aligning the cut out with the drive pin.
lnstall with its punch mark facing the pump body.
1
1
1
1
1
1
Lubrication Svstem
Oil Cooler Removal/lnstallation
NOTE
Use care to prevent dust and din from entering the engine.
After installation, check that there are no oil leaks.
,
Requisite Sewice
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Removal Order
Oil hose joint bolt (upper)
O-ring
Oil cooler mounting bolt
Oil cooler
Oil hose joint bolt (lower)
Washer
Oil hose
O-ring
Q'w
-
Remarks
Be careful not to bend the hose
Lubrication System
I IIP
Oil Pressure Check

Warm the engine up to normal operating temperature
laooroximatelv
8OC1176'FI.
. ..
Stop the engine.
Place the motorcycle on its side stand.
Remove the right sealing bolt and connect an oil pressure
gauge
- - to the .lug
- hole with an attachment.
Check the oil level, with motorcycle in an upright position.
Stan the engine and check the oil pressure at 6,000 rpm.
Oil pressure gauge

07506-3000000
Oil pressure gauge attachment
07510-MJ10100
or
equivalent commercially available i n U.S.A.
Q ,
, ,
(1) SEALING BOLT
OIL PRESSURE: 6 3 0 kPa (6.3 kglcm2, 9 0 psi) at ( 8 0 C I

176F) 6,000 rpm
Stop the engine and place the motorcycle on its side stand.
Remove the pressure gauge and attachment.
Apply sealant to the sealing bolt threads and install the bolt
with new sealing washer.
Toque: 30N.m (3.0 kg-m. 22ft-lb)
Start the engine.
Check that the oil pressure warning indicator goes out after
one or two seconds.
If the pressure warning indicator stays on, stop the engine
immediately and determine the cause.
(1) OIL PRESSURE GAUGE ATTACHMENT
5. Fuel System
5-1
Carburetor DisassemblylAssembly
5-8
Troubleshooting
5-2
Carburetor C o m b i n a t i o n
5-10
Air Cleaner Housing Removal/lnstallation
5-3
Pilot Screw Adjustment (U .S.A. Only) 5-12
Carburetor R e m o v a l l l n s t a l l a t i o n
5-4
High Altitude Adjustment
Carburetor Separation
5-6
(U.S.A.
Only) 5-13
Service Information
. Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF
- CHILDREN.
Bending or twisting the control cables w i l l impair smooth operation and could couse the cables to stick or bind,
Service Information
resultina in loss of vehicle control.

CAUTION
Be sure to remove the carburetor diaphragms before cleaning air and fuel passages w i t h compressed air.
.
. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
a fire or explosion.
- cause
Refer to section 2 for fuel tank removal and installation.
disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
- When
Before removing the carburetors, place an approved gasoline container under the carburetor drain tube, loosen the drain
bolts and drain the carburetors.

After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to
prevent any foreign material from dropping into the engine.
The vacuum chamber and float chamber can be serviced with the carburetors assembled.
California Model Only:
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, page 1-30
NOTE
If the vehicle is to be stored for more than one month, drain the float bowls. Fuel left in the float bowls may cause
cloaaed iets resultina in hard startina or Door driveabilitv.
Fuel System
Troubleshooting
Engine Won't Start
Too much fuel getting to the engine
-Air cleaner clogged
-Flooded carburetor
Intake air leak
Fuel contaminatedldeteriorated
No fuel to carburetor
-Fuel strainer clogged
-Fuel tube clogged
-Fuel valve stuck
-Float level misadjusted
-Fuel tank breather hole clogged
-.
Lean Mixture
Fuel jets clogged
Float valve faulty
Float level too low
Fuel line restricted
Carburetor air vent tube clogged
lntake air leak
Throttle valve faulty
Vacuum piston faulty
California Model Only: EVAP CAV control valve faulty
--
Rich Mixture
Bystarter valve in ON position
Float valve faulty
Float level too high
Air jets clogged
Air cleaner contaminated
Flooded carburetor
Engine Stalls, Hard To Start. Rough Idling
Fuel line restricted
Ignition malfunction
Fuel mixture too leanlrich
Fuel contarninatedldeteriorated
lntake air leak
Idle speed misadjusted
Float level misadjusted
Fuel tank breather hole clogged
Pilot screw misadjusted
Slow circuit or bystarter circuit clogged
Emission control system malfunction
-EVAP CAV control valve faulty
-EVAP purge control valve
-loose, disconnected or deteriorated hoses of the emission control system
..
..
Afterburn When Engine Braking Is Used

Lean mixture in slow circuit
-pulse secondan/ air supply system faulty
-loose, disconnected or deteriorated hoses of the
emission control system
Afterburn Or Misfiring During Acceleration
Ignition system faulty
Fuel mixture too lean
Poor Performance (Driveability) And Poor Fuel Economy

Fuel system clogged
lgnition malfunction
-EVAP CAV control valve faulty
-loose, disconnected or deteriorated hoses of the
emission control system
--
Fuel System
Air Cleaner Housing Removal/lnstallation
Requisite Service
. Rear wheel removal/installation (page 11-2)
Rear fairing removal/installation (page 2-4)

Battery removal/installation (page 13-4)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Procedure
Removal Order
Fusebox
Rear fender B mounting nut/bolt
Rear fender B
Crankcase breather tube
Crankcase breather drain tube
Connecting tube band screw
Air cleaner case mounting bolt
Canister-to-air cleaner housing tube
Starter relay switch
Air cleaner housing assembly
@W
Remarks
Installation is in the reverse order of removal
Loosen only.
California model only
Remove the air cleaner case from the right.
Fuel System
Carburetor Removal/lnstallation
Fuel Svstem
Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF
CHILDREN.
Work in well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can
cause a fire or explosion,
..-.-
Before removal, turn the fuel valve OFF.
Requisite Service
Fuel tank removal/installation (page 2-4)
Procedure
Carburetor draining
O'W
Removal Order
Fuse box
Connecting tube band screw

Air cleaner housing mounting bolt
Insulator band screw
Throttle cable
Choke cable
No. 6 vacuum tube (from the 3 way joint)
No. 5 tube (from the 5 way joint)
No. 11 tube (from the PCV)
Carburetor assemblv
4
4
4
2
1
1
1
1
1
Remarks
Release the hooks in the rear fender B from the frame as
shown, then move the rear fender B rearward.
Loosen only.
Move the air cleaner housing rearward.
Loosen only.
California Model Only

Fuel System
Carburetor Se~aration
Fuel System
Requisite Service
Carburetor removallinstallation (page 5-4)
Procedure
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Separate carburetors 314 from carburetors

112
Air joint pipe (3-way)
No. 5 tubelair joint pipe (5-way)
Starting enrichment valve arm screw
Starting enrichment valve arm shaft
Spring
Starting enrichment valve arm
Front bracket
Rear bracket
No. 3 carb. synchronization spring
Fuel joint pipe (3-way)/O-ring
1
411
4
1
1
4
1
1
1
1I 2
(1 1)
(12)
(13)
(14)
Separate No. 3 carb. from No. 4 carb.

Thrust spring
Air vent pipelO-ring
Fuel joint pipe (2-way)IO-ring
1
1
112
112
(15)
(16)
(17)
(18)
Separate No. 1 carb. from No. 2 carb.

Thrust spring
Fuel joint pipe (2-way)lO-ring
1
1
1I 2
1I 2
(1)
(2)
(3)
Remarks
Q'W

Loosen only.
Fuel System
Carburetor Disassembly/Assembly
I
1 .'
'
~-
Fuel System
'
'
NOTE
The vacuum chamber and float chamber can be serviced with the carburetors assembled.
The pilot screws are factory pre-set and should not be removed unless the carburetors are overhauled.
Before disassembling the carburetors, 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 reference when reinstalling the screws. If new pilot screws are installed, turn
each one out to the initial opening (page 1-6. Canadian model only).
-.-
Requisite Sewice
Carburetor separation (page 5-6)
Carburetor removallinstallation (page 5-41

Procedure
Vacuum Chamber Disassmbly Order
(1) Vacuum chamber cover screw
(2) Vacuum chamber cover
(3)
(4)
(5)
(6)
(7)
Spring
Diaphragmlvacuum piston
Jet needle holder
Spring
Jet needle
4
1
(9) Float chamber

(10) Float pin
(11) Float
(12)
(13)
(14)
(15 )
(16)
Float valve
Main jet
Needle jet holder
Needle jet
Slow jet
Starting Enrichment Valve DkassembhlOrder

(17) Valve nut
(18) Spring
(19) Starting enrichment valve
(20)
(21)
(22)
(23)
Pilot Screw Disassembly Order

Pilot screw
Spring
Washer
O-ring
NOTE
At installation, hold the piston up t o align the diaphragm
and to avoid pinching the it with the cover.
1
1
1
1
1
Float Chamber Disassembly Order
(8) Float chamber cover screw
Remarks
Q'W
4
1
1
1

At installation, first tighten the two screws on the dowel pin
side.
For float level inspection, refer to section 8 of the Common

Service Manual.
1
1
1
1
1
1
1
1
Assembly
1
1
1
1
IS
in the reverse order of disassembly.
Fuel System
Carburetor Combination
Fuel System
Requisite Service
Carburetor assembly (page 5-8)
Procedure
Q'W
Assemble the No. 1 and No. 2 carburetors

Fuel joint pipe (2-way)/O-ring
Thrust spring
Remarks
No. 2 carburetor is the base carburetor.
Install on No. 2 carburetor.
Assemble the No. 3 and No. 4 carburetors

Thrust s ~ r i n a
(10)
(1 1)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
1201
Assemble the carburetor pairs:

Front bracket
Front bracket screw
Rear bracket
Rear bracket screw
Starting enrichment valve arm
Spring
Starting enrichment valve arm shaft
Starting enrichment valve arm screw
Air joint pipe (3-way)
15-wav1
No. 5 tubelair ioint ~ i o e
FrontIRear Bracket Bracket Installation

Install the front bracket and screws loosely.
Place the carburetors on a flat surface with the front side
facing up.
Press the carburetors together carefully and tighten the front
bracket screws in the sequence shown in two or three steps
to prevent carburetor misalignment.
Install the rear bracket and screws using the sequence

shown in two or three steps.
-Installation (see below)

California Model Onlv
(1) FRONT BRACKET
Fuel System
Pilot Screw Adjustment (U.S.A.

Only)
ldle Drop Procedure
If the engine must be running to do some work,

make sure the area is well ventilated. Never run the
engine i n an enclosed area. The exhaust contains
poisonous carbon monoxide gas that may cause loss
of consciousness and lead to death.
NOTE
I.
Make sure the carburetor synchronization is within

specification before pilot screw adjustment.
The pilot screws are factory pre-set and no adjustment
is necessary unless the pilot screws are replaced.
Use a tachometer with graduations of 50 rpm change.
1. Turn each pilot screw clockwise until it seats lightly, then

back it out to the specification given. This is an initial
setting prior to the final pilot screw adjustment.
07908-4730001 or
available i n U.S.A.
(Cal Van 466)
Initial Opening: 2-518 turns out (49 states model)
: 2-318 turns out (California modell
Pilot screw wrench
CAUTION
Damage t o the pilot screw seat will occur if the pilot

screw is tightened against the seat.
2.Warm up the engine to operating temperature.

Stop and go riding for 10 minutes is sufficient.
3. Attach a tachometer according to its manufacturer's
instructions.
4. Adjust the idle speed to the specified rpm with the throttle
stop screw.
ldle Speed: 1,000+ 100 rpm
5. Turn all oilot screws 112 turn counterclockwise from the
intial setting
Pilot screw wrench
07908-4730001 or
(Cal Van 466)
6. If the engine speed increases by 50 rpm or more, turn all

pilot screws out by successive 112 turn increments until
engine speed does not increase.
7. Adjust the idle speed with the throttle stop screw.
8. Turn the No.2 carburetor pilot screw in until the engine
speed drops 50 rpm.
9. Then turn the No.2 carburetor pilot screw counterclockwise 1/2 turn from the ~ositionobtained in steo 8.
10. Adjust the idle speed with the throttle stop screw.
11. Perform steps 8.9 and 10 for the No. 1.3 and 4 carburetor pilot screws.
5-12
Fuel System
12. Apply Loctite 601 or eqivalent to the inside of the limiter
caps. Place the caps over the pilot screws so that they
can be turned clockwise only. This will prevent adjustment in the counterclockwise direction which richens
the fuel mixture.
NOTE
Be careful not to turn the pilot screw when installing
the limiter cap.
(1) PILOT SCREW
(2) STOPPERS
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.
Warm up the engine to operating temperature. Stop and go
riding for 10 minutes is sufficient.
Turn each pilot screw to the specification below.
High Altitude Sening: 112-turn i n
Adjust the idle speed to 1,000+ 100 rpm (California:
1,000+ 100 rpm) with the throttle stop screw.
1.....1
Pilot screw wrench
07908-4730001 or
(Cal Van 466)
NOTE
This adjustment must be made at high altitude to
ensure proper high altitude operation.
1.
mnlcLE EMISSON CONTROL INFDRMA~ONUPDATE

HDNDA MOTMI CD..LTD
,----.
THE MHW HAS BEEN MJUE-TED m

IMPROW EY18sWm CDNlROL P E R F D R Y W
WHEN WERATED A1 HIGH UTrmlK
ALTITUDE -E
P
MJUsTWENl INSTRUeMNS
I R E AVNLbBlE AT YOUR AUTHaYED HONDA DUIER.
Anach a Vehicle Emission Control Information Update Label

onto the rear fender under the seat as shown in the label
position illustration.
NOTE
/.
Do not anach the label to any pan that can be easily

removed from the vehicle.
Sustained operation at an altitude lower than

5.000 feef (1,500 m) with the carburetor adjusted
for high altitude may cause the engine to idle
roughly and the engine may stall i n traffic and may
TROL INFORMATION
system
b-When the vehicle
is t o be operated continuously below

1,500 m (5,000 feet), turn each pilot screw to the specification below, its original position.
Low Altitude Setting: 112-turn out
Adjust the idle speed t o 1,000f 100 rpm (Caliornia:

1,000f 100 rpm) with the throttle stop screw.
Be sure to make these adjustments at low altitude.
Remove the Vehicle Emission Control Information Update
Label that is attached to the rear fender under the seat after
adjusting for low altitude.
Service Information
6. Engine Removalllnstallation
1
6-1
Engine Removal/lnstallation
Service Information
A floor jack or other adjustable support is required to support and maneuver the engine.
The following components can be serviced with the engine installed in the frame:
-Oil pump (Section 4)
-Cylinder headlcylinderlpiston (Section 7)
-Clutch/gearshift linkage (Section 81
-Alternator (Section 13)
The following components require engine removal for service:
-Transmission/shift forkslshift drum (Section 9)
-Crankshaft/connecting rodlstarter clutch (Section 9)
6-2
NOTE
Support the motorcycle using a safety stand or a hoist.
Turn the ignition switch OFF and disconnect the battery negative terminal.
When removing the engine, be careful not to pinch the wire harnesses between the engine and frame.
Note the direction of the engine mounting bolts.
At installation, first install all engime mounting bolts and nuts loosely, then tighten the nuts to the specified torque.
Requisite Service
Exhaust system removallinstallation (page 2-2)

Fuel tank removallinstallation (page 2-4)
Carburetor rernovallinstallation (page 5-4)
Oil filter removallinstallation
Procedure
(8)
(9)
i10)
Removal Order
Starter motor cable
Engine ground (-) cable
Alternator wire connector
Side stand switch connector
Ignition pulse generatorloil pressure1
neutral switch connector
Clutch cable
Drive sprocket bolt
Washer
O-ring
Drive s~rocket
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Right engine lower mounting bolthut

Left engine lower mounting bolthut
Right engine lower bracket bolt
Right engine lower bracket
Engine front mounting bolthut
Engine front bracket boltlnut
Engine front bracket
Engine rear mounting bolthut
Engine rear mounting collar
Engine rear bracket bolt
Engine rear bracket
(1)
(2)
(3)
(4)
(5)
(6)
(7)
sprocket cover rernovallinstallation (page 8-9)

. Drive
lgnition coil rernovallinstallation (page 14-6)
. Oil cooler removallinstallation (page 4-5)
Q'tv
Remarks
Loosen the drive chain.
California model only.
California model only: Remove the EVAP purge control

valve.
Move the engine out of the frame on the right.
CAUTION
Carefully align mounting points with the jack to prevent damage t o mounting bolt threads, wire harnesses and cables.
MEMO
7. Cylinder
Head/Cvlinder/Piston
.
.
Service Information
7-1
Cylinder Head Removal/lnstallation
Troubleshooting
7-1
Cylinder Head Disassembly/Assembly 7-10
Camshaft Removal/lnstallation
7-2
Cylinder, Piston Removal/lnstalltion
7-8
7-12
Service Information
Camshaft service can be done with the engine in the frame.
The engine uses hydraulic tappets that eliminate manual valve adjustments. The hydraulic tappets have de-foaming
chambers. Fill the chambers with clean engine oil before assembling.
When adjusting the valve timing, do not turn the camshaft before installing camshaft holders and filling the de-foaming
chambers with engine oil.
Bleed air from the tappets thoroughly whenever the camshaft is removed (page 7-7).
Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the
cylinder head.
Clean all disassembled parts with cleananon-flammableor high flash-point solvent and dry them with compressed air
before inspection.
Lubricate the camshaft journals and cam lobes with a 50-50 solution of disulfide grease and engine oil before reassembly.
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
Troubleshooting
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down
test, or by tracing noises in the top-end with a sounding rod or stethoscope.
If performance is poor at low speeds, check for white smoke in crankcase breather tube. If the tube is smoky, check for
a seized piston ring.
Compression Too Low, Hard Starting Or Pool

Performance At Low Speed
Valves
-Faulty hydraulic tappet
-Burned or bent valves
-Incorrect valve timing
-Broken valve spring
-Uneven valve seating
Cylinder head
-Leaking or damaged head gasket
-Warped or cracked cylinder head
Cylinder, piston
-Leaking cylinder head gasket
-Loose spark plug
-Worn, stuck or broken piston ring
-Worn or damaged cylinder and piston
Excessive Noise
Hydraulic valve tappet system
-Low engine oil level
-Contaminated oil
-Low oil pressure
-Damaged hydraulic tappet
Cylinder head
-Sticking valve or broken valve spring
-Damaged or worn camshaft
-Loose or worn cam chain
-Worn or damaged cam chain
-Worn or damaged cam chain tensioner
-Worn cam sprocket teeth
-Worn rocker arm and/or shaft
Cylinder, piston
-Worn cylinder and piston
-Worn piston pin and piston pin hole
Compression Too High, Overheating Or Knocking

Excessive carbon build-up in cylinder head or on top of
piston
Excessive Smoke
Cylinder head
-Worn valve stem or valve guide
-Damaged stem seal
Cylinder, piston
-Worn cylinder, piston, or piston rings
-Improper installation of piston rings
-Scored or scratched piston or cylinder wall
Rough Idle
Low cylinder compression
.
.
Cvlinder Head/Cvlinder/Piston
Camshaft Removal/lnstallation
Cylinder HeadICylinderlPiston
CAUTION
-. .- . .- ..
Do not turn the camshaft before filling the de-foaming chamber.

NOTE
. Do not allow dust or d i n to enter the cvlinder.
Requisite Service

Procedure
Camshaft Removal Order
Crankcase breather tube
No. 16 tube
Cylinder head cover bolt
Sealing washer
Cylinder head cover
Gasket
(1)
Ignition coil removallinstallation (page14-6)
1 Q'W
Remarks
Install with the "UP" mark facing up

NOTE
To hold the gasket on the cylinder head cover, apply a
small amount of adhesive to several points on the cover.

Cam chain guide bolt
Oil pipe boltlsealing washer
Oil pipe
CAUTION
During removal and installation, do not bend the oil
) ( l o ) Cam chain auide
/ (1 1) /
~e-foaminqchamber
cover bolt
(12) De-foaming chamber cover
(13) Cam sprocket bolt
(14) Camshaft holder bolt

(15) Camshaft holder
( 16) Dowel pinlo-ring
(17) Camshaft
(18 ) Cam s ~ r o c k e t
Hydraulic Tappet Removal Order
(21) Dowel pin

(22) Hydraulic Tappet
NOTE
Remove the t w o cam sprocket bolts first from both
sprockets, turn the crankshaft clockwise. then remove
the two other sprocket bolts.
-Camshaft removal (page 7-4VCamshaft installation
(page 7-5)
Inspection (page 7-7), Installation age 7-7)
Cylinder Head/Cylinder/Piston
Camshaft Removal
Remove the cylinder head cover.
Remove the cam chain guide and oil pipes
Remove the de-foaming chamber covers.
Loosen the cam chain by pushing the cam chain tensioner

lock pin down and pulling the lock plate up until the lock
plate resets on the lock pin shoulder as shown.
Remove the right crankcase cover.

Remove the two cam sprocket bolts first from both
sprockets.
Rotate the crankshaft clockwise one turn (360) and remove
the two other sprocket bolts.
NOTE
Be careful not to let the sprocket bolts fall into the
crankcase.
Remove the cam sprockets from camshaft flange with the

cam chain.
Remove the camshaft holder bolts and holders.
NOTE
Loosen the holder bolts in 2 or 3 steps in a crisscross
pattern.
Remove the dowel pins and O-rings.
Remove the camshafts and cam s~rockets.
( 1 ) CAM SPROCKET BOLTS
Cylinder HeadICvlinderlPiston
Camshaft Installation
(1) CRANKSHAFT
Turn the crankshaft clockwise and align the "T" mark on the
pulse rotor with the index mark on the left crankcase.
Coat the cylinder head journal surfaces of the camshaft with

molybdenum disulfide oil.
lnstall the intake and exhaust camshafts and sprockets
through the cam chain with the timing marks facing the right
side.
Install the cam chain over the sprockets.
NOTE
I.
The camshafts are identified by marks:

"IN" : lntake camshaft
"EX": Exhaust camshaft
Rotate the camshafts so the No.4 cylinder cam lobes face

each other.
Install the two O-rings and dowel pins into the oil passage
holes.
Install the eight dowel pins into the camshaft holder holes.
(1) 0-RINGS/DOWEL PINS
Install each camshaft holder in its original location.

NOTE
The holders are identified by marks:
"IN R": lntake right
"IN L": lntake left
"EX R": Exhaust right
"EX L": Exhaust left
Temporarily tighten the camshaft holder bolts.
Align cam sprocket timing marks with the top of the cylinder
head.
lnstall the cam sprockets on the camshaft flange and recheck that the timing marks align with the top of the cylinder
head.
Cvlinder Head/CvlinderlPiston
Fill the de-foaming chambers with clean engine oil.
CAUTION
Do not turn the camshaft before filling the defoaming chamber.
Apply a locking agent to the cam sprocket bolt threads, then

install and tighten the cam sprocket bolts.
Torque: 1 9 N.m (1.9kg-m, 1 4 f t - l b )
Turn the crankshaft clockwise (viewed from the right side of
the engine) and re-align the "7mark on the pulse rotor with
the index on the crankcase.
Make sure that the "IN" and "EX" lines on the cam sprockets
align with the cylinder head.
Push the cam chain tensioner lock pin forward to release it

from the lock plate.
Install the cam chain guide.

Install the oil pipes with the oil bolts and sealing washers.
Tighten the camshaft holder bolts and the oil bolts to the
specified torques in a crisscross pattern in 2 or 3 steps.
Torque:
Camshaft holder bolts: 1 4 N - m (1.4 kg-m. 10 ft-lb)
Oil bolts
: 1 2 N - m (1.2 kg-m. 9 ft-lb)
Install the de-foaming chamber covers with the socket bolts.
( 1 ) DE-FOAMING CHAMBERS
Hydraulic Tappet Inspection
Inspect the hydraulic tappets for wear, damage and clogged
oil holes.
Never attempt to disassemble the tappets.

Always use the special tool when bleeding the
tappets. Use of wire can damage them.
Measure the free length of each hydraulic tappet as follows:

Attach the Hydraulic Tappet Bleeder to the tappet and
compress and extend the tappet slowly in a jar filled with
kerosene.
NOTE
Keep the hydraulic tappet
below the surface of the
..
kerosene.
Hold the tappet upright while compressing and extending it.
Continue priming the hydraulic tappet until the air bubbles

stop and the tappet no longer collapses.
07973-MJ000O0
Quickly try to compress the tappet by hand. Measure the

compression stroke with the dial gauge.
Compression stroke : 0
- 0.2
mm(0 - 0.008 in)
Hydraulic Tappet Installation

Place the tappet in a jar filled with kerosene.
Place the tappet bleeder over the tappet.
Hold the tappet upright and pump the tappet until air bubbles stop coming out. Remove the tool, and try to quickly
compress the tappet by hand. You should not be able to
compress it more than 0.2mm (0.008in).
Remove the tappet from the fluid keeping it upright.
07973-MJ00000
(3) HYDRAULIC TAPPET
Fill the tappet hole with clean engine oil.

Install the hydraulic tappets in the cylinder head.
Install the dowel pins into the cylinder head.
Install the rocker arm holders and tighten the bolts
lnstall the rocker arms.
Cylinder HeadICylinderlPiston
Cylinder Head Removal/lnstallation
Cylinder Head ICylinderIPiston

NOTE
Cylinder head service can be done with the engine in the frame.
Requisite Service
Hydraulic tappet removal/installation (page 7-2)

Exhaust system removal/installation (page 2-2)
Procedure
Carburetor removal/installation (page 5-4)
Remarks
Be careful not to let the clips and pins fall into the crankcase.
Attach a piece of wire to the cam chain t o prevent it from
being dropped into the crankcase, then remove it.
(6) Oil pipe mounting bolt

(7) Oil pipe bolt
(81 Sealing washer
(9) Oil pipe
CAUTION
During removal and installation, do not bend the oil
pipes.
(10) Cylinder head mounting bolt

(1 1)
(12)
(131
(141
(15)
(16)
(17)
(18)
Cylinder head cap nutlwasher

Cylinder head assembly
Cam chain guide
Dowel pin
Gasket
Caburetor insulator
O-ring
Insulator plate
Remove the nuts in a crisscross pattern in 2 or 3 steps.
Each insulator plate is indexed.

Two index tabs: No. 1. 2 cylinder
One index tab: No. 3, 4 cylinder
Cylinder Head DisassemblyIAssembly
(1)
(page 1-17)
Cylinder Head/Cvlinder/Piston
CAUTION
Do not compress the valve springs more than necessary.
LOT,-
Mark all parts during disassembly so they can be reinstalled in their original positions.
Remove carbon deposits from the combustion chamber and clean off the head gasket surface before assembly.
-Avoid damaging the gasket surface.
-Gaskets will come off easier if they soaked in solvent.
For valve guide replacement, see section 9 of the Common Service Manual.
Requisite Service
Cylinder head removal/installation (page 7-8)
Procedure
Disassembly Order
Valve spring cotter
Retainer
Valve spring
Inlet valve
Exhaust valve
Valve stem seal
Valve spring seat
Valve guide
O-ring
Q'tv
Remarks
To prevent loss of spring tension, do not compress the v a l v ~
more than necessaty.
Install them with the tightly wound coils facing down
To avoid damaging the stem seal, turn the valve slowly

when inserting.
Cylinder HeadlCylinderIPiston
Cylinder, Piston Removal/lnstallation
NOTE
Do not damage the gasket surface.

Do not let any material fall into the crankcase.
Requisite Service
Cylinder head removallinstalation (page 7-8)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Q,tY
Removal Order
PAlR check valve case mounting bolt
PAlR check valve case
PAlR check valve case joint pipe
O-ring
Cylinder holding nut
Oil hose stay
Cylinder
Dowel pin
Gasket
Piston pin clip
Piston pin
Piston assembiy
Remarks

-California model only
Install new piston pin clips
1I
4
8
(17) Piston
~O~~ installation, install the ciston with the "IN,' mark

facing towards the intake side.
NOTE
Use care when removing or installing the rings.
Insert the outside surface of the ring into the proper ring
groove and roll the ring around the groove to make sure
that the ring has a free fit around the piston's circumference.
1I
1
MEMO
8. ClutchIGearshift Linkage
Service Information
8-1
Clutch Installation
8-6
Troubleshooting
8-1
Drive Sprocket Cover Removal/lnstallation
8-9
Clutch Cover R e r n o v a l / l n s t a l l a t i o n
8-2
Gearshift Linkage R e m o v a l / l n s t a l l a t i o n 8-10
Clutch R e m o v a l
8-4
Service lnformation
Clutch maintenance can be done with the engine in the frame.

Transmission oil viscosity and level have and effect on clutch disengagement. When the clutch does not disengage or
the vehicle creeps with the clutch disengaged, inspect the transmission oil level before servicing the clutch system.
If the shift forks, drum and transmission require servicing, remove the engine and separate the crankcase (section 9)
Troubleshooting
Clutch Lever Too Hard
Damaged, kinked or dirty clutch cable
Improperly routed clutch cable
Damaged clutch lifter mechanism
Faulty clutch lifter plate bearing
Clutch W i l l Not Disengaged Or Motorcycle Creeps W i t h

Clutch Disengaged
Too much clutch lever free play
Clutch plates warped
Oil level too high, improper oil viscosity, or additive used
--
Clutch Slips
Clutch lifter sticking
Worn clutch discs
Weak clutch springs
No clutch lever free play
.
.
-.
Hard To Shift
Misadjusted clutch cable
Damaged or bent sift fork
Bent shift fork shaft
lncorrect engine oil viscosity
lncorrect gearshift spindle assembly
Damaged shift drum cam grooves
Transmission Jumps Out Of Gear
Worn shift drum stopper arm
Weak or broken gearshift spindle return spring
Bent shift fork shaft
Worn gear dogs or slots
--
Gearshift Pedal W i l l N o t Return

Weak or broken gearshift spindle return spring
Bent gearshift spindle
Clutch/Gearshih Linkage
Clutch Cover Removal/lnstallation
ClutchIGearshift Linkage
Requisite Service
. Engine oil draininglrefill

Procedure
(1)
(2)
(3)
(4)
Removal Order
Clutch cable
Clutch cover bolt
Clutch cover
Gasket
Ob
Remarks
1
9
1
1
Clutch Lifter Disassembly Order

(5) Clutch liter rod
16) Return spring
17) Spring pin
1
1
1
(8) Clutch lifter arm

(9) Oil seal
1
1
Assembly is the reverse order of disassembly
Drive in a new spring pin using a pin driver until the pin does
not interfere with the lifter arm as shown.
Clutch Removal
NOTE
I.
Turn the crankshaft clockwise until the No.4 crank weioht is oositioned at BTDC.
Requisite Service
Clutch cover removal (page 8-2)

Procedure
Removal Order
Clutch lifter plate bolt
Clutch lifter plate
Clutch lifter plate bearing
Clutch spring
Clutch center lock nutllock washer
(6)
(71
. .
(8)
(9)
(10)
(11)
(12)
(13)
(14)
1151
Clutch assembly
-clutch center
-spring seat
-judder spring
-clutch friction disc C
-clutch plate 8
-clutch friction disc 8
-clutch plate A
-clutch friction disc A
-0ressure date
Q'tv
4
1
Remarks
Removal (page 8-51
Larger I.D. disclColor: black

Color: gray
Smaller I.D. disc
Color: silver
Smaller I.D. disc1Color: black
1
Pull the clutch outer guide out with needle nose pliers.
Clutch Center Lock Nut Removal
Unstake the nut
Set the clutch center holder to the pressure plate bosses and
loosely install the nuts.
rn
07JMB-MN50300 or
07HGB401000A 1U.S.A.onlyl
Temporarily remove the tool and tighten nuts;then reinstall

the clutch center holder onto the bosses. Use at least four
clutch lifter plate bolts t o secure the tool t o the clutch.
Hold the clutch center holder and remove the lock nut as
shown.
rn
Extension bar
077160020203
077160020500 or
available in U.S.A.
I 1. 1 .)
CLUTCH
PLATE BOLTS
Clutch Installation
Proper Order Shown
Requisite Service
Clutch removal (page 8-4)

Procedure
lnstallation Order
(1) Collar
drive sorocket
12)
. . Oil oumo
,
(3) Needle bearing
(4) Clutch outer
(5) Clutch outer guide
1 (6)1 Clutch assembly
Remarks
Q'W
1
1
1
1
17
Installation (see below)
1 - 1
(7)
(8)
(9)
(10)
(1 1)
(12)
(13)
(14)
(15)
-pressure plate
-clutch friction disc A
-clutch plate A
-clutch friction disc B
-clutch plate 8
-clutch friction disc C
-spring seat
+udder spring
-clutch center
(16)
(17)
(18)
( 19 )
(20)
(21)
l(22)
Lock washer
Clutch center lock nut
Clutch spring
Clutch lifter plate
Clutch lifter plate bearing
Clutch lifter plate bolt
Right crankshaft coverlgasket
1
1
4
1
1
4
1
Clutch cover installation (page 8-21
I
Smaller I.D. disc1Color: black
Color: silver
Smaller I.D. disc
Color: gray
Larger I.D , discIColor: black
I Face the dished side of the judder spring to the outside.

Install with the "OUTSIDE" mark facing up.
Installation (page 8-8)
Install with the marked side facing out.

lnstall in a gradual, crisscross pattern.
Clutch Outer Installation

Turn the crankshaft clockwise until the No. 4 crank weight is
positioned at BTDC.
lnstall the clutch outer over the mainshaft.
lnstall the clutch outer guide between the mainshaft and
clutch outer and push it in until it stops.
NOTE
lnstall the clutch outer guide onto the mainshaft while
movina the drive sub gear
- to align
. the two gear teeth
using a screwdriver. Take care not t o damage the gear
teeth.
Push the clutch outer ,. ..n~le moving the primary drivin

gears with a screwdriver,then further push it in while moving
the oil pump driven sprocket with the screwdriver to fit the
oins on the drive sorocket into the holes in the clutch outer.
2 SCREW DRIVER
(1) DRIVE SPROCKET
UTCH OUTER
Clutch Center Lock Nut Installation
Position the tools as shown and use at least four clutch
lifter plate bolts to secure the tool to the clutch.
1 (1) CLUTCH
,
'
C
H
PLATE BOLTS
07JMEi-MN50300 or
07HGg001000A (U.S.A. only)
Hold the clutch center holder and torque the clutch centel
lock nut as shown.
Lock nut wrench. 26 x 30 m m

Extension bar
077160020203
077164020500or
Torque: 110 N - m (11 kg-m, 8 0 it-lb)

Stake the lock nut onto the rnainshaft
Drive Sprocket Cover Removal/lnstallation
CAUTION
Be careful not to damage the wire harnesses b y pinching them between the sprocket cover and engine.
."..
I
Route the wire harnesses properly (page 1-25).
Requisite Service
. Engine oil draininglrefill

Remarks
Procedure
Removal Order
Gearshift spindle joint bolt
Gearshift spindle joint
Change cover cap
O-ring
Drive sprocket cover bolt
Drive sprocket cover plate
. . Drive sorocket cover
(8) Drive chain guide
(9) Dowel pin
At installation, align the punch marks on the joint and

spindle.
1
2
Gearshift Linkage Removal/lnstallation
NOTE
Shift the transmission into neutral before removing or installing the gearshift linkage.
Requisite Service
Drive sprocket cover removallinstallation (page 8-9)
Q'W
Remarks
.
-
(3)
(4)
(5)
(6)
(7)
(8)
Neutral switch joint

Gearshift linkage cover bolt
Gearshift linkage cover
Gearshift spindle assembly
-snap ring
-return spring
(9) Washer
(10) Gasket
11 1) Dowel pin
112) Guide plate mounting bolt
(13) Guide plateldrum shifter assembly
(14) -guide plate
(15) -ratchet pawl
(16) -plunger
(17) -spring
(18 ) -drum shifter
(23)
(24)
(25)
(26)
Stopper arm
Spring
Collar
Washer
Disconnect the neutralswitch connector.

Installation (page 8-12)
- Removelinstall as an assembly.
. Installation (page 8-12)
Assembly:as illustrated
Pawl orientation as shown
Gearshift Linkage CoverIGearshih Spindle
Assembly Installation
linkage.
With the transmission in neutral, the index line on the
Remove the 4mm screw and washer from gearshift linkage

cover.
lnstall the gearshift spindle assembly in the gearshift linkage
cover.
Align the holes in the gearshift spindle and linkage cover with
a screwdriver. (Keep the screwdriver in place.)
lnstall the dowel pins and new gasket.
lnstall the linkage coverlgearshift spindle assembly with the

screwdriver through the hole in the shifter.
lnstall and tighten the gearshift linkage cover bolts.
(1) SCREWDRIVER (2)LINKAGE
(3) ALIGN
01I
1
Torque: 12 N.m (1.2 kg-m. Sft-lb)
Remove the screwdriver, install the washer and 4mm screw.

1
Neutral Switch Installation
( 1 ) GROOVE
lnstall the neutral switch joint, aligning the joint pin with the
groove in the gearshift drum.
lnstall the neutral switch, aligning the switch pin of the
switch with the cutout in the switch joint.
(6)JOINT
(5) PIN
( 2 ) CUTOUT
Service Information
9-1
Transmission DisassemblyIAssembly
9-8
Troubleshooting
9-1
Crankshaft.Connecting Rod Removal
9-10
Countershaft Bearing Cover
9-2
Alternator Shaft DisassemblylAssembly9-12
Removalllnstallation
9-3
Crankshaft Bearing Replacement
Crankcase Separation
9-4
Crankshaft, Connecting Rod Installationg-16
Transmission Removalllnstallation
9-6
Crankcase Installation
9-14
9-1 8
Service lnformation
This section covers crankcase separation in order to service the crankshaft, transmission and alternator shaft.
The following parts must be removed before separating the crankcase.
-Alternator (Section 13)
-Clutchlgearshift linkage (Section 8 )
-Cylinder headlcylinderlpiston (Section 7)
-Engine (Section 6)
-Oil pump (Section 4)
-Starter motor (Section 15)
Prior to assembling the crankcase halves. apply a sealant to their mating surfaces. Wipe off excess sealant thoroughly.
Mark and store the bearing inserts to be sure of their correct locations for reassembly. If the inserts are improperly
installed they will block the oil holes, causing insufficient lubrication and eventual engine seizure.
Troubleshooting
Excessive Noise
Worn connecting rod big-end bearing
Bent connecting rod
Worn crankshaft main bearing
Worn transmission bearing
--
Hard To Shift
Improper clutch operation
Incorrect engine oil viscosity
Incorrect clutch adjustmest
Bent shift fork
Bent fork shaft
Bent fork claw
Bent shift spindle
Transmission Jumps Out Of Gear

Worn gear dogs or slots
Bent fork shaft
Broken shift drum stopper
Worn or bent shift forks
Broken shift linkage return spring
Engine Vibration
Excessive crankshaft runout
Loose engine mount bolts
Countershaft Bearing Cover Removalllnstallation
NOTE
After installation.check that there are no oil leaks.
Lequisite sewice
. Engine removallinstallation (page6-2)

Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(1 0)
(11)
(12)
Remarks
Q'W
Installation is in the reverse order o f removal.
Removal Order
Oil pipe mounting bolt
Oil pipe bolt
Sealing washer
Oil pipe A
1
2
4
1
Countershah bearing cover bolt

Oil pipe stay
Countershah bearing cover
Gasket
Oil orifice
O-ring
Oilseal
Oil seal
10
1
1
1
1
1
1
1
NOTE
Be careful not t o bend oil pipe.
Crankcase Se~aration
I
I
Refer to Setvice Information

(page 9-1) a list of pans which must be removed before separating the
crankcase.1
.
. .
Procedure
lgnition pulse generator rotor bolt
lgnition pulse generator rotor
Upper crankcase bolt ( 6 mm)
Upper crankcase bolt (7 mm)
Sealing bolt
Sealing washer
Lower crankcase bolt (6 mm)
Lower crankcase
Dowel in
Q'W
Remarks
Bolts (8 pcs) have sealing washers.
Transmission Removal/lnstallation
Crankshaft/Transrnission
Requisite Service
Crankcase separation (page 9-4)

--
Procedure
(1)
Removal Order
Mainshaft/countershaft assembly
Q'tY
1/ 1
(2) Dowel pin

(3) Center fork mounting bolt
1
1
(4) Lock washer

(5) Shift fork shaft
( 6 ) Shih fork
1
1
3
(7) Shift drum bearing stopper plate bolt

(8) Shift drum bearing stopper plate
(9) Shift drum
1
1
1
Remarks
At installation, align the mainshaft bearing set ring with the
case groove and align the countershah bearing case hole
with the dowel pin. Align the bearing holder bolt holes
and ensure that they align with the countershaft bearing
cover. (Refer to page 9-2)
Remove after bending down the lock washer tab.
Bend new lock washer tabs as shown.
Install a new lock washer.
Install with the identification mark (R: Right, M: Center. L:
Left) side facing the right side as shown.
Install the dowel pin and then tighten the stopper plate bolt.
Transmission Disassembly1Assembly
Mainshaft
SHIFTER GEAR
GROOVE
GEAR SLIDING
SURFACE
NOTE
When assembling the transmission, apply molybdenum disulfide oil to M3/M4.C5 and shifter gear shift fork groove
Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from from the thrust
load.
After installing a snap ring, slightly open the ring and rotate it in its groove to be sure it is fully seated.
Do not use worn snap rings which could easily spin in the groove. They may be too loose t o properly seat in the groove.
Alian the aao in the snao rino with the s ~ l i n ecrroove.
..
.
.
.
Requisite Service
Transmission removallinstallation (page 9-61
Procedure
Mainshaft Disassembly Order
Orifice plate
Bearing case
Needle bearing
Thrust washer
M 2 gear (18T)
Snap ring
M31M4 gear (22125T)
Snap ring
Spline washer
M 5 gear (27T)
M 5 bushing
Mainshaft bearing
Set
ring
(13)
(14) Mainshaft ( M I gearll4T)
0.W
Remarks
Procedure
Countershaft Disassembly Order
Bearing case
Needle bearing
"
Thrust washer
C1 gear (42T)
Needle bearing
(6) Thrust washer
(7) C5 gear (29T)
(8) Snap ring
(9) C4 spline bushing
(10) C4 gear (31T)
(1 1) Lock washer
(12) Spline washer
(13) C3 gear (34T)
(14) C3 spline bushing
(15) Snap ring
(16 ) Shifter gear
117) Snao rina
(1)
I21
. .
(3)
(4)
(5)
Remarks
Assembly is in the reverse orderof disassembly.
Crankshaft, Connecting Rod Removal
NOTE
Determine the replacement bearing color code according to the main bearing selection table (page 9-14) or the
connecting rod bearing selection table (page 9-1 5).
Mark and store the bearina inserts to be sure of their correct locations for reassemblv.
Refer to page 1-8 for crankshaft and rod specification.
Refer to section 14 of the Common Service Manual for bearina ins~ection.
.
.
Requisite Service
Crankcase separation (page 9-4)
Procedure
. .
(7)
(8)
19)
(10)
(1 1)
(12)
(13)
(14)
(1 5)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Q'W
Removal Order
Connecting rod bearing cap nut
Bearing cap
Connecting rod
Connecting rod bolt
Connecting rod bearing
Alternator drive chain tensioner bolt
Alternator drive chain tensioner
Oil chamber cover
Gasket
Washer
Alternator shaft assembly
O-ring
Starter clutch assembly
Collar
Alternator driven sprocket
Crankshaft
Cam chain
Alternator drive chain
Crankshaft main journal bearing
Alternator drive chain slipper pin bolt
Washer
Alternator drive chain slipper pin
Alternator drive chain slipper
Air separator bolt
Air separator cover
(29) O-ring
(30) Alternator shaft bearing (6203)
Alternator Shaft Nut Rernoval/lnstallation

Temporarily install the alternator rotors and hold the rotor
with the universal holder.
07725-0030000
Remove the alternator shaft nut.

Torque: 34 N.m (3.4 kg-m. 25 ft-lb)
Remarks
Do not remove unless necessary.
Removal (see below)

Disassembly and assembly (page 9-12)
Disassembly and assembly (page 15-8)
Blow the oil hole in the air separator cover with compressed
air.
For removal use remover, 17 mm (07936-3710300) and
handle (07936-3710100) and sliding weight (077410010201 or 0793&3710200).
Do not remove. without necessaw.
1(31)1Crankcase breather separator
Universal holder
Transmission removal/installation (page 9-6)
Crankshaft/Transmission
Alternator Shaft Disassembly/Assembly
NOTE
. Never reinstall the old bearing; once the bearing is removed,

. Blow the oil line in the alternator shaft with compressed air.
it must be replaced with a new one.
Requisite Service
Crankshaft removal (page 9-10)
Procedure
Disassembly Order
(1) Snap ring
(2) Damper cam
(3) Damper spring
(4) Alternator shaft assembly
(5)
(6)
(7)
(8)
(9)
(10)
(7)
(8)
(6)
(5)
(3)
(2)
(1)
110)
-Collar
-Washer
-Bearing
-Alternator shaft
Alternator case
Oil seal
Assembly Order
Bearing
Alternator shaft
Washer
Collar
Damper spring
Damper cam
Snap ring
Oil seal
O'W
Remarks
Press the alternator shaft assembly out of the alternator

case.
P a g e 9-1 3.
Alternator Shaft Assembly

Drive a new bearing in the alternator case.
Attachment, 42x47 m m
Pilot, 20 m m
Driver
07746-0010300
07746-0040500
07749-0010000
Support the case bearing with special tools and press the
alternator shaft into the bearing.
Attachment. 20 m m I.D.
Driver, 22 m m I.D.
07746-0020400
07746-0020100
Install the washer.

Support the collar with special tools and press the alternator
shaft into the collar.
Attachment, 20 m m I.D.
Driver, 22 m m I.D.
07746-0020400
07746-0020100
DAMPER CAM
Install the four damper springs with the dished faces facing
each other as shown.
Install the damper cam onto the alternator shaft, aligning the
oil holes in the damper cam and shaft.
Place the alternator shaftlcase in the hydraulic press with

the damper cam sup~orted
. .
Compress the damper spring and secure the damper cam
with the snap ring.
(3) SNAP RING
Support the case and press a new oil seal into the case using
the special tool.
-
a-
---
Attachment, 30 m m I.D.
Driver, 40 m m I.D.
07746-0030300
07746-0030100
Crankshaft Bearing Replacement

Main Journal Bearing Selection
Record the crankcase I.D. code letters from the left side of
the crankcase.
NOTE
The letters (A or 8) on the upper crankcase are the
codes for the main journal 1.D.s. reading from the left.
Record the corresponding main journal O.D. code numbers

from the crank weight.
NOTE
The numbers (1 or 2) on the crank weight are the codes
for the main journal O.D.s, reading from the left.
Cross reference the case and journal codes to determine the

replacement bearing color code.
Crankcase
I. D. code
'1
II
39.000-39.008 mm
(1.5354-1.5357 in)
39.008-39.015 mm
(1,5357-1.5360 in)
Bearing thickness
Yellow: Thick
Pink:
Red
Thin
35.99236.000 mm
(1.4170-1.4173 in)
35.98435.992 mm
(1.41661.4170 in)
Red
Pink
Pink
Yellow
(1) MAIN JOURNAL BEARINGS

(2) COLOR CODE
CrankshaftITransmission
Connecting Rod Bearing Selection
Record the connecting rod I.D. code numbers on the rod.
NOTE
The numbers (1 or 2) on the connecting rod are the
codes for the connectino rod I. D.s.
(1) CONNECTING ROD

I.D. CODE
Record the crankpin O.D. code letters from the crank

weight.
NOTE
The letters (A or 8) on the crank weight are the codes
for the crankpin 0.D.s. reading from the left.
Cross reference the crankpin and rod codes to determine the

replacement bearing color code.
(1) CONNECTING ROD BEARINGS
Crankpin
Connecting rod
I.D. code
(2) COLOR CODE
(1.41701.4173 in)
39.000-39.008 mm
(1.5354-1.5357 in)
39.008-39.016 mm
(1.5357-1.5360 in)
(1.41661.4170 in)
Green
Green
Brown
Bearing thickness
Brown: Thick
Green:
!
Yellow: Thin
Connecting Rod Replacement
.~
Be sure to use the connecting rods having the same weight

code in an engine.
CAUTION
If a connecting rod having the differat weight coda
is to be used, be sure that the difference i n weight
(code) is held within a single weight rank.
(1) WEIGHT CODE
Crankshaft, Connecting Rod Installation
NOTE
At installation, apply molybdenum disulfide oil to the main journal bearing and connecting rod bearing surface.
Requisite Service
-
Crankshaft, connecting rod removal (page 9-10)
Procedure
Installation Order
(1) Crankcase breather separator
(2) Alternator shaft bearing (6203)
O'tV
Remarks
To install use driver (07949-3710001) and attachment, 37 x

40 mm (07746-0010200) and pilot, 17 mm (07746-0040400).
Align the separator cover tang with the slot in the upper
crankcase.
Air separator cover bolt

Alternator drive chain slippel
Alternator drive chain slipper pin
Washer
(9)
(10) Alternator drive chain slipper pin bolt
( 1 1) Crankshaft main journal bearing
(12)
(13)
(14)
( 15)
(16)
(17)
- Wipe all oil from the bearing seating areas.

. Align the bearing tabs with the groove in the crankcase.
Alternator drive chain

Cam chain
Crankshaft
Alternator driven sprocket
Collar
Starter clutch assembly
shaft assembly
1 I
(2 1)
(22)
. .
(23)
(24)
(25)

Gasket
Oil chamber cover
Alternator drive chain tensionel
(26) Alternator drive chain tensioner bolt

(27) Connecting rod bearing
(28)
(29)
(30)
(31)
Connecting rod bolt

Connecting rod
Bearing cap
Connecting rod bearing cap nut
Installation (page 9-1 1)
Push the notch on the chain tensioner with a screwdriver

and squeeze the tensioner until the hole in the rod appears.
Insert a pin into the hole i o lock the tensioner.
After tightening, remove the tensioner lock pin.
Wipe all oil from the bearing seating areas.
Align the bearing oil hole with the oil hole in the connecting rod.
Face the oil holes to the intake side.

Install them with the code letters read properly.
At installation, apply molybdenum disulfied oil to the
threads and torque them in 2 or 3 steps.
Requisite Service
Transmission removallinstallation (page 9-6)
Crankshaft, connecting rod installation (page 9-16)

Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(1 1)
Dowel pin
Lower crankcase
Sealing washer
Sealing bolt
Ignition pulse generator rotor
Ignition pulse generator rotor bolt
Q'W
3
1 --Crankcase
1115121
1
1
1
1
Remarks
installation (see next page)
Apply a light but thorough coating of sealant to the upper
crankcase mating surface except to the main bearing journal
bolt mating areas as shown.
Assemble the crankcase
Install the crankcase bolts and sealing washers

NOTE
Ten 8 mm bolts (for the crankshaft main journals) have
sealing washers.
Tighten all crankcase bolts in a gradual, crisscross pattern,

beginning with larger diameter bolts first as shown.
Toque:
8 mm crankcase bolt: 23 N.m (2.3 kg-m, 17 ft-Ib)
6 m m crankcase bolt: 12 N - m (1.2 kg-m. 9 ft-lb)
Apply a sealant t o the countershaft bearing cover and clutch

cover mating surfaces as shown.
20-30mm(0.8-1.2in
(3) CLUTCH COVER

MATING SURFACE
(2) COUNTERSHAFT
BEARING COVER
MATING SURFACE
10. Front Wheel/Suspension/Steering

Service Information
10-1
Fork Removalllnstallation
10-6
Troubleshooting
10-1
Fork Disassembly
10-8
Handlebar Removalllnstallation
10-2
Fork Assembly
10-10
Front Wheel Removalllnstallation
10-4
Steering Stem Removalllnstallation
10-12
Front Wheel DisassemblylAssembly
10-5
Service lnformation
Brake dust may contain asbestos fibers.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers.
Keep grease off of brake disc and pads.

CAUTION
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
. Refer to section 12 for brake system information.

. Refer to section 16 for light. meter and switch information.
. Tubeless tire removal, repair, and remounting procedures are covered in section 16 of the Common Service Manual.
. When servicing the front wheel. fork or steering stem, support the motorcycle securely with a jack or other support.
Do not use the oil filter as a jack point.
Troubleshooting
Hard Steering
Steering head bearing adjustment nut too tight
Faulty steering head bearings
lnsufficient tire pressure
Faulty tire
Steers To One Side Or Does Not Track Straight

Bent fork
Bent front axle
Wheel installed incorrectly
Faulty steering head bearings
Bent frame
Worn wheel bearing
Worn swingarrn pivot components
Front Wheel Wobbling

Bent rim
Worn front wheel bearings
Faulty tire
Unbalanced tire and wheel
.
.
.
Wheel Turns Hard

Faulty wheel bearing
Faulty speedometer geal
Bent front axle
.
.
Soft Suspension
lnsufficient fluid in fork
Weak springs
Low fluid level in fork
Low tire pressure
.
-.
.
Hard Suspension
Incorrect fluid weight
Bent fork tubes
Clogged fluid passage
High tire pressure
Front Suspension Noisy

lnsufficient fluid in fork
Loose fork fasteners
Lack of grease in speedometer gear
Front WheellSuspensionlSteering
Handlebar Removal/lnstallation
NOTE
Using wires. hang the front brake master cylinder at least as high as the position it was oringinally installed at t o prevent
air from getting into the master cylinder. Do not twist the brake hose.
Route the cables and wire harnesses properly (page 1-21).
After installing the handlebar, adjustthe throttle cable
the clutch cable
the choke cable
.
.
Procedure
Q'tY
Removal Order
(1) Rearview mirror

(2) Wire band
Clutch switch connector
Clutch lever assembly
(5) Left handlebar switch housing screw

(6) Left handlebar switch housing
(7) Choke cable end
( 8 ) Handlebar grip
(9) Brake light switch connector

(10) Master cylinder
(1 1) Right handlebar switch housing screw

(12) Right handlebar switch housing
(13) Handlebar holder bolt
(14) Handlebar holder
(15) Throttle cable end
(16) Throttle pipe
(17) Handlebar
Remarks
2
4
Align the holder end with the punch mark on the handlebar
and face the holder "UP" mark upward. Tighten the upper
bolt first, then the lower bolt.
Tighten the front screw first, then the rear screw.
Apply Honda Bond A or Honda Hand Grip Cement (U.S.A.

only) to the inside surface of the grip.
Align the holder end with the punch mark on the handlebar
and face the holder "UP" mark upward. Tighten the upper
bolt first, then the lower bolt.
Tighten the front screw first, then the rear screw.
Tighten the front bolts first, then the rear bolts.
Install the upper holder with its punch mark facing forward.
Place the handlebar onto the lower holder and align the
punch marks on the handlebar with lower surface of the
handlebar holder.
Front Wheel Removal/lnstallation

asbestos fiber have been found t o cause respiratory disease and cancer.
Keep grease off of brake disc and pads
CAUTION
disc w i t h a high quality brake degreasing agent.
Do not use the oil filter as a jack point.
NOTE
Do not squeeze the brake lever when the caliper is removed, or it will be defficult t o refit the disc between the brake
oads.
Procedure
Wty
Removal Order
Speedometer cable
Axle bolt
Axle pinch bolt
Front axle
1
1
4
Front wheel assembly
Side collar
Speedometer gear box assembly
Remarks
At installation, apply a thin coating of grease to the front

axle. Insert the axle through the fork leg. Align the groove in
the axle with the outer surface of the fork leg.
At installation, align the projection of the speedometer gear
box with the projection on the fork leg.
Front Wheel Disassembly/Assembly
ALIGN THE SLOT WITH THE TAB
43(4.3,31)
TO B$ BOTTOM
I.
Inhaled asbestos fiber have been found t o cause respiratory disease and cancer.
NOTE
Always replace wheel bearings as a set.

For wheel bearing replacement, refer to section 1 of the Common Service Manual.
Requisite Service
Front wheel removallinstallation (page 10-4)
Procedure
Q'ty
Disassembly Order
Brake disc bolt
Brake disc
Dust seal
Speedometer gear retainer
Left wheel bearing (6004 UU)
Distance collar
Right wheel bearing (6004 UU)
1 (8)/ Front wheelltire
Remarks
6
1
2
1
1
1
1
111
Install with the stamped side outward as shown.

At installation, apply grease to the dust seal lips.
At assembly. drive in the right side bearing first. then the

left s ~ d ebearing
Fork Removal/lnstallation
TOP BRIDGE
CAUTION
Support the removed caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the
brake hose.
NOTE
Do not squeeze the brake lever when the caliper is removed, or it will be difficult to refit the disc between the brake
pads.
Before removing the fork, loosen the fork cap but do not remove it.
Requisite Service
Front wheel removal/installation (page 10-4)
Procedure
Q'w
Remarks
/ (8)1 Fork assembly
Only loosen the bolts.

Only loosen the bolts.
If the fork legs were disassembled, temporarily tighten the
bottom pinch bolt and tighten the fork cap.
Front WheellSuspensionlSteering
Fork Disassembly
. The fork cap is under spring pressure. Use care w h e n removing
it and face protection.
LoTE
Temporarily install the fork spring,spacer, and fork cap if the socket bolt turns with the fork piston, during socket bolt
removal.
Always replace oil seal with new one.
Requisite Service
Fork removal (page 10-6)

Procedure
Q'W
Remarks
I I
(1) Fork cap cover

(21
. . Fork c a ~
(3) O-ring
(4) Spacer
(5) Spring seat
(6) Fork spring
(7) Dust seal
( 8 ) Stopper ring
(9) Fork socket bolt
(10) Sealing washer
(1 1) Fork piston
(12) Fork piston ring
(13) Rebound spring
(14) Fork tube
(15) Oil seal
(16) Back up ring
(17) Slider bushing
(18) Fork tube bushing
119) Oil lock oiece
i20i Fork slider
After removing, pour out any remaining fork oil.

W h e n removing, do not damage the fork tube.
Do not remove it unless replacement is necessary
1
1
1
1
1
Do not remove it unless replacement is necessary
Front WheelISuspensionlSteering
Fork Assembly
Front WheelISuspensionlSteering
NOTE
Always replace the oil seal with a new one.
Coat the new oil seal with the recommended fork oil and install it with the mark facing up.
After assembling the fork legs, install each fork leg into the lower fork bridge first, then torque the fork cap.
Requisite Service
Fork disassembly (page 10-8)

Procedure
(1)
(2)
(3)
(4)
(5)
Rebound spring
Fork piston ring
Fork piston assembly
Oil lock piece
Fork tube bushing
(6) Fork tube

(7) Sealing washer
(8) Fork socket bolt
Q'W
1
1
1
1
1
1
1
1
(9) Slider bushing

(10) Back up ring
(11) Oil seal
1
1
1
(12) Stopper ring

(13) Dust seal
1
1
(14) Fork spring
(15)
(16)
(17)
(18)
1
1
1
1
Spring seat
Spacer
O-ring
Fork cap
(19) Fork cap
Fork installation (page 10-6)
Remarks
Replace with a new one if it was removed from the piston.
Insert into the fork tube.
Insert onto the piston.
Replace with a new one if it was removed from the fork
tube.
If the socket bolt turns with the fork piston, temporarily

install the fork spring, spacer and fork cap, then tighten the
socket bolt.
Wrap vinyl or plastic tape around the fork tube top

end to avoid damaging the oil seal during installation.
Use fork seal driver (07947-KA50100) and attachment
(07947-KF00100) for fork seal installation.
After installing, compress the fork tube fully and pour the
specified amount of fork fluid (page 1-1 1) into the fork
tube.
Wipe all oil off the spring thoroughly using a clean lint free
cloth and install with tightly Wound coil end facing down.
Apply oil to the new O-ring.

CAUTION
Be careful not to cross-thread the fork cap.
Screw i n the cap, but do not tighten yet.
Front Wheel/Sus~ension/Steerina
Steering Stem Removal/lnstallation
NOTE
I.
Reolace the bearinos and races as a set.

At installation, apply grease to all bearing surfaces.
Check the steerina head bearins ~reload(oase 1-1 1) after torouins the stem nut
Repuisite Service
Fork removallinstallation (page 10-6)
Handlebar removal/installation (page 10-2)
Procedure
Removal Order
Steering stem nut
Thrust washer
Ignition switch connector
Top bridge assembly
HeadlightIStay assembly
(6)
(7)
(8)
(9)
(10)
(1 1)
(12)
(13)
(14)
(15)
(16)
Lock nut
Lock washer
Dust seal
Steering stem
Upper bearing inner race
Upper bearing
Lower bearing
Lower bearing inner race
Dust seal
Upper bearing outer race
Meter removal/installation (page 16-5)
Q'W
Remarks
After removing, remove the fork tubes.
Disconnect inside the headlight case (page 1-21)
Support with a piece of wire so it dose not hang from the
cable or wire harness.
Remove, after straightening the lock washer tabs.
Use steering stem socket 07916-3710100
- Replace if removed.
Use race remover attachment (07953-MJ1010A)with

driver (07949-3710001) and attachment, 37x40 mm
(07746-0010201)for upper outer race removal.
Use race remover (07946-3710500) for lower outer
race removal.
(17) Lower bearing outer race

(18)
(19)
(20)
(21)

Washer
Handlebar holder cushion
Handlebar holder
(20)
(2 1)
(19)
(18)
(17)
(16)
(15)
(14)
(13)
(12)
(11)
Installation Order
Handlebar holder cushion
Handlebar holder
Washer
Lower bearing outer race
Upper bearing outer race
Dust seal
Lower bearing inner race
Lower bearing
Upper bearing
Upper bearing inner race
Steering stem
Dust seal
Lock washer
Lock nut
HeadlightIStay assembly
Top bridge assembly
Ignition switch connector
Thrust washer
Steering stem nut
After installing handlebar, torque the nuts.

Replace as a set, if necessary.
Use attachment. 52X55mm (07746-0010400) and
driver (07749-0010000) for lower outer race installation.
Use attachment, 42X47mm (07746-0010300) and
driver (07749-0010000) for upper outer race installation.
Use steering stem driver (07946-MB00000) for lower
inner race installation.
Installation : refer to section 18 of the Common Service

Manual (Retainer-Type Ball Bearings).
Temporarily install fork and torque the nut
MEMO
:.
:.I
11. Rear WheelISuspension

-
11-6
Service Information
11-1
Shock Absorber Rernovalllnstallation
Troubleshooting
11-1
Shock Absorber DisassemblylAssembly11-7
Rear Wheel Removalllnstallation
11 -2
Swingarm Removalllnstallation
11-9
Rear Wheel Disassembly/Assembly
11-4
Swingarm DisassemblyIAssembly
11-10
Service Information

Inhaled asbestos fiber have been found to cause respiratory disease and cancer.
Keep grease off of brake drum and shoes.
CAUTION
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a
contaminated disc with a high quality brake degreasing agent.
. Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service Manual.
- For rear wheel, shock absorber or swingarm removal, a hoist or other support is required to support the motorcycle.
. Refer to section 12 for brake system information.
Troubleshooting
Steers To One Side Or Does Not Track Straight

Bent rear axle
Axle alignmentlchain adjustment not equal on both
sides
Hard Suspension
lncorrect suspension adjustment
Bent swingarm pivot
Damaged swingarm pivot bearings
Bent damper rod
High tire pressure
. Bent rim
. Worn rear wheel bearings
. Faulty tire
.. Unbalanced
tire and wheel
Low tire pressure
. Faulty swingarm pivot bearings
Soft Suspension
Weak spring
Oil leakage from damper unit
lncorrect suspension adjustment
Low tire pressure
Rear Wheel Wobbling
r-Rear WheelISuspension
Rear Wheel Removal/lnstallation
Rear Wheel/Susoension
Never use an air hose or drv brush to clean brake assemblies. Use an OSHA-amroved
vacuum cleaner or alternate method
..
I.
Keep grease off of brake drum and shoes
a
-
CAUTION
contaminated disc w i t h a high quality brake degreasing agent.
NOTE
For rear wheel removal, a hoist or other support is required to support the motorcycle.
Adjust the drive chain free play after installing the wheel.
Procedure
(6)
(7)
(8)
(9)
(10)
(1 1)
(12)
(13)
(14)
Removal Order
Brake adjusting nut
Brake rod
Spring
Brake rod joint piece
Drive chain adjusting nut
Cotter pin
Nut
Washer
Rubber cushion
Brake stopper arm pivot bolt
Brake stopper arm
Rear axle nut
Drive chain adjuster
Drive chain
(15)
(16)
(17)
(18)
(19)
Rear axle
Rear wheel assembly
Right side collar
Left side collar
Brake panel assembly
(1)
(2)
(3)
(4)
(5)
Remarks
Loosen the adjusting nut fully.
Move the rear wheel forward and derail the drive chain from
the driven sprocket.
Disassembly (page 12-7).
r
Rear WheelISuspension
Rear Wheel DisassemblyIAssembly

Never use an air hose or drv brush to clean brake assemblies. Use an OSHA-auuroved
vacuum cleaner or alternate method
..
..
CAUTION
contaminated disc w i t h a high quality brake degreasing agent.
NOTE
For driven sprocket removal, loosen the sprocket nuts with the driven flange installed into the wheel hub.
Replace wheel bearings as a set.
For wheel bearing replacement, refer to section 1 of the Common Service Manual.
Requisite Service
. Rear wheel removallinstallation (page 11-21

1
Procedure
Q'W
Disassembly Order
1
(8) O-ring
(9)
(10)
(1 1)
(12)
/ /
Rear wheel damper

Left wheel bearing (6303 UU)
Distance collar
Right wheel bearing (6303 UU)
(13) Rear wheelltire
Remarks
Assembly is in the reverse order of disassembly

At assembly, apply grease to the dust seal lips.
Drive in the right side bearing first, then the left side bearing.
Shock Absorber Removal/lnstallation
NOTE
. For shock absorber removal, a hoist or other support is required to support the motorcycle.
Adjust the shock absorber to the softest position for disassembly.
Procedure
Removal Order
Rear fairing screw
Collar
Washer
Shock absorber mounting bolt (upper)
Plain washer
Shock absorber mounting bolt (lower)
Shock absorber assemblv
Q'tv
Remarks
Shock Absorber Disassembly/Assembly
Requisite Service
.
1
Rear shock absorber removal/installation (page 11- 6)

Procedure
Disassembly Order
Upper seat
Spring
Preload adjuster
Damper unit assembly
Q.tv
Remarks
See page 1 1-8.
Install with tightly wound coil end facing up.
R e a r WheellSuspension
Spring, Upper Seat R e m o v a l l l n s t a l l a t i o n

lnstall the shock absorber compressor and attachment on
the shock absorber.
(1) COMPRESSOR
NOTE
lnstall the compressor securely against the spring and

tighten the nut securely.
a
Shock absorber compressor
Compressor attachment
07GME-0010000
07959-MB10000
(2) ATTACHMENT
Compress the shock spring and remove the upper seat.

CAUTION
I.
Do not compress the spring more than nesessary.
Loosen the shock absorber compressor slowly and remove

the shock absorber and attachment.
Remove the shock absorber spring.
lnstall the shock absorber spring with tightly wound coil

end facing up.
.
I
'
Install the special tools and compress the shock spring
lnstall the spring seat securely.
(1
Shock absorber com~ressor

Compressor attachment
COMPRESSOR
07GME-0010000
07959-ME10000
NOTE
lnstall the compressor securely against the spring and
tighten the nut securelv.
Loosen the shock absorber compressor slowly and remove
the shock absorber and attachment.
(2) AmACHMENT
Swingarm Removal/lnstallation
NOTE
I.
For swingarm removal, a hoist or other support is required to support the motorcycle.
. Rear wheel removal/installation (page11-2)

Procedure
(1)
(2)
(3)
(4)
(5)
(6)
Removal Order
Drive chain cover
Shock absorber lower mounting bolt
Cap
Swingarm pivot nut
Swingarm pivot bolt
Swingarm assembly
Q'W
Evaporative emission canister removal/installation

(California model only)
Remarks
1
2
2
1
1
1
NOTE
For pivot bearing replacement, see next page.
Requisite Service
. Swingarm removal/installation (page 11-9)

Procedure
Disassembly Order
Drive chain adjuster
Cotter pin
Nut
Plain washer
(5) Rubber cushion
(6) Brake stopper arm
(7) Drive chain slider
( 8 ) Right pivot collar
(9) Left pivot collar
(10) Dust seal
(1 1 ) Distance collar
(12) Snap ring
(13) Ball bearing
(14) Needle bearinq
Q'tv
Remarks
/ Assembly is in the reverse order of disassembly.
(1)
(2)
(3)
(4)
Install the drive chain slider as shown
Apply grease to the lip.

Install into the groove securely.
Rear Wheel/Sus~ension
Swingarm Pivot Bearing Replacement
Press the right plvot bearlng (ball bearlng) out of swingarm.
a
Driver shaft
'
or
Driver
07946-MJ00100
(Not available i n U.S.A.)
07949-3710001
Set the needle bearing remover onto the left pivot bearing
(needle bearing) as shown.
Needle bearing remover attachment07GMD-KT70200

07946-MJ00100
Driver shaft
or
M967X-038-XXXXX
Bushing remover
Driver
07949-3710001
Pilot, 17 mm
07746-0040400
Press the needle bearing into the swingarm with the marked
side facing out.
NOTE
The bearing surface should be flush with the pivot

inside surface as shown.
(3) ATTACHMENT
m
Driver
Attachment, 28X 30mm
Pilot, 22mm
07749-0010000
07946-1870100
07746-00410 0 0
Press the ball bearing in until it bottoms in the swingarm.
Driver
Attachment, 32X35mm
Pilot. 15mm
(2) ATTACHMENT
07749-0010000
07746-0010 10 0
07746-0040300
F"~
MEMO
12. Brake System

Service Information
Troubleshooting
Front Brake Pad Replacement
Front Master Cylinder Removal1
Installation
Front Master Cylinder Disassembly1
Assembly
12-1
12-1
12-2
12-3
Front Brake Caliper Removalllnstallation12-5

Front Brake Caliper Disassembly1
Assembly
12-6
Rear Brake Panel Disassembly1
Assembly
12-7
Brake Pedal Removalllnstallation
12-8
12-4
Service Information

/.
Inhaled asbestos fiber have been found to cause res~iratorvdisease and cancer.
Keep grease off of brake disc, drum, pads and shoes.
CAUTION
I-
A contaminated brake disc, durm, pad or shoe reduces stopping power. Discard contaminated padslshoes and
clean a contaminated disc with a hiah aualitv brake deareasina aaent.
Once the hydraulic system has been opened, or if the brakes feel spongy, the system must be bled.
Never allow contaminants (dirt, water, etc) to get into an open reservoir.
Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag or shop towel over these parts whenever the I
system is serviced.
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid
as they may not be compatible.
Always check the brake operation before riding the motorcycle.
Troubleshooting
From Brake :
Brake Lever Soft Or Spongy
Air bubbles in the hydraulic system
Leaking hydralic system
Contaminated brake padldisc
Worn caliper piston seal
Worn master cylinder piston seal
Worn brake padldisc
Contaminated caliper
Caliper not slidinq
- .properlv
.
.
LOW fluid level
Clogged fluid passage
Waroedldeformed brake disc
~ t i c k i n ~ l w o rcaliper
m
piston
Stickinglworn master cylinder piston
Contaminated master cylinder
Rear brake :
Poor Brake Petformance
lmproperly adjusted brake
Worn brake linings
Worn brake drum
Worn brake cam
lmproperly installed brake linings
Brake linkage needs lubrication
Contaminated brake linings
Comtaminated brake drum
Worn brake shoes at cam contact area
Improper engagement between brake arm and cam
serrations.
--
-.
Brake Lever Hard

Cloggedlrestricted brake system
Stickinglworn caliper piston
Caliper not sliding properly
Cloggedlrestricted fluid passage
Worn caliper piston seal
Stickinglworn master cylinder piston
Bent brake lever
Brakes Drag
.. Contaminated
brake padldisc
Misaligned wheel
brake padldisc
-. Worn
Warpedldeformed brake disc
Caliper not sliding properly
Brake Pedal Hard Or Slow Return

Wornlbroken return spring
lmproperly adjusted brake
Sticking brake drum due to contamination
Worn brake shoes at cam contact area
Brake linkage needs lubrication
lmproperly installed brake linings
..
.
-
Squeaks
..Brake
Worn brake linings
brake drum
.- Worn
Contaminated brake linings
Contaminated brake drum
Brake System
Front Brake Pad Replacement

ALIGN
(3)

approved by OSHA. designed to minimize the hazard caused by airborne asbestos fibers.

CAUTION
NOTE
1.
Pushing the caliper against the disc, push the caliper pistons all the way in to allow the installation of new pads.
Do not squeeze the brake lever when the caliper is removed, or it will be difficult to refit the disc between the brake
pads.
Replace brake pads as a set.
Apply a thin of silicone grease onto the pad pin as a rust preventative.
After replacement, operate the brake lever to seat the caliper pistons against the oads.
Procedure
Removal Order
Pad pin plug
( 2 ) Pad pin
( 3 ) Brake pad
( 1)
Q'tv
Remarks
1
1
2
Insert the pin. pushing the pads against the pad spring.
Align the pad lug with the pad retainer as shown.
1
1
Brake System
Front Master Cylinder Removal/lnstallation
CAUTION
Spilled brake fluid will damage painted. plastic, or rubber parts. Cover these parts when servicing the brake
system.
Requisite Service
Brake fluid replacementlair bleeding (section 17 of the Common Service Manual)

Remarks
Procedure
/ Installation is in the reverse order of removal
Removal Order
Right rearview mirror
Brake lever pivot bolt
Brake lever
Brake hose bolt
Brake hose
Sealing washer
Front brake light switch connectol
Master cylinder holder bolt
Master cylinder holder
Master cylinder assembly
At installation, press the hose end against the stopper while

tightening the hose bolt.
2
1
1
Tighten the upper bolt first, then the lower bolt.

Face the "UP" mark upward.
Align the holder end with the punch mark on the handlebar.
Brake System
Front Master Cylinder Disassembly/Assembly
Jal.5(o.15.1.1)
0'
(page 1-17)
j
CAUTION
I.
Spilled brake fluid will damage painted, plastic, or rubber parts. Cover these Darts when servicins
- the brake
system.
NOTE
Replace the master piston, spring. cups, stopper plate, snap ring and boot as a set.
The master piston, cups and spring must be installde as a set.
Requisite Service
Front master cylinder removal/installation (page 12-3)
Procedure
Q'W
Disassembly Order
Y 1) ReSe~oircover
Diaphragm plate
Diaphragm
Front brake light switch
Boot
Snap ring
1
1
1
1
1
1
(7) Stopper plate

( 8 ) Master piston assembly
19) Spring
1
1
1
12)
(3)
(4)
(5)
(6)
Remarks
COUTION
Be certain the snap ring is fully seated in the groove.
Install it with its small coil end toward the piston.
Brake System
Front Brake Caliper Removal/lnstallation
.
:..

Never use an air hose or drv brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimlze the hazard caused by airborne asbestos fibers.
Inhaled asbestos fiber have been found t o cause respiratory disease and cancer.

CAUTION
I.
A contaminated brake disc or ad reduces stopping

power. Discard contaminated pads and clean a contaminated
. . -~
Spilled brake fluid will damage painted, plastic, or rubber parts. Cover these parts when servicing the brake
system.
Requisite S e ~ i o e
. Brake pad removal/installation (page 12-2).

. Brake fluid replacementlair bleeding (section 17 of the Common Service Manual)
7
Procedure
Removal Order
(11 Brake hose bolt
( 2 ) Seallng washer
(3) Brake hose
(4) Callper bracket bolt

(5) Front brake callper assembly
I
I
Q'tv
1
2
1
2
1
I
Remarks
1 Installation is in the reverse order of removal.
At ~nstallat~on,
press the hose end agalnst the stopper whlle
tlghtenlng the hose bolt
1
1
Brake System
Front Brake Caliper Disassembly/Assembly
:PISTON SEALS,
PISTONS

asbestos fiber have been found t o cause respiratory disease and cancer.
CAUTION
Spilled brake fluid will damage painted, plastic, or rubber parts. Cover these parts w h e n servicing the brake
system.
Requisite Service
--
Brake pad removal/installation (page 12-21

Front brake caliper removal/installation (page 12-51
Procedure
-
Disassembly Order
Pad spring
Caliper bracket
Bracket pin bolt boot
Caliper pin bolt boot
Bracket pin bolt
Caliper pin bolt
Caliper piston
Dust seal
Piston seal
Q'tv
Remarks
Note the spring direction as shown.
Install into the bracket groove securely.

Apply a locking agent t o the threads before torquing. Apply
silicone grease to the pin.
Install them with the concaved side away from the pads.
-CAUTION
Be careful not to damage the piston sliding surface
w h e n removing seals.
Brake System
Rear Brake Panel Disassembly/Assembly

I.
Inhaled asbestos fiber have been found to cause respiratow disease and cancer.

CAUTION
/.
contaminated disc w i t h a hiah aualitv brake deareasina aaent.
Requisite Service
Rear wheel removal/installation (page 1 1-2)

Procedure
Disassembly Order
(1) Brake arm pinch bolt
(2) Brake arm
(3) Brake indicator
(4) Felt seat

(51 Cotter pin
(61 Cotter pin plate
(71 Brake shoe
(81 Shoe spring
(9) Brake cam
l(10) Brake panel
Q'tv
Remarks
At installation, align the punch marks on the brake cam and
pin.
At installation, align the wide tooth with the wide slot in the
brake cam.
Install with endless side facing out
At installation, apply grease to the sliding surface and cam

portion.
Brake System
Brake Pedal Removal/lnstallation
Requisite Service
Evaporative emission canister removal/installation (California model only.)

Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Removal Order
Brake pedal pinch bolt
Brake pedal
Brake rod adjusting nut
Brake rod spring
Brake rod joint piece
Brake switch spring
Brake pedal return spring
Brake linkage assembly
-cotter pin
-joint pin
111) -brake linkage

(12) -brake rod
Q'h,
Remarks
1
1
1
1
1
1
Align the punch mark on the shaft with the brake pedal slot.
1
1
1
1
At assemble, align the cutout of the joint pin with the boss
in the brake rod.
Apply clean grease to the sliding surface of the shaft.
13. Charging System/Alternator

Service Information
13-1
Charging System Inspection
13-5
System Location
13-2
RegulatorIRectifier
13-6
Troubleshooting
13-3
Alternator
13-7
Battery R e m o v a l / l n s t a l l a t i o n
13-4
Alternator R e m o v a l l l n s t a l l a t i o n
13-8
Service Information
The battery gives off explosive gases ; keep sparks, frames, and cigarettes away. Provide adequate ventilation
when chariging or using the battery i n an enclosed space.
The banery contains sulfuric acid (electrolyte). Contact w i t h skin or eyes may cause severe burns. Weal
protective clothing and a face shield.
-If electrolyte gets on your skin, flush with water.
-If electrolyte gets in your eyes, flush with water for a t least 15 minutes and call a physician immediately.
Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow w i t h milk of magnesia
or vegetable oil and call a physician.
KEEP OUT OF REACH OF CHILDREN.
For alternator shaft assembly removallinstallation, refer to section 9.
Always turn off the ignition switch before disconnecting any electrical component
CAUTION
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the
ignition switch is O N and current is present.
For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service
life, charge the stored battery every two weeks.
For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
NOTE
. Refer to Section 2 2 of the Common Service Manual and the instructions in the Operation Manual for the HONDA
Battew Tester and Christie Batterv Charaer for detailed batterv charaina stew.
The battery can be damaged if over charged or undercharged, or of left to discharge for long periods. These same
conditions contribute to shortening the "life span" of the battery. Even under normal use. the performance of the battery
deteriorates after 2-3 years.
Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually
die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge often results from
problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells is shorted and
battery voltage does not increase. the regulatorlrectifier supplines excess voltage to the battery. Under these conditions.
the electrolyte level goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the
motorcycle
The battery will self-discharge when the motorcycle is not is use. For this reason, charge the battery every two weeks
to prevent sulfation from forming.
Filling a new battery with electrolyte will produce some voltage. but in order to achieve its maximum performance, always
charge the battery. Also, the battery life is lengthened when it is initial-charged
When checking the charging system, always follow the steps in the troubleshooting flow chart (page 13-3).
For battery testinglcharging, refer to section 2 2 of the Common Service Manual.
For charging system component locations. see page 13-2.
Charging System/Alternator
System Location
( 6 ) IGNITION SWITCH
(5) REGULATOR/
(1) ALTERNATOR
12V14Ah
Charging System/Alternator
Troubleshooting
Battery Overcharging
faulty regulatorlrectifier
Battery Undercharging
NOTE
In order to obtain accurate test readings, the battery must be fully charged and in good condition. Refer to the
Common Service Manual, section 22, for instructions on checking the battery condition.
Measure the battery current leakage

(leak test : page 13-5)
Incorrect
Check the regulatorlrectifier

(unit inspection : page 13-7)
I
Ir
Incorrect
Correct
Correct
Shorted wire harness

Faulty ignition switch
Faulty regulatorlrectifier
Check the regulated vol
Correct
Check the battery using a Honda Battery Tester
I
I
Not charging
a
r
Check the va~ltagesof the regulatorlrectifier batcharging line and ground line (page 13-6)
A,.
-"I
IY1II1~1--
-. n
--..
Upall
-:
Electric system overloading

Faulty battery
:--,. ------
:.:
LllLull III Wllr; 1 1 6 1 1 1 1 > 5
"ted connectors
I
Normal
Check the alternator (charging and field coils)

resistance at the regulatorlrectifier connector
(page 13-6)
Abnormal
Check the alternator charging and field coils

(page 13-7)
Abnormal
Poorly connected
alternator connector
Normal
i.
Faulty alternator
Check the regulatorlrectifier
(unit inspection : page 13-7)
Normal
Abnormal-.
Faulty regulatorlrectifiel
3
Charging SystemIAlternator
Battery Removal/lnstallation
I
NOTE
With the ignition switch OFF, remove the negative terminal at the banery first, then remove the positive terminal.
Requisite Service
Right side cover removal/installation (page 2-3)
Procedure
(19
Removal Order
Banerv holder bolt
Q'W
Remarks

3
With the "OUTSIDE" mark facihg up
Charging System Inspection

Leakage Test
Turn the ignition switch off, and disconnect the ground (-)
cable from the battery.
Connect the ammeter (+) probe to the ground cable and the
ammeter (-1 probe to the battery (-) terminal.
With the ignition switch off, check for current leakage.
UOTE
When measuring the current using a tester, set it to a

high range, and then bring the range down to an
appropriate level. Current flow larger than the range
selected may blow out the fuse in the tester.
While measuring current, do not turn the ignition
switch ON. A sudden surge of current may blow out
the fuse in the tester.
Specified Current Leakage : O.OlmA max.

If current leakage exceeds the specified value, a shorted
circuit is likely.
Locate the short by disconnecting connectors one by one
and measuring the current.
Regulated VoltageIAmperage Inspection

NOTE
Before performing this test, be sure the battery is fully
charged and that the specific gravity is greater than 1.
27 (20'C/68F)
Start the engine and warm it up t o operating temperature,
then turn the ignition switch OFF.
[Battery Regulated Voltage]
Connect the multimeter between the battery terminals
Digital rnultimeter
Analogue tester
07411402W00 or
KS-AHM-32-003 (U.S.A. onlyl or
073084020001 or
TH-SH-1 (U.S.A. onlyl or
Charging SysternlAlternator
If the engine must be running to do some work,

make sure the area is well-ventilated. Never run the
engine i n an enclosed area.
The exhaust contains poisonous catlmn monoxide
gas that may cause loss of consciousness and lead
to death.
Disconnect the starter relay switch connector remove the

main fuse (30A). Reconnect the connector onto the relay
switch.
Connect the ammeter as shown.
I
Start the engine and increase the engine speed gradually.

CAUTION
Be careful not to short the tester probes.
Although the current could be measured when the
ammeter is connected between the battery positive
terminal and the positive cable, a sudden surge of
current to the starter motor could damage the ammeter .
Always turn the ignition OFF when conducting the
test. Disconnecting the ammeter or wires when
current is flowing may damaae the ammeter.
Regulated Voltage :
Charging current
: 13.0-1 5.0\1/2,000 rpm

: Below0.5A
System Inspection
Disconnect the regulatorlrectifier 6P connector.
Check the connectors for loose or corroded terminals
Measure the following between the connector terminals of
the wire harness side.
Item
charging
Terminals
Black (+) and

ground (-)
Charging
coil line
Yellow and Yellow
Field
coil line
White and Black
Battery voltage
should register.
and ground (-)
"'Itage
detection
line
Specification
When the ignition switch is ON, battery voltaw should re~ister.
0.4-0.6 n
(2m16B.F)
2.1-2.6 n
(20%/68'F)
If the charging coil line reading is out of specification, check

the alternator (page 13-7).
Unit Inspection
Provided the circuit on the wire harness side is normal and
there are no loose connections at the connector, inspect the
regulatorlrectifier unit by measuring the resistance between
the terminals.
NOTE
You'll get false readings if the probes touch your fingers.

Use the specified multimeters. Using other equipment
may not allow you to obtain the correct results. This is
due to the characteristic of semiconductors, which
have different values depending on the applied voltage.
Specific Multirneter :
(KOWA Digital type)
-0 7 4 11-0020000
-07308-0020001
ISANWA Analoaue Woe)
.. -TH-5H
(KOWA Analogue type)
Select the following range :
SANWA : X k 0
KOWA: X l 0 0 Q
An old battery stored in the multimeter could cause
inaccurate readings. Check the battery if the test
results are not as ex~ected.
When using the KOWA multimeter, remember value
that all readings should be multiplied by 100.
Replace the regulatorlrectifier unit if the resistance value

between the terminals is abnormal.
RECTIFIER PORTION
Probe3
Unit : k n
7
1,
0.5-50
10.5-5010.5-5010.5-5010.5-501
REGULATOR PORTION
ProbeO
3
Probee
2
1
1 1-30
Unit : k n
7
10.5-20
Remove the fuel tank (page 2 - 4 )

Remove the fuel tank front cushion and left front side cover
Disconnect the regulatorlrectifier connector.
Remove the mounting bolt and regulatorlrectifier unit.
Alternator
NOTE
It is not necessaty to remove the stator to make this

test.
Disconnect the alternator 4P connector
Measure the resistance between the two Yellow wire terminals, and between the White and Black wire terminals.
Standard :
Yellow - Yellow
White - Black
0.4-0.6Q ( 2 U C l 6 8 F )
2.1-2.6Q (2UC168F)
Replace the stator if the resistance is out of specification or

if there is continuity between the Yellow or White wire
terminal and ground.
(1) ALTERNATOR
\CONN~CTOR
-w I
Charging SystemlAlternator
NOTE
For alternator shaWshaft bearing replacement, see page 9-12.
Requiste Service
Left side cover removal/installation (page 2-3)
Procedure
(1)
(2)
(3)
(4)
WtY
Removal Order
'~lternatorwire connector
Alternator cover bolt
Alternator cover
Alternator rotor bolt
When removing and intalling, shift the transmission into

gear and apply the rear brake.
18) Stator assembly
1
1
1
1
(9) Rotor Alfan A
(5) Washer
( 6 ) Fan B
( 7 ) Rotor B
Remarks
To install, align the holes with the holes in rotor 6.

Install with the hole aligned with the boss on rotor A.
At installation, align the painted groove with upper right
groove for the alternator cover mounting bolt.
14. lgnition System

Service Information
14-1
Ignition Coil
14-6
14-2
Ignition Pulse Generator
14-7
Troubleshooting
14-3
lgnition Pulse Generator Removalllnstallation 14-8
System Inspection
14-6
Ignition Timing
14-9
Service Information
Ifthe engine must be running to do some work, make sure the area is well-ventilated. Never run the engine i n
an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness
and lead t o death.
CAUTION
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the
ignition switch is ON and current is present.
When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 14-3).
The ignition control module may be damaged if dropped.Also, if the connector is disconnected when current is
present, the excessive voltage may damage the ignition control module. Always turn off the ignition switch before
servicing.
The transistorized ignition uses an electrically controlled ignition timing system. No adjustments can be made to the
ignition timing.
A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect.
A faulty ignition system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
Use spark plugs of the correct heat range. Using the wrong spark plugs can damage the engine. Refer to section 2 of
the Common Service Manual.
Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine
cranking speed as well as no spark at the spark plugs.
For side stand inspection, refer to section 25 of the Common Service Manual.
For neutral switch inspection, refer to page 16-8.
For the ignition switch and engine stop switch inspection, check for continuity using the chart on the Wiring
Diagram, page 17-1. Disconnect each switch connector inside the headlight case (page 1-21) ahd check it.
For side stand inhibitor system instructions, see page 14-5 "N0TE"of the troubleshooting.
Ignition System
System Location
(8) IGNITION
CONTROL
0)SlDE STAND
GENERATOR
(9) DIODE
(14) CLUTCH
(7) FUSE
(6) MAIN
(5) BATERY
(7) FUSE
(1) SIDE STAND

INDICATOR
(10) SlDE STAND

SWITCH
-- -. -. -.
SWITCH
Ignition System
Troubleshooting
No Spark At All Plugs (Faulty Input System)
Ifthere is no spark at all plugs, the problem could be at the input of the ignition system (ignition pulse generator, power
input circuit of the ignition control module (ICM), neutral switch, side stand switch or ICM).
Check for loose or poorly connected ICM
connector.
Poorly connected connector
Poorly connected connectors
Abnormal---
Normal
Check for loose or poorly connected ignition coil
connectors.
Abnormal-.
Normal
-No
voltage-.
Faulty ignition switch or engine stop switch

Open circuit in wire harness
Loose or poor contact of related circuit connectors
Measure the ignition pulse generator resistance

at the ICM connector (page 14-61,
Check the ignition pulse generator (page 14-7)
I.
..
Faulty lgnltlon pulse generator
Open circuit between the ICM and ignition pulse

generator
Loose or poor contact of the ignition pulse
generator connector
Check the neutral switch for continuity at the

ICM connector (page 14-6).
Check the neutral switch (page 16-8)
Normal
I
Faulty neutral switch
Open circuit between the ICM and neutral switch

Loose or poor contact of the neutral switch
connectors
Check the side stand switch.
Abnormal
Good
Checkthe side stand switch atthe ICM connector

(page 14-61,
~bnbrmal
I
Normal
Faulty ICM
.
-
Abnormal
I
Faulty side stand

switch
Open circuit between the ICM and side stand

switch
Loose or poor contact of the side stand switch
connector
Ignition System
At Either lgnition Group
.NoIfSpark
there is no spark at either group, the problem is suspected in the primary coil side of the ignition system (ignition coil.
or unit and ignition coil circuit).
"No Spark"
Remove the faulty pair ignitioin coil and check the
ignition coil resistance (page 14-7),
faulty pair
~bndrmal
"No Spark" condition

shifts to other pair
Faulty ignition coil

Faulty spark plug wire
I
Out of
standard-.
value
spark unit connector (page 14-6).
Poor or loose
contact of ignition
coilconnectors
Open circuit between the unit and ignition coil
Faulty spark unit
No Spark A t One Plug (Trouble In Secondary Coil Side)

Faulty spark plug is most likely.
Replace (suspected bad spark plug) with known
good spark plug and conduct spark test.
Put the spark plug wire on and measure

tance of ignition secondary coil (page 14-7).
Spark-.
Original spark plug no good.
,"",,,,a,-
Out of star(dard value

Remove the spark plug wirerand measure the
resistance of the ignition secondary coil (page
14-71,
Good
i of spark plug wire

. Poor contact
. Faulty spark plug wire
Out of
standard
value
-0
S~ark
Ignition System
Engine Starts. But Side Stand Switch Does Not Function A t All.
NOTE
The side stand switch should function as follows :

When the transmission is shifted into a gear from neutral with the side stand down, the ignition shuts off and the engine
will stop.
When in neutral, the neutral switch line (a) of the spark unit is connected to ground via the neutral switch. When the
side stand is up, the side stand switch line (b) of the spark unit passes to ground via the side stand switch. The spark
unit monitors lines (a) and (b), and provides spark only when one or both of those lines is connected to ground via the
neutral switch or the side stand switch.
Normal-.
Open circuit in GreedWhite wire
Normal-.
Loose or poor contact of related connectors

Open circuit in GreenIWhite wirre
Burnt indecator bulb
I
~bnbrmal
Check the side stand s
Abnormal
i
Faulty side stand switch
lgnition System
System Inspection
NOTE
Check the svstem comoonents and lines ste~-bv-steo

. . .
according to the troubleshooting chart on pages 14-3,
4.5.

Disconnect the connector from the ICM and conduct these
tests at the connector.
Item
Terminals
Power source input line
Black (+) and Green (-1
Ignition primary coil
No.1-4 : Black and YellowlBlue

No.2-3 : Black and BluelYellow
Standard (2UCI68F)
Battery voltage should register with the ignition
switch ON and the engine stop switch RUN.
2.6
Ignition pulse generator coil Yellow and WhiteIYellow
- 3.20
297 -363~1
Neutral switch line
Light GreenIRed and Ground
Continuity in neutral
No continuity in any gear except neutral
Side stand switch line
GreenIWhite and Ground
Continuity with the side nand up

No continuity with the side stand down
Ground line
Green and body ground
Continuity.
lgnition Coil
Remove the fuel tank (page 2- 4).
Remove the fuel tank front cushions and front side covers
(page 13-71,
Disconnect the spark plug caps from the spark plugs.
Disconnect the ignition primary terminals from the coils and
remove the mounting bolts and nuts.
Remove the ignition coils.
Install the ignition coils in the reverse order of removal
NOTE
Route the spark plug wires properly as shown.

. 4
(5) WIRE HARNESS
Ignition System
Inspection
Disconnect the ignition coil primary terminals under the fuel
tank and measure the primary coil resistance of the ignition
coil.
- 3.2.Q (2UCI68'Fl
Standard : 2.6
Disconnect the spark plug caps from the spark plug and
measure the secondary coil resistance with the spark plug
wire at each ignition pair :
No. 114 secondary coil : between cylinders 1 and 4 wire

No.213 secondary coil : between cylinders 2 and 3 wire
Standard : 1 8
- 22kR (2OCl68'Fl
If the resistance is
(open wire), disconnect the spark plug
. .
cap and measure the secondary coil resistance as shown.
Standard : 1 3 - 17kQ (2UCI68'Fl
If the resistance is m (open wire), disconnect the spark plug
wire and measure the secondary coil resistance as shown.
Standard : 1 3 - 17kQ (20ZI6BF)
lgnition Pulse Generator
Inspection
/Y
NOTE
It is not necessary remove the ignition pulse geneator

from the engine.
Remove the fuel tank (page 2- 4).

Disconnect the ignition pulse generator 4P connector.
Measure the resistance between the Yellow and White1
Yellow terminals.
Standard : 297
- 363Q (20%/68F)
(1) IGNITION PULSE GENERATOR CONNECTOR
lanition Svstem
Ignition Pulse Generator Removal/lnstallation
CAUTION
Be careful not to damage the wire harnesses by pinching them between the sprocket cover and engine.
NOTE
Route the wire harnesses properly (page 1-25).
Requisite Service
. Left crankcase cover removal/installation (page 14-9) .

. Drive sprocket cover removal/installation (page 8-9)
Procedure
Removal Order
(1) Ignition pulse generator connector
(2) Oil pressure switch terminal
(3) Neutral switch connector
(4) Ignition pulse generator screw
(5) Ignition pulse generator
Q'W
Remarks
1
1
1
2
1
Ignition System
lgnition Timing
Warm up the engine.
Stop the engine and connect a timing light to the No.1
cylinder spark plug wire.
NOTE
I.
Read the instructions for timing light for operating.
Remove the left crankcase cover.
If the engine must be running to do some work.make

sure the area is wall ventilated. Never run the
engine i n an enclosed area. The exhaust contains
pobonous carbon monoxide gas that may cause loss
of consciousness and lead m death.
Start the engine and allow it to idle.
Inspect the ignition timing.
The timing is correct if the "F"mark aligns with the index
mark on the crankcase at idle speed.
Idle Speed : 1,000 ? 100 rpm
Increase the engine speed, make sure the "F"mark begins to
move counterclockwise at approximately 1.500 rpm.
1 1 )INDEX MARK.
MEMO
15. Electric StarterlStarter Clutch

Service Information
15-1
Starter Motor Removalllnstallation
15-5
System Location
15-2
Starter Motor DisassemblylAssembly
15-6
Troubleshooting
15-3
Starter Clutch Disassembly/Assernbly
15-8
Service Information
turn the ignition switch "OFF" before servicing the starter motor. The motor could suddenly start,
causing serious injury.
A week battery may be unable t o turn the starter motor quickly enough, or supply adequate ignition current.
If the current is kept flowing through the starter motor t o turn it while the engine is not craking over, the starter motor
may be damaged.
For the following component inspections, refer t o the following pages ; for the parts locations, see page 15-2 of this
manual (System Location).
Clutch switch diode
Starter motor
I Starter relay switch

I Clutch switch
Ignition switch
I Side stand switch
Section 2 4 of the Common Service Manual
1 Section 2 4 of the Common Service Manual

1 Section 24 of the Common Service Manual ( " A circuit type)
I (page 1 6 - 8 )
Check for continuity on the continuity chart of the Wiring Diagram, page 17-1.
Disconnect the switch connector inside the headliaht case loaae 1-21 1 and check IT.
I
I
1
Electric Startartstarter Clutch
System Location
( 6 ) STARTER
(2) NEUTRAL
(1) SlDE STAND
SWITCH
INDICATOR
RELAY SWITCH/
5 BATTERY
(10) SlDE STAND

SWITCH
SWITCH
DIODE
(9) NEUTRAL
SWITCH
RELAY
MAIN FUSE 30A
To Regulator/Rectif~er
(1) SlDE STAND

SWITCH INDICATOR
12) NEUTRAL
INDICATOR
Electric StarterIStarter Clutch
Troubleshooting
Starter Motor W i l l Not Turn
Check for a blown out main or sub fuses before servicing.
Make sure the battery is fully charged and in good condition.
Check for loose or poorly connected battery terminals, and opened or shorted battery cable.
Poorly connected battery terminals

Open or short circuit in battery cable
Normal
Check for loose or poorly connected starter relay
switch terminals and 4P connector.
Abnormal-.
Abnormal-.
Poorly connected terminals or 4P connector
Abnormal-.
Poorly connected motor cable

Open circuit in motor cable
~o;mal
t
Check for loose or poorly connected starter motor
cable, and opened cable.
1
With the ignition switch "ON", push the starter

switch and check for a "click" sound from the ----Clicksstarter relay switch.
Connect the starter motor terminal to the battery

positive terminal directly. (Because a large
amount of current flows, do not use thin wires)
No click
check the relay coil ground wire lines as below for

continuity :
1. GreenlRed terminal-clutch switch diodeneutral switch line (with transmission in neutral and clutch lever released.)
2. GreenlRed terminal-clutch switch-side stand
switch line (in any gear except neutral, and
with the clutch lever pulled in and the side
starter
motor
turns
~ t a r t e ;motor
does not turn
1-.
Faulty starter motor
Loose or disconnected starter motor cable

Faulty starter relay switch
.
.
Faulty neutral switch

Faulty clutch switch diode
Faulty clutch switch
Loose or poor contact of connector
.
.
Faulty ignition switch

Faultylstarter switch
Blown out main or sub fuses
Loose or poor contact of connectol
No continuity-.
Continuity
b
Connect the starter relay switch connector. With

the ignition switch ON and the starter switch
No voltage-.
starter switch connector (between YellowlRed
Voltage appeared
Normal-.
Abnormal-.
Loose or poor contact of the starter relay

switch connector
Faulty starter relay switch
Electric StartertStarter Clutch

The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position except
neutral, with the side stand up and the clutch lever pulled in.
ed with the ignition switch ON.
Abnormal-.

Burnt bulb
Abnormal-.
Faulty clutch switch
Abnormal-.
Normal
t
Check the clutch switch op
Nojmal
Check the side stand switch.
I
Starter Motor Turns Slowly

Low specific gravity in battery lor dead banery)
Poorly connected banery terminal cable
Poorly connected starter motor cable
Faulty starter motor
Poorly connected battery ground cable
..
Starter Motor Turns. But Engine Does Not Turn

Starter motor is runnning backwards
Case assembled improperly
Terminals connected improperly
Faulty starter clutch
Damaged or faulty starter pinion
Damaged pinion gears
Starter Relay Switch "Clicks", But Engine Does Not Turn Over
Crankshah does not turn due to engine problems
Excessive pinion gear friction
-0

Loose or poor contact of connector
Starter Motor Removal/lnstallation
Procedure
Removal Order
( I ) Starter motor cable
( 2 ) Starter motor mountlng bolt
( 3 ) Starter motor
( 4 ) 0-r~ng
Q'W
Remarks
lnstallat~onIS in the reverse order of removal.
1
2
1
1
Starter Motor Disassembly/Assembly
'
Electric StarterlStarter Clutch
Requisite Service
. Starter motor removal/installation (page 15-5)

Procedure
Disassembly Order
(1) Starter motor pinion gear
(21 Set screw
(3) Front cover assembly
(4) - idle pinion
(5) - ring gear
(6) - pin
(7) - front cover
(8) O-ring
(9) Separator
(10) Washer
(1 1) Brush terminal holding nut
(12) Washer
(13) Insulated washer (larger)
(14) Insulated washer (smaller)
(15) O-ring
(16) Brush holder assembly
(17) Brush and terminal
(18) O-ring
(19) Rear cover
(20) Shims
(2 1) Armature
(22) Motor case
Q'W
Remarks
1
2
-
2
1
1
1
1
1
1
2
1
1
2
1
1
1
1
Aligh the holder tab with the rear cover groove.
Record and store the shims in the same order they were
installed in the original positions.
1
1
Starter Clutch DisassemblvIAssemblv
Requisite Service
Crankshaft, connecting rod removal/~nstaIlat~oln

(page 9-1 0, 16)
Procedure
Disassembly Order
( 1 ) Starter driven gear
( 2 ) Needle bearing
( 3 ) Starter clutch
I ww I
Remarks
1
1
1
At installation. make sure the starter clutch roller is installed

oro~erlvinto the clutch housing
Service Information
System Location
16-1
Meter Disassembly/Assenbly
16-6
16-2
Tachometer Inspection
16-7
Headlight Removal/lnstallation
16-3
Side Stand Switch
16-7
TailIBrake Light
16-4
Neutral Switch
16-8
Turn Signal Bulb
16-4
Ignition Switch Removal/lnstallation
16-9
Meter Removal/lnstallation
16-5
Service Information
I
..,, ,,.,ogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it i s
turned OFF. Be sure to let it cool d o w n before servicing.
Use a flame and heated waterlcoolant mixature for the thermo sensor inspection. Keep all flammable materials
a w a y from the burner. Wear protective clothing. gloves and eve orotection.
Note the following when replacing the halogen headlight bulb.
Do not put finger prints on the headlight bulb. as they may create hot
spots on the bulb and cause it to break.
- If you touch the bulb with your bare hands. clean it with a cloth moistened with alcohol to prevent its early failure.
- Be sure to install the dust cover after replacing the bulb.
Check the battery condition before performing any inspection that requires proper battery voltage.
A continuity test can be made with the switches installed on the motorcycle.
For the following component locations, see page 16-2 of this manual (System Location) ; for inspections, refer to the
applicable pages.
- Wear clean gloves while replacing the bulb.
Component
Clutch switch
Front brakelight switch
Horn
Handlebar switches
Ignition switch
Inspection method
Remarks
II
I Section 2 5 of the Common Service Manual I

1 Section 2 5 of the Common Service Manual I
I
Check for continuity on the continuity chart Switch connectors are located inside the
of the Wiring Diagram, page 17-1
headlight case (page 1-21)
Oil pressure switchlwarning Section 2 5 of the Common Service Manual

light
Rear brakelight switch
Turn signal lights
Section 25 of the Common Service Manual
Oil pressure check : Section 4 of the Common Service Manual

Oil pressure switch torque :
12 N - m (1.2 kg-m. 9 ft-lb)
3 terminal relay.
LightslMeterslSwitches
System Location
(2) FRONT BRAKELIGHT

SWITCH
STAND
SWITCH
\ ( 7 ) NEUTRAL
SWITCH
Headlight Removal/lnstallation
The halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it is
turned OFF. Be sure to let it cool down before servicing.
CAUTION
Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create
hot spots on the bulb and cause it to break.
If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early
failure.
Be sure to install the dust cover after replacing the bulb.
Procedure
Removal Order
Screw
Headlight bulb socket
Dust seal
Headlight bulb
Headlight assembly
Connectors
Headlight case
Remarks
Install with the ''TOP" mark facing up.
Connection (page 1-2 1)

Align the index marks on the case and bracket.
TailIBrake Light
Remove the seat (page 2-3)
Remove the bulb socket from the tail/brake light body by
turning it counterclockwise.
Remove the bulb from the socket by turning it counterclockwise and replace with a new one.
Turn Signal Bulb

SCREW
Remove the mounting screw and turn signal lens

Remove the bulb from the socket by turning it counterclockwise and replace with a new one.
(3)LENS
Lights/Meters/Switches
Meter Removal/lnstallation
Requisite service
. Headlight removal/installation (page 16-3)

Procedure
Removal Order
Meter
connector
( I)
(2) Speedometer cable
(3) Speedometer mounting bolt
(4) Speedometer assembly
Q'W
Remarks
1
1
2
1
I
I
Meter Disassembly/Assernbly
(1) SCREWS
Remove the screws and disconnect the connectors.

ORS
\ I
Remove the meter rear cover and meter stay.
AN0 STAY
Pull the indicator bulbs out of the meter.

Remove the wire harness clamp.
Disconnect the meter terminals, and remove the wire harness.
(1) REAR COVERS
I:
1' ..
.
Assemble the meters in the reverse order of disassembly

NOTE
Connect the proper color wire to the meter terminals.
YIG : YellowIGreen
G : Green
BIBR : BlacklBrown
Tachometer Inspection
Remove the headlight assembly (page 16-31, and disconnect the 9P mini Black connector.
'
:a
Connect a voltmeter across the BlackJBrown (+) and Green

(-1 terminals of the main wire harness side.
Turn the ignition switch ON ; battery voltage should register.
If battery voltage dose not register, the electric tachometer is
not getting power. Trace and repair the related wiring, sub
fuse and/or connectors.
Disconnect the ICM connector.

Check for continuity between the YellowJGreen wire terminals of the 9P mini Black connector and the ICM connector.
There should be continuity in all cases.
If there is no continuity, replace the main wire harness.
If all checks are 0.K., replace the tachometer.
Side Stand Switch

Removal/lnstallation
Remove the fuel tank (page 2-4).
Disconnect the side stand connector.
(1) SIDE STAND CONNECTOR
Remove the side stand switch mounting bolt and the side
stand switch.
Install the switch in the reverse order of removal.
Torque : ION-m (1.Okg-m, 7.2ft-lb)
NOTE
Align the switch pin with the side stand hole and align
the switch groove with the side stand return spring
holding pin.
Route the side stand switch wire harness properly (page

1-25).
Neutral Switch
Remove the drive sprocket cover and disconnect the neutral
switch connector.
Check the switch for continuity between the light greenlred
wire terminal and ground first with the transmission in
neutral and then with the transmission in any gear.
For neutral switch replacement, refer to page 8-10, 12.
lgnition Switch Removal/lnstallation
Requisite Service
Meter removal/installation (page 16-5)
Headlight removal/installation (page 16-3).

Procedure
Removal Order
lgnition switch connector
lgnition switch mounting bolt
lgnition switch
Remarks
Remvoe the bolts using the tom bit T 4 0 (077030010100).

At installation.apply a locking agent to the threads.
MEMO
MEMO
18. Troubleshooting
Poor Performance At High Speed
Engine Does Not Start Or Is Hard

To Start
Engine Lacks Power
l8-'
Poor Handling
8-2 Hydraulic Tappet
Poor Performance At Low And Idle

Speeds
18-3
18-3
18-4
18-4
b g i n e ~ o e s~ o Stan
t
Or IS Hard TO Stan
Possible Cause
1 . Check fuel flow to carburetor
Not Reaching Carburetor
-.
-
~ e a i h i n gCarburetor
I
2. Perform a spark test
Clogged fuel tube or fuel strainel

Sticking float valve
clogged fuel tank breather
Disconnected or faulty auto fuel
valve vacuum tube
. Faulty spark plugs

. Fouled
spark plugs
Faulty ignition control module
. Broken or shorted spark plug wires
. Broken or shorted ingition coil
. Faulty ignition switch
. Faulty ignition pulse generator
- Faultv. enaine
stor, switch
. Loose or -disconnected ignition
Weak Or No Spark
Good Spark
system wires
I
3. Test cylinder Compression
Low Compression
-.-
Compression Normal
4. Start by following normal procedure-Engine Starts But Stops
I
~ n g i n eDoes Not Fire
-0
Valve stuck open

Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
lmproper valve timing
Improper choke operation
. Carburetor incorrectly adjusted

- Intake pipe leaking
. l m. ~ r.o ~ianition
e
- r timina (Faultv
ignition control moduleor igniion
pulse generator)
Fuel contaminated
5. Remove and inspect spark plug-
Wet Plug
-. Carburetor flooded
. Choke closed
. Throttle valve open
. Air cleaner dirty
Troubleshooting
Engine Lacks Power

Possible Cause
1. Raise wheels off ground and spin -Wheels

by hand
Do Not Spin Freely
Wheel Spins Freely
1 : .
2. Check tlre pressure
Pressure Low
*.
--
Brake dragging
Worn or damaged wheel bearings
Wheel bearings need lubrication
Drive chain too tight
Faulty tire valve
~re$sureNormal
I
3. Accelerate rapidly from low to -Engine Speed Not Changed When-.

second
Clutch is Released
Engine Speed Lowered When

Clutch is Released
I
1
Engine Speed Increases
4. Accelerate lightly
Engine Speed Does Not Increase-.
5. Check ignition timing
Incorrect
Clutch slipping
Worn clutch discstplates
Warped clutch discstplates
Weak clutch spring
Carburetor choke closed
-.
6. Check hydraulic tappet conditions -Incorrect
I
7. Test cylinder compression
1
Too Low
8. Check carburetor for clogging-
Clogged
Correct

Faulty ignition pulse generator
Correct
NOri"'
i
Clogged air cleaner

Restricted fuel flow
Clogged muffler
Pinched fuel tank breather
*.
-.
Clogged tappet oil holes

Worn valve seat
Damaged tappaet
Valve stuck open
Worn cylinder and piston rings
Leaking head gasket
Improper vlave timing
Caburetor not sewiced frequently
enough
Not Clogged
9. Remove spark plug
Plugs not serviced frequently
Fouled or Discolored-.
enough
Spark plugs are incorrect heat range
Not Fouled or Discolored
10. Check oil level and condition
*- Oil level too high

Oil level too low
Contaminated oil
Valve Train Not Lubricated

Properly
*- Clogged oil passage

Clogged oil control orifice
Correct
11. Remove cyl~nderhead cover andinspect lubrication
Valve Train Lubricated

Properly
I
!
18-2
Incorrect
Troubleshooting
12. Check for engine overheating Overheating
--
Not Overheating
13. Accelerate or run at high speed-
Engine Knocks
--
Engine Does Not Knock
Possible Cause
Excessive carbon build-up in combustion chamber
Use of poor quality fuel
Clutch slipping
Lean fuel mixture
Wrong type of fuel
Worn piston and cylinder
Wrong type of fuel
Excessive carbon build-up in combustion chamber
Ignition timing too advanced
(Faulty ignition control module)
Lean fuel mixture
Poor Performance At Low And Idle Speeds

1. Check ignition timing and
hydraulic tappet condition
lncorrect
Cor~ect
2. Check carburetor pilot screw

adjustment
Incorrect
--
--
Possible Cause
Tappet oil holes clogged
Tappet damaged
Improper ignition timing
(Faulty ignition control module)
See Fuel System Section
Correct
.I
3. Check for leaking intake pipe
I
No Leak
t
4. Perform spark test
Leaking
Loose insulator clamps

Damaged insulator
Weak or Intermittent Spark-.
Faulty, carbon or wet fouled spark

plug
Broken or shorted spark plug wires
Faulty engine stop switch
Fautly ignition switch
Loose or disconnected ignition
system wires
Good Spark
Poor Performance At High Speed

Possible Cause
1. Check ignition timing and

hydraulic tappet conditon
Incorrect
-.
Correct
2. Disconnect fuel tube at

carburetor
Fuel Flows Freely
Fuel Flow Restricted
--
Damaged hydraulic tappet

Clogged fuel line
Clogged fuel tank breather
Clogged fuel strainer
J
-
18-3
Troubleshooting
Possible Cause
3. Remove carburetor and check for-
Clogged
-.
Clean
clogged jets
I
Clogged
NO;
4. Check valve timing
Incorrect
Cam sprocket not installed properly
correct
5. Check valve spring
week
I
Not Weakened
Poor Handling
---Check
Faulty spring
-0
tire pressure
Possible Cause
1. If steering is heavy
-.
2. If either wheel is wobbling
-.
3. If the motorcycle pulls to one side
-.
Steering stem adjustment nut too

tight
Damaged steering head bearings
Excessive wheel bearing play
Bent rim
Improperly installed wheel hub
Swingarm pivot bearing excessively
worn
Bent frame
Faulty shock absorber
Front and rear wheels not aligned
Bent fork
Bent swingarm
Bent front axle
Hydraulic Tappet
Noisy Tappet
Possible Cause
1. Check for low oil level

Incorrect
Ride for five minutes with the engine
speed over 3.000 rpm
Check oil level and condition
-.. Contaminated
oil
Contaminated oil filter
I
~oll,ect
.I
I
2. Check oil pressure
Too Low
-.
Clogged oil control orifice

Oil level too low
Not Clogged
3. Remove cylinder head cover and--Not
Lubricated Properly
check lubrication
1.
4. Remove hydraulic tappet and check-Incorrect
Correct
Clogged oil passage
. Clogged oil pipes
Falty O-ring
--. Plunger
sticking
Faulty tappet
- Faulty one way valve
1.
' / -
Troubleshooting
Engine Lacks Power
Possible Cause
1. Turn the engine for a few seconds-Engine
with the starter
Starts
*.
Bubbles in engine oil when rewed

UP
~ngineDoes Not Start
2. Check 011pressure
Too Low
Oil level too low

Clogged oil passage
Contaminated oil
Contaminated oil filter
" O r r
3. Remove
t tappet and check
I-.
Incorrect
-.
Faulty tappet (Replace)
MEMO
19 . Index
Carburetor Combinatio
Clutch Installati
Crankshaft. Connecting Rod Installation...................

Remova
Cylinder Head
........................
Removalllnstallation..............................................
Cylinder, Piston Removal/lnstallation........................
Drive Sprocket Cover Removalllnstallation..............
Emission Control Information Labels...........................
Emission Control Syste
Engine Does Not Start Or Is Hard To Start ..............
Engine Lacks Power
Engine Removalllnstal
Exhaust System Remo
.........................
Fork Assembl
Front Brake Pad Replacement.......................................
Front Brake Caliper DisassemblyIAssembly .............
Front Master Cylinder DisassemblyIAssembly.........
Front Wheel Disassembly
Fuel Tank Removalllnstal
Gearshift Linkage Removalllnstallation......................
Oil Pump Disassembly/Assembly .................................

Removal/lnstallatio
Pilot Screw Adjustment(U.S.A.Only) ........................
4-4
4-3
5-12
Poor Performance At Low And Idle Speeds .............

Ignition Pulse Generator
Ignition Pulse Generator Removalllnstallation ........
Rear Brake Panel Disassemblv/Assemblv
..................
..
Rear Fairing Removalllnstallation...............................
Rear Wheel DisassemblylAssembly...........................
Removalllnstallatio
RegulatorIRectifie
Sewice lnformation
Brake Syste
Charging SystemIAlternator...............................
Electric StarterIStarter Clutch............................
Front WheelISuspensionlSteering...................
Rear WheelISuspension...................................
ClutchIGearshift Linkage .....................................
CrankshaftITransrnission.....................................
Cylinder HeadlCylinderlPiston ..........................
Engine Removalllnstallation...............................
FrameIBody PanelsIExhaust System ..............
18-3
14-7
14-8
12-7
~-.
2-4
11-4
11-2
13-6
2-3
3-2
12-1
13-1
15-1
10.1
11-1
8-1
9-1
7-1
6-1
2-1
Shock Absorber DisassemblylAssembiy....................

11-7
Removalllnstallatio
11-6
Side Cover Removal/lnst
..................................
2-3
Side Stand Switch
16-7
Specification
1-4
Starter Clutch DisassemblyIAssembly........................ 15-8
Starter Motor DisassernblyIAssembly......................... 15-6
Steering Stem Removallln
Swingarm Disassembly/Assembly ............................. 11-10
11-9
14-6
Svstem lnsoection
system ~odation
Charging System/Alternator...............................
13-2
15-2
IgnitionSystem
.....................................................
14-2
.
LightsIMeterslSwitches .......................................
16-2
Headlight Removal/lnstallation......................................
High Altitude Adjustment(U.S.A.Only) .....................
Hydraulic Tappet
Ignition Timing.....................................................................
Lubrication & Seal Point
Meter Disassembly/Assembly ........................................
Removalllnstallatio
Model Identification
Neutral Switch
Oil Pressure Check
Rernovalllnstallation..............................................
Troubleshooting
Brake System
Charging SystemIAlternator...............................
Clutch/Gearshifl Linkage ..................................
CrankshaftITransmission.....................................
Cylinder HeadICylinderlPiston .........................
FrameIBody PanelsIExhaust System ..............
Front WheelISuspensionlSteering...................
Fuel Syste
9-6
12-1
13-3
8-1
9-1
7-1
15-3
2-1
10-1
5-2
19-1
Index
Troubleshooting

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1(

Indicates a possibility of equipment damage if instructions are not followed.

Gives helpful information.

This servlce manual describes the servlce procedures for

Sections 1 and 3 apply to the whole motorcycle. Section

Date of Issue: December, 1990

Follow the Maintenance Schedule (Section 3)

If you don't know the source of the trouble, go to section

Most sections describe the service procedure through a

How to Use Thi

Finding Fhe Information You Need

This manual is divided into sections which cover each of

Understanding The Instructions

Replace the partlsl with new one(s1 before assembly.

Use special tool.

Use recommended engine oil, unless otherwise specified.

Use Fork or Suspension Fluid.

Lubrication & Seal Points

Cable & Harness Routing

Emission Control System

Emission Control Information Labels

Used Engine/Transmission Oil

kesl may cause skin cancer if repeatedly left i n

gas that can cause loss of consciousness and may

Gasoline is extremely flammable and is explosive

asbestos fibers have been found to cause

and remain hot forsome timeaftertheengine is run.

Avoid spilling engine coolant on the exhaust

Use only nitrogen to pressurizethe shock absorber.

Banery Hydrogen Gas & Electrolyte

The battery gives off explosivegases; kaepsparks.

(1) FRAME SERIAL NUMBER

( 1 ) The frame serial number is stamped on the right side of

(3)VEHICLE IDENTIFICATION NUMBER

(2)The engine serial number is stamped on the upper right

the Safety Certification Label on the left side of the

(4) COLOR CODE LABEL

(4) The color label is attached as shown. When ordering

15) The carburetor identification number is stamped on the

Dimensions Overall length

Bore and stroke

Constant vacuum 4 carburetors

Left foot operated, return system, 1-N-2-3-4-5

Engine oil capacity at draining

2.7 lit. (2.8 USqt, 2.4 Imp qt)

I Other viscosities shown in the chart may I

be used when the average temperature

Oil pressure (80'C/176'F)

630 kPa (6.3 kg/cm2, 90 psi) at 6,000

Oil pump rotor tip clearance@)

See page 5-1 2

981 -1 373kPa(142-199ps1,10-14kg/cm) 250/rpm

Cylinder compression synchronization difference

Camshaft journal 0.0. (A)

"IN" mark facing toward the intake side

0.01 -0.050 (0.0003-0.001 9)

Crankpin oil clearance

Countershaft O.D. at C1 gear

Transmission gear I.D. M5