Manual de Taller CRF 450 X 2005 2012 PDF

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HOW TO USE THIS MANUAL CONTENTS
ThtS service manua l descnbes th e serv ice procedures tor the
CRF450X. GENERAL INFORMATION
Follow Ihe Ma in tenance Schedule (Sedoon 4) recommenda tions to
ensure that the ve hicle is ,n pea~ operahng cond ition and the emIssion
1ev€ls are withi", the standards set by the U.s. Environrmmta l
ProtecTion Ag<lncy (EPA) and Calrlo,ma Air Resources Board (CARB).
Pertorm,ng the '"5\ schedUled maintenance '5 very imiX'ftant. It

compensales for the IniMI Wear that occurs during the break.,n
period. MAINTENANCE
Sections 1 and 4 apply to the whole motorcycle. Section 3 Illustrates
procedures lor remDValli nstaliatlOn of components that may t>e LUBRICATION SYSTEM
required to perlorm service described in Ihe lolJow ,ng sections.
Section 5 through 20 describe parIs of the motorcycle, grouped
..
accord,ng to location. FUEL SYSTEM
z
Find the section you wa nt on This page, then tu rn to the table 01
conlents on the lirst page 01 the section. a: COOLING SYSTEM
Most sectiOils start wit h an assembly or system illustrahon. 5elVlCe w
inlormation and troubleshooting lor the section. The subsequent > ENGINE REMOVAUINSTALLATION
pages give detailed procedu re . a:
c CYLINDER HEADNALVES
It you are not fam il iar with Ihis mo torcycle. read Technicat Featu re in c
Sectron 2. z
z"
If you don't know tile source 01 the Irouble, go to section 22
CYLINDER/PISTON
w
TrouOleshootlng.
Your satety. and the safety of others. Is very impol1a n1. To he lp

you ma~e informed decisions we haWl provided safety
messages and other information throughout this manual. Of
"z
w
ALTERNATOR
course. il is not practical or poSSible to warn yo u about all the
haza rds associated with servicing th is I'€hicle.
You must use your own good judgement
You will find important safety Inform ation In a ~ariety 01 torms
induding: FRONT WHEEl/SUSPENSION/STEERING
<J)
• Safety Labe ls - on the vehicle
• Safety Messages - preceded by a safety alert symbol Land iii
one 01 three stgnal words. DANG ER , WARNING . or CAU·
<J) REAR WHEEUSUSPENSION
TION .
These srgn~1 words mean: "
:I:
,:;
r.'.l.Jdf1:h'
• You WILL be KILLED or SERIOUSLY
HUI'1T if you don't follow Inst ructions. " HYDRAULIC BRAKE
BATTERY/CHARGING SYSTEM
fflZQ;@IUt. You CAN be KILLED or SERIOUSLY
HURT if you don't follOW onstructions.
..J
IGNITION SYSTEM
"lMm[,)?' You CAN be HURT ~ you don't follow
instructions "a:
~
ELECTRIC STARTER
• Instructions - how to ser~lce this ~ehicle correctly and safely, t;
w
AS you read this manual, you will find information that IS pl'€ceded by a ..J LIGHTS/METER/SWITCHES
l..NOnro symbol. The purpose of thi s message IS to help prev!ml
W
damage to your I'€hlCle, other property, or Ihe (lflVlfOnment
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
¢l'P
...- Replace the part(s) with new one(5) before assembly.
""78 Use the recommended engine oil, unless otherwise specified.
-, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1: 1) .
•..s;;;m. Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
~ Example: Moly\<oteJ!l BR-2 plus manufactured by Dow Corning U.S.A.

Multi-purpose M-2 manufactured by Milsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A.
~ Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Racol Limited, U.K.
Rocol Paste manufactured by Sumico lubricant, Japan
...-'iiSitI Use silicone grease.
Dum Apply a locking agent. Use a medium strength locking agent unless otherwise specified .
.,('Illll! Apply sealant .
Use DOT 4 brake fluid. Use the recommended brake lIuid unless otherwise specified .
.. Use fork or suspension fluid.
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1. GENERAL INFORMATION
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SERVICE RULES ··· .. ·· ...... ········ .. ·················· 1-2 REAR WHEEL/ SUSPENSION
SPECIFICATIONS ································.... ·1 ·11
MODEL IDENTIFICATION ··· ········ ················ 1-2
HYDRAULIC BRAKE SPECIFICATIONS ··· 1-12
GENERAL SPECIFICATIONS ······················ 1-5
BATTERY/ CHARGING SYSTEM
LUBRICATION SYSTEM SPECIFICATIONS ············· ························ 1· 12
SPECiFiCATIONS ········· ······ ··· ······················1 -7
IGNITION SYSTEM SPECIFICATIONS ·· ·· 1· 12
FUEL SYSTEM SPECIFICATIONS ···· ·········· 1·7
ELECTRIC STARTER SPECIFICATION ····· 1·13
COOLING SYSTEM SPECIFICATIONS ······1·7
LIGHTS/ METER/SWITCHES
SPECIFICATIONS ..................................... 1-13
CYLINDER HEADIVALVES
SPECIFICATIONS ········································ 1·8
STANDARD TORQUE VALUES··············· 1· 14
CYLINDER/ PISTON SPECIFICATIONS ...... 1·8
ENGINE & FRAME TORQUE VALUES···· 1·14
CLUTCH/STARTER CLUTCH /
KICKSTARTER / GEARSHIFT LINKAGE LUBRICATION & SEAL POINTS ···· ·· ········ 1·21
SPECiFiCATIONS ····· ··································· 1-9
CABLE & HARNESS ROUTING
CRANKCASE/ CRANKSHAFT/ ('OS - ·07) ············· .. ··············· ····················· 1·25
TRANSMISSION / BALANCER
SPECIFICATIONS (,OS - ·07)-······················ 1-9 CABLE & HARNESS ROUTING
IAfter '07) .......... ........................................ 1·32
CRANKCASE/CRANKSHAFT/
TRANSMISSION / BALANCER OPTIONAL PARTS··· .. ············ ················· ·· 1·37
SPECIFICATIONS IAfter ·07) ······· ········· ···· 1· 10
EMISSION CONTROL SYSTEMS ............ 1-40
FRONT WHEEL/ SUSPENSION/ STEERING
SPECIFICATIONS ······································ 1· 11
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-re commended parts and lubricants or their equivalents. Parts that do not meet
Honda 's design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
English fastener.
4. Install new gaskets, O'rings, cotter pins. and lock plates when reassembl ing.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. lubricate any sliding surfaces before reassembly.
7. After reassembly, check all pans for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing.
- '05 - '07: (page 1-25)
- After '07: (page 1-32)
MODEL IDENTIFICATION
'05 - '07 shown:
1-2 •
GENERAL INFORMATION
The Vehicle Identification Number IV.I.N.) is stamped on the right side
of the steering head.
The engine serial number is stamped on the left side of the lower ~~=~~~~~~~~~~~~~~---,
crankcase.
ENGINE SERIAL NUMBER

The carburetor identificat ion number is stamped on the left side of the
ca rburetor body.
The name plate (U.S.A.) or Safety Certification Label (Canada) is

attached on the right side of the fr ame.
1-3
GENERAL INFORMATION
The Vehicle Emission Control Information label is attached on the rear
fender ('05 - '06 California type, '07 U.S.A.!. '05 - '06 California type, '07 U.S .A. :
/'
DO ~
~:/~~ "
EMISSION CDNTROllNFORMATION LABEL
The Vehicle Emission Control Information label is attached on the rear
fender (After '07 U.S .A. and Canada). After '07 U.S.A. and Canada:
/ada type only
;:...-
~"-
~ ~V
~~ ~
~:/~
EMISSION CONTRO~NFORMATION LABEL
1-4 •
GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECIACATION
DIMENSIONS Overall length ('05 - ' 07) 2,180 mm (85.8 in)
(After ' 07) 2,179 mm (85.8 in)
Overall width 82 1 mm (32.3 in)
Overall height 1,273 mm (50.1 in)
Wheelbase 1'05 - '07) 1,483 mm (58.4 in)
(After '07) 1,480 mm (58.3 i n)
Seat height 963 mm (37.9 in)
Footpeg height 43 1 mm (17.0 in)
Ground clearance 345 mm (13.6 in)
FRAME Frame type Twin tube
Front suspension Telescopic fork
Front suspension axle travel 279 mm (" .0 i n)
Front suspension cushion stroke 315 mm (12.4 in)
Rear suspension Pro-link
Rear w heel travel 313 mm (12.3 in)
Rear damper Decarbon type with nitrogen gas filled
damper
Front tire size 80/100· 21 5 1 M
Rear tire size ,,0/100·1884M
Tire brand (Dunlop) ('05- '07) Front: D742F
(After '07) Front: D742FA
Rear: 0756
Front brake Hydraulic single disc
Front brake swept area 334.5 cm 2 (51.8 in 1 )
Rear brake Hydraulic sing le disc
Rear brake swept area 391.1 cm! (60.6 1n2)
Caster angle ('05 - '07) 27" 10'
(After '07) 27°03'
Trail length ('05 - '07) 110 mm (4.3 in )
(After '07) 114.7 mm (4.52 in)
Fu el tank capacity ('05 - '07) 8.6 liter (2.27 US gal, 1.89 Imp gal)
(After '07) 7.2 liter (1.90 US gal, 1.58 Imp gal)
Fu el tank re serve capacity ('05 - '07) 1.4 liter (0.37 US gal, 0.31 Imp gat)
(After '07) 1.6 liter (0.42 US gal, 0.35 Imp gat)
ENGINE Bore and s1roke 96.0 x 62.1 mm (3. 78 x 2.44 in)
Displacement 449 cm' (27.4 cu· in)
Compressi on ratio 12.0 : 1
Valve train Chain dr ive and OHC w ith rocker arm
Intake valve opens at 1.0 mm (0.04 in) lift 10" BTOC
closes at 1.0 mm (0.04 in) lift 45" ABDC
Exhaust valve opens at 1.0 mm (0.04 in) lift 50" BBOC
closes at 1.0 mm (0.04 in) lift 15" ATOC
Lubricatio n system Forced pressure and wet sump
Oil pump type Troch oid
Cooling system Liquid cooled
Air filtration Oiled polyu rethane foam
Crankshaft type Assembled type
Engine dry weight 32.3 kg (71.2 IbsJ
Cylinder arrangement Sing le cylinder, inclined 6" from vertical
CARBURETOR Carbu retor type Piston valve type
Venturi diameter 40 mm (1.6 in)
1-5
GENERAL INFORMATION
ITEM SPECIFICATION
DRIVE TRAIN Clutch sy stem Multi-plate, wet
Clutch operation system Cable operated
Transmission Constant mesh, 5-speed
Primary reduction 2.739 (63123 )
Final reduction
Gear ratio ,,, 3.923 (51 /13)
2.230 (29/13)
2nd 1.625 (26116)
3,d 1.235 (2 1/17)
. th lOOO ( 19119 )
5th 0.826 (19123)
Gearshift panern Left foot operated return system,
l -N-2 - 3 - 4 - 5
ELECTRICAL Ignition system leM (Ignition Control Module)
Starting system Electric starter motor and kickstarter
Charging system Si ngle phase output alt ern ator
Regu lato r/rectifier SeR shorted/Single phase, half wave
rectificat ion
lighting system Alternator
'·6 •
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
iI i i
Canada) or equivalent motor oil

API seNice classification: SG or Higher
JASO T 903 standard: MA
Canada) or equivalent motor i

API seNice classification: SG or Higher
SAE lOW-3D
I pump
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Fuel tank capacity '05 '07 8.6 liter (2.27 US gal. 1.89 Imp gal)
After '07 7.2 liter (1.90 US gal. 1.58 Imp gal)
Carburetor identification number '05, '06 FCR04A
'07 FCR13A
After '07 FCR13B
Main jet '05 - '07 #142
After '07 #145
Slow jet #45
Jet needle '05, '06 NCVU
'07 NHTU
After '07 NNEU
Jet needle clip position (Standard) '05, '06 2nd position from the top
Afte r '06 Fixed position
Pilot screw initial opening '05 '07 '·114 turns o ut
After '07 1-1/8 turns out
Float level 8.0 rnm (0.31 in)
Idle speed 1,700 ± 100 rpm
Throttle grip 'reeplay 3 5mm(1/8-3116in)
Hot starter lever freeplay 2 3 mm (1 116 118 in)
PAIR control valve specified vacuum
56 kPa (420 mmHg)
('05 and '06 California type, After '06)
Throttle position sensor (Blue Black) resistance
4 -6 kO
(at 20°CJ68 ~ F)
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Coolant capacity At change 1.21 liter (1.28 US qt 1.06 Imp qt)
At disassembly 1.45 liter (1.53 US qt, 1.28 Im p qt)
Radiator cap relief pressu re 108 - 137 kPa (1. 1 1.4 kgf/cm , 16 - 20 psi)
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethyl-
ene glycol antifreeze containing silicate-free corrosion
inhibitors
Standard coolant concentration 1 : 1 mixture with distilled water
1-7
GENERAL INFORMATION
CYLINDER HEADIVALVES SPECIFICATIONS
"
valve guide
EX 17.9-18.1(0.70-0.71)
I.
CYLINDER/PISTON SPECIFICATIONS
Top 0.065 - O. lOa (0.0026 - 0.0039) 0.'15 (0.0045)
0.20 - 0.70 (0.008 - 0.028) 0.90 (0.035)
1-8 •
GENERAL INFORMATION
CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
SPECIFICATIONS
Unit: mm )
'. gear
gear
gear
CRANKCASE/CRANKSHAFT /TRANSMISSION/BALANCER
SPECIFICATIONS ('05 - '07)
i i
,,
'.
clearance
C2 0.020 - 0.062 (0.0008 - 0.0024) 0.12 (0.005)
fork shaft
1-9
GENERAL INFORMATION
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
•
SPECIFICATIONS (After '07)
Unit: mm
I I
clearance
M5, C2, C3 0.020 - 0.062 (D.OOOS - 0.0024) 0.12 (0.005)

;
fork
I .
•
1-10 •
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
0'
0'
(After '
i, 9 clicks out from full in
REAR WHEEl/SUSPENSION SPECIFICATIONS
i I
absorber
20.0 - 24.0 kgf (44. 1 - 52.9 Ibf)
j j
I i
10 clicks oul from full in
j j
1-11
GENERAL INFORMATION
HYDRAULIC BRAKE SPECIFICATIONS
Fi~m~~~~;==R79~.6
mm (3.13 in)
BATTERYICHARGING SYSTEM SPECIFICATIONS
•
Below 12.4 V
i cur-
IGNITION SYSTEM SPECIFICATIONS
I ;
resistance
(at 20° CJ68~F)
I
I
I
, 4 - SkO
I
1-12 •
GENERAL INFORMATION
ELECTRIC STARTER SPECIFICATION
ITEM STANDARD SERVICE UMIT
Starter motor brush length 10.25 (0.404) 6.75 (0.266)
LIGHTS/METER/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Headlight 12V 35W
Tail light LED
Fuse 15 A
,
\
r
\
1-13
GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N 'm (kgf'm, Ibf.ft) N·m (kgf·m. Ibf·ttl
5 mm hex bolt and nut 5.2 (0.5, 3.81 5 mm screw 4.2 (0.4, 3.11
6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt
10 mm hex bolt and nut 34 (3.5, 25) (8 mm head) 9.0 (0.9, 6.6)
12 mm hex bolt and nut 54 (5.5, 40) 6 mm flange bolt
(10 mm head) and nut 1211.2,9)
8 mm fla nge bolt and nut 2712.8, 20)
10 mm flange bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners .
• Others should be tightened to standard torque values listed above.
NOTE:
1. Apply oil to the threads and seating surface.
2. Apply locking agent to the th reads.
3. Stake.
4. U·nut
5. AlOe bolt/screw; replace with new one.
6. Loosen the bolt 118 to 1/4 turns after tightening it to the specified torque, then tighten the pivot nut.
7. Apply grease to the threads.
8. uas nut
9. After '07: Apply molybdenum disulfide grease (T8190 1 or equivalent) to the threads.
lO.Apply Honda Hondalock 3 or equivalent high strength locking agent to th e threads.
ENGINE
MAINTENANCE
THREAD TORQUE
ITEM Q'TV REMARKS
Engine oil drain bolt ,, OIA. (mm)
8
N'm (kgf·m. Ibf.ftl
16 (1.6, 12) NOTE 1
,,,
Transmission oil drain bolt 8 16 (1.6, 12) NOTE 1
Transmission oil check bolt 6 10 (1.0. 7)
Crankshaft hole cap 30 15(1.5,11) NOTE 7
Decompressor adjuster lock nut
Spark plug
('05 - '07)
, ,.
5 10 (1.0, 7)
2212.2,16)
NOTE 1
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Oil jet mounting bolt , DIA. (mm)
6
N'm (kgf'm , Ibf.ftl
10 (1.0, 7) NOTE 2
1-14 •
GENERAL INFORMATION
FUEL SYSTEM
THREAD TORQUE
ITEM O'TV REMARKS
DIA. (mm) N'm (kgf'm, Ibf·ftl
Throttle drum cover bolt 1 5 3.4 (0.3, 2.5)
Needle jet 1 7 1.8 (0.2, 1.3)
Main jet 1 5 1.5 (0.2, 1. 1)
Slow jet 1 10 1.5 (0.2, 1.1)
Slow air jet ('05 - '07) 1 5 0.9 (0. 1, 0.7)
Starter jet 1 5 1.5 (0.2, 1,1)
"
, Ace. pump bypass
Carbu retor top cover bolt
Throttle shaft screw ('OS, '06)
1
2
1
4
4
4
0.3 (0.03, 0.2)
2.1
2.1
(0.2, 1.5)
(0.2, 1.5) NOTE 2
Throttle shaft torx screw (After '06) 1 4 2.1 (0.2, 1.5) NOTE 2
Float chamber screw 4 4 2.1 (0.2, 1.5)
Accelerator pump cover screw 3 4 2.1 (0.2, 1.5)
Carbu retor drain plug 1 18 4.9 (0.5, 3.6)
Carburetor drain screw (After '05) 1 6 1.5 (0.2, 1.1)
'. Choke valve lock nut 1 12 2.1 (0.2, 1.5)
Hot start valve lock nut 1 12 2.1 (0.2, 1. 5)
Needle holder 1 8 2.1 (0.2, 1.5)
Throttle position sensor torx screw (,05, '06) 1 5 3.4 (0.3, 2.5)
Throttle position sensor bolt (After '06) 1 5 3.4 (0.3, 2.5)
COOLING SYSTEM
THREAD TORQUE
ITEM O'TV REMARKS
DIA. (mm) N'm (kgf'm, Ibf.ft)
Water pump im peller 1 7 12 (1.2, 9)
ENGINE REMOVAl/INSTALLATION
THREAD TORQUE
ITEM OTI DIA. lmmJ N'm (kgf'm, Ibf·tt)
REMARKS
Drive sprocket bolt 1 8 31 (3.2, 23)
THREAD TORQUE
ITEM O'TV REMARKS
DIA. lmm) N'm (kgf'm , Ibf.ftJ
Cylinder head cover bolt 3 6 10 (1.0, 7)
Camshaft holder mounting bolt 4 6 14 (1.4, 10) NOTE 1
Decompressor l ifter arm mounting
o u1
Decompressor cam mounting bolt
('05 - '07)
('05 - '07) ,
1 8
8
22 (2.2, 16)
24 (2.4, 18)
NOTE 1
NOTE 1
Cylinder head nut 4 10 66 (6.7, 49) NOTE 1
Cam sprocket bolt 2 7 20 (2.0, 15) NOTE 2
CYLINDER/ PISTON
THREAD TORQUE
ITEM O'TV REMARKS
DIA. (mml N'm (kgf.m, Ibf·tt)
Cam chain tensioner lifter mounting bolt 2 6 12 11.2, 9)
Cylinder stud bolt 4 - - See page '·17
CLUTCH/ STARTER CLUTCH/ KICKSTARTER/ GEARSHIFT LINKAGE
THREAD TORQUE
ITEM O'TV REMARKS
DIA .(mm) N'm (kgf'm, tbf·tt )
Gearshift drum center pin 1 8 22 (2.2, 16) NOTE 2
Gearshift drum stopper arm bolt 1 6 12 (1.2, 9)
Clutch center lock nut 1 18 SO (S.2, 59) NOTE 1
Clutch spring bolt 6 6 12 (1. 2, 9)
Gearshift retu rn spring pin 1 8 22 (2.2, 16)
Gearshift pedal pinch bolt 1 6 12(1.2,9)
l Kickstarter pedal bolt
Primary drive gea r bolt
1
1 12
8 3S (3.9, 28)
108 (11.0, 80) NOTE 1
Starter gear holder mounting bolt 3 7 18 (1.8, 13) NOTE 1
1-15
GENERAL INFORMATION
'.
ALTERNATOR
THREAD TORQUE
ITEM an DIA. /mm) N 'm (kgf'm , Ibf·ft)
REMARKS
Flywheel nut 1 12 6416.5,471 NOTE 1
Ignition pulse generator mounting bolt 2 5 5.2 (0.5, 3.8) NOTE 2
Stator mounting bolt 3 5 4.7 !O.5, 3.5) NOTE 2
CRANKCASE/ CRANKSHAFT/ TRANSMISSION/ BALANCER
THREAD TORQUE
ITEM a'TV
DIA.(mm)
REMARKS
N'm (kgf'm, Ibf.ft)
Crankshaft bearing set p late torx 1'05 '07) 2 6 10 (1.0, 7) NOTE 10
screw
Countershaft bearing set plate screw
Gearshift drum bearing set plat e bolt
(After '07) 2
2
2
6
6
6
20 (2.0, 15)
10 (1.0, 7)
10 (l O, 7)
NOTE 10
NOTE 2
NOTE 2
•
Mainshaft bea ring set plate bolt 2 6 10 (1.0, 7) NOTE 2
Balancer shaft bearing set plate bolt 2 6 10 (to, 7) NOTE 2
Balancer shaft nut 1 14 44 (4.5, 32) NOTE 1
Cam chain tensioner bolt 1 6 12 (1.2. 9) NOTE 2
IGNITION SYSTEM
THREAD TORQUE
ITEM a 'TV REMARKS
DIA. (mm) N'm (kgf'm, IbUt)
Timing hole cap 1 14 10 (lO, 7) NOTE 7
ELECTRIC STARTER
THREAD TORQUE
ITEM a 'TV REMARKS
DIA.(mm) N'm (kgf'm , Ibf.ft)
Starter motor case bolt 2 4 3.4 (0.3, 2. 5)
1-16 •
GENERAL INFORMATION
Insulator band :
'05 - '07: Cylinder head and ca r buretor side.
12.0 ± 1.0 mm (0.47 ± 0.04 in)
After '07: Ca rburetor side.
Cylinder head side insulator band (After '07):

9.0 ± 1.0 mm (0.35 ± 0.04 in)
Cylinder stud bolt:

'2
g
-
w
m
in
~
ci
"" '33"
KTi
0
M
.n
E
E ,.
;;;
~
"""
~
~
0
,.'"
~ 0
Water hose clamp:

~
~
- ---- , -- , ,
,,
,,
,,,
~
,,
- ---- -- ,
+
,
t 0 - 1.0 mm (0 - 0.04 in)
I
~
1-17
GENERAL INFORMATION
FRAME
FRAME/BODY PANELS/ EXHAUST SYSTEM
THREAD TORQUE
ITEM a'TV REMARKS
DlA .{mm) N 'm (kgf'm , Ibf.ft)
Seat mounting bolt 2 B 2612,7, 19)
Sub-frame upper mounting bolt ('05 - '07) 2 B 30 (3.1, 22)
Sub-frame lower mounting bolt 1'05 - '07) 2 10 4915.0, 36)
Sub-frame upperl10wer mounting
bolt (After '07) 4 10 49 (5.0, 36)
Seat bracket screw 1 5 4 (0.4, 3.0)
Tank band hook screw
Muffler joint band bolt
Muffler mounting bolt
1
1
2
5
B
B
4 (0.4, 3.0)
21 (2.1, 15)
26 (2.7, 19)
•
Exhaust pipe joint nut 2 B 2112. 1, 15)
Heat shield bolt 2 6 12 (1.2, 9)
Exhaust pipe protector bolt 2 6 12 (1.2. 9)
Diffuser mounting tOf'}( screw ('05 - '07) 1 5 ll0.l,8)
Radiator shroud upper mounti ng bolt 4 5 5 (0.5, 3.7)
Rear fender mounting bolt 4 6 13 (1.3, 10)
MAINTENANCE
THREAD TORQUE
ITEM a'TV REMARKS
OlA. (mm) N·m (kgf·m. Ibf.ft)
Sidestand pivot bolt 1 10 See page 4· 34 NOTE 6
Sidestand pivot nut 1 10 39 (4.0, 29) NOTE 4
Throttle cable adjuster lock (throttle side) 1 7 4 (0.4, 3.0)
nut (carburetor side) 1 6 4 10.4, 3.0)
Spark arrester mounting bolt ('05- '07) 4 6 12 (1.2, 9)
(After '07) 4 6 6 (0.6, 4 .4) NOTE 9
FUEL SYSTEM
THREAD TORQUE
ITEM a 'TV REMARKS
DIA. lmmJ N 'm (kgf'm , IbUt)
Throttle bolt (carburetor side) 1 6 410.4,3.0)
PAIR control valve mounting nut 2 6 13 (1.3, 10)
THREAD TORQUE
ITEM a 'TV REMARKS
DIA. (mmJ N ·m (kgf'm , Ibf.ft)
Engine hanger plate bolt 4 B 26 (2.7, 19)
Engine mou nt ing nut (front) 1 10 54 (5.5, 40)
(u pper ) 1 10 54 (5.5, 40)
(lower) 1 10 54 15.5, 40)
1-18 •
GENERAL INFORMATION
FRONT WHEEU SUSPENSION/$TEERING
THREAD TORQUE
ITEM Q'TY REMAR KS
DIA. (mm ) N'm (kgf'm, Ibf·ft)
Front axle nut 1 16 88 (9.0. 65)
Front axle holder bolt 4 8 20 (2.0. 15)
Front spoke 36 BC3.5 3.68 (0.4, 2.71
Front rim lock 1 8 12 (1.2. 9)
Front brake disc nut 6 6 16 (1.6,12) NOTE 4
Steering stem nut 1 26 108 '11.0, 80)
Steering stem adjusting nut 1 30 See page 14·51
Fork top bridge pinch b olt 4 8 22 (2.2. 16)
Fork bonom bridge pinch bolt 4 8 20 (2.0, 15)
Fork cap 2 39 30 (3. 1, 22)
Fork center bolt 2 22 69 (7.0, 51)
Fork center bolt lock nut 2 12 22 (2.2, 16)
Pressu re release screw 2 5 1.2 (0. 1, 0.9)
Fork damper 2 50 34 (3.5, 25)
Fork protector mounting bolt 6 6 7 (0.7, 5.2) NOTE 2
Front brake disc cover bolt 2 6 13 (1.3,10)
Handlebar upper holder bolt 4 B 22 (2.2, 16)
Handl ebar lower holder nut 2 10 44 (4.5, 32) NOTE 4
Clutch lever pivot bolt 1 6 See page 14-52 NOTE 6
Clutch lever pivot nut 1 6 10 (1.0, 7) NOTE 4
Eng ine stop button screw 1 4 1.5 (0.2, 1.1 )
Eng ine starter switch housing screw 2 4 1.15 (0.1,0.8)
Thronle bolt (thronle side) 1 6 4 (0.4, 3.0)
Tripmeter cable clamp screw 2 4 0.7 (0.1, 0.5)
Steering damper mounting bolt (After '07) 2 7 20 (2.0, 15) NOTE 2
REAR WHEEL/ SUSPENSION

THREAD TORQUE
ITEM a 'TY REMARKS
DIA. (mmJ N 'm (kgf' m , IbUt)
Rear axle nut 1 22 128\13. 1, 94) NOTE 4
Rear spoke 32 4.5 3.7 (0.4, 2.7)
Rear rim lock 1 8 12 (1.2, 9)
Rear brake disc nut 6 6 16 (1.6, 12) NOTE 4
Driven sprocket nut 6 8 32 (3.3, 24) NOTE 4
Rear wheel bearing retain er 1 50 44 (4.5, 32)
Swingarm pivot nut 1 14 88 (9.0, 65) NOTE 4
Shock arm nut (swingarm side) 1 12 53 (5.4, 39) NOTE 1,4
(shock link side) 1 12 53 (5.4, 39) NOTE 1,4
Shock link nut (frame side) 1 12 53 (5.4, 39) NOTE 1,4
Shodc abso rber upper mounting nut 1 10 44 (4.5, 32) NOTE 4
Shodc abso rber lower m ounting nut 1 10 44 (4.5, 32) NOTE 4
Shodc absorber spring lock nut 1 60 44 (4.5. 32)
Orive chain slider screw 3 5 4.2 (0.4. 3. 1) NOTE 2
Drive chain roller bolt 1 B 12 (1.2. 9)
Drive chain roller nut 1 6 12 (1.2.9) NOTE 4
Drive chain guide m ounti ng bolVnut 2 6 12 (1.2. 9) NOTE 4
Drive chain adjuster lock nut 2 8 27 (2.8, 20) NOTE 8
Shock absorber damper rod end nut 1 12 37 (3.8, 27) NOTE 3
Shock absorber compression dampi ng adjuster 1 27 29 (3.0. 21) NOTE 3
left step bracket m ounting (u pper) 1 12 55 (5.6, 41)
bolt (lower) 1 8 30 (3. 1. 22)
1-19
GENERAL INFORMATION
HYDRAULIC BRAKE
THREAD TORQUE
ITEM a 'TY REMARKS
CIA. (mm) N 'm (kgf·m. Ibf.ft)
Brake hose oil bolt 4 10 34 (3.5, 25)
Brake lever adjuster lock nut 1 5 5.9 (0.6, 4.41
Brake lever pivot nut 1 6 5.9 (0.6, 4.4)
Brake lever pivot bolt 1 6 lOIO.1.a.7 )
Front brake hose guide bolt 2 6 5.2 (O.5, 3.B)
Rear brake hose guide screw 6 5 1.2 (0.1,0.91
Front master cylinder reservoi r cover screw 2 4 1.0 (0.1, 0.7)
Front master cylinder holder bolt 2 6 9.9 (lO, 7.3)
Front b rake caliper mounting bolt 2 8 30 (3.1, 22) NOTE 2
Front/rear caliper bleed valve 2 8 5.4 (0.6, 4.0)
Rear master cylinder mounting bolt 2 6 13 (1.3, 10)
Rear master cylinder reservoir cover bolt 2 4 1.0 (0. 1. 0.7)
Front caliper pin bolt 1 8 22 (2.2, 16) NOTE 2
Rear caliper pin bolt 1 12 27 (2.8, 20)
Brake cali per pad pin 2 10 18 (1.8,13)
Front brake caliper pad pin plug 1 10 2 (0.2, 1.5)
Front caliper bracket pin bolt 1 8 22 (2.2, 16) NOTE 2
Rear cali per bracket pin bolt 1 8 12 (1.2,9) NOTE 2
Brake pedal pivot bolt 1 10 36 (3.7, 27) NOTE 7
Brake pedal adjuster lock nut 1 6 5.9 (0.6, 4.4)
LIGHTS/METER/SWITCHES
THREAD TORQUE
ITEM a 'TY REMARKS
DIA. (mm) N 'm (kgf'm , Ibf·ft)
Headlight mounting screw 2 5 0.7 (0. 1, 0.5)
Taillight mounting screw 2 5 4.2 (0.4, 3.1)
Taillight wire clamp screw 2 4 0.7 (0.1, 0.5)
OTHERS
THREAD TORQUE
ITEM a'TY REMARKS
DIA.(mm) N 'm (kgf'm, Ibf·ft )
Right step bracket mounting (upper) 1 12 55 (5.6, 41 )
bolt (lower) 1 8 30 (3.1, 22)
1-20 •
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
LOCATION MATERIAl REMARKS
Decompressar shaft 20.9 mm and 14 mm 0.0. areas Use molybdenum oil solu-
!Atter '07) tion (mixture afthe engine
Decompressar p lunger slidi ng area (After '07) oil and molybdenum
Camshaft journal and lobes grease with the ratio 1009
Rocker arm bore and valve slipper surfaces : 70ce)
Valve stem (valve guide sliding surface)
Valve stem end sliding surface
Valve lifter outer surface
Clutch outer guide inner surface
Clutch outer needle bearing roll ing area
Clutch lifter lever cam area
Kickstarter pinion gear inner surface
Kickstarter spindle spline area and gea r rollin g area
St arter gea r holde r gea r rolli ng su rface
Connecti ng rod big end sliding area
Connecting rod small end inner surface
Transmission gear spline area, rolling area and sliding
surface
Shift fork gear guide area and guide pin area
Shift fork sl iding surface
Shift fork shaft outer surface
Each gear sliding surface
Mainshaft spline area and sliding surface Use molybdenum oil solu-
Countershaft spl ine area and sliding surface tion (mixtu re of the engine
oil and molybdenu m paste
with the ratio 1 : 1)
Camshaft holder mounting bolt threads Engine oil
Cylinder head nut threads and seating surface
Balancer shaft nut threads
Piston outer surface and piston pin hole
Piston pin outer surface
Piston rings
Cylinder bore
Decompressor cam mounting bolt th reads ('05 - '07)
Decompressor lifter arm mounti ng nut threads and
seating surface ('05 - '07)
Decompressor adju ster lock nut th reads {'OS - '07)
Clutch lifter and lifter rod sl iding area
Clutch lifter piece need le bearing
Clutch disc linings and plates
Clutch center lock nut threads and seating surface
Clutch outer sliding surfaces
Engine oil drain bolt th reads and seating surface
Plug hole seal circumference
Primary drive gear bolt threads
One-way clutdl out er su rface
Starter clutch ou ter sliding surface
St arter dr iven gear slid ing surf ace
Starter gea r holder mounting bolt threads
Flywheel nut threads and seat ing surface
Transmission gear teeth
Transmission oil drain bolt threads and seating surface
Shift drum guide grooves
Gearshift spindle serration area
Oil pump rotors sliding area
\ Kickstarter spindle journal 115 mm 0.0.)
Crankshaft oil seal outer surface
Each bearing
Each O-ring
1-21
GENERAL INFORMATION
LOCATION MATERIAL REMARKS
Crankshaft hole cap threads Mu lti-purpose grease
Timing hole cap threads
Countershaft collar D-ring
Armature shaft end
Each oil seal lips
Dust seal lips
Oil fitter spring contact area
•
Mechanical seal Ii 5
Gearshift drum center pin bolt threads locking agent
Stator mounting bolt threads Coating width: 4.5 ± 1.0 mm
(0.18 ± 0.04 in) from tip
Ignition pulse generator mounting bolt threads Coating width: 4.5 ± 1.0 mm
(0.18 ± 0.04 in) from tip
Cam sprocket bolt threads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Balancer shaft bea ring set plate bolt threads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Mainshaft bearing set plate bolt threads
Gearshift drum bearing set plate bolt threads
Countershaft bearing set plate screw threads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Cam chain tensioner bolt threads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Throttle shaft screw threads ('05, '06)
Throttle shaft torx screw threads (After '06)
Oil jet mounting bolt threads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Crankcase tightening bolt th reads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Crankshaft bearing set plate torx screw threads l ocking agent Coating w idth: 6.5 ± 1.0 mm
(Pro Honda Hondalock 3 (0.26 ± 0.04 in) from tip
or equivalent high
Alternator wire grommet sealing surface

strength locking agent)
liquid sealant •
1-22 •
GENERAL INFORMATION
FRAME
LOCATION MATERIAL REMARKS
Steering head bearing rofling area and dust seal lips Urea based mUlti-purpose Apply 3 5 9 for each
grease with extreme pres- bearing
sure (example: Kyodo
Yushi EXCELITE EP2, Shell
stamina EP2 or equiva-
lent)
Wheel bearing dust seal lips Multi-purpose grease
Wheel bearing rolling area
Kickstarter arm joint
Swingarm pivot bolt sliding suriace
Sw ingarm pivot need le bearing rolling area
Swingarm pivot thrust bearing rolling area
Swingarm pivot dust seal lips
Shock arm needle bearing rolling area
Shock arm dust seal lips
Shock linkage side collars
Shock linkage needle bearing sliding area
Rear shock absorber spherical bearing rolling area
Rear shock absorber dust seal lips
Brake pedal pivot bolt sliding suriace
Gearshift change pedal sliding area of pin
Throttle cable end and sliding area
Clutch cable end adjuster ins ide suriace
Clutch lever pivot bolt sliding suriace
Sidestand pivot bolt sl iding suriace
Air deaner element-to-air deaner housing con t acting
area (After '07 ) Apply 3.5 ± 2 g
Brake caliper pin bolt sliding area Silicone grease
Brake caliper bracket pin bolt sliding area
Brake caliper dust seal lips
Brake caliper and bracket pin boots inside surface
Brake lever pivot bolt sliding suriace
Brake lever adjuster tip
Rear master cylinder push rod rounded surface
Rear master cylinder boot fitting area
Drive chain slider screw threads Locking agent
Fork protector mounting bolt threads
Front brake cal iper mounti ng bolt threads
Front cal iper pin bolt threads
Front caliper bracket pin bolt threads
Rear caliper bracket pin bolt threads
Steering damper mounting bolt threads (After '07 )
Brake caliper piston seal lips DOT4 brake fluid
Brake caliper piston outer surface
Master cylinder inner suriace
Master cylinder piston outer suriace
Handleba r grip rubber inner suriace Honda Bond A or Pro
Air deaner housing connecting suriace Honda Handgrip Cement
(U.S.A. only)
Fork cap O-rings Pro Honda HP Fork Oil 5W
Center bolt O-rings
Fork bushing
Fork oil seal
Fork dust seal
Steering damper plug bolt O-ring (After '07 )
Steering damper end cap O-r ing (After '07 )
Steering damper free piston O-ring (After '07 )
\ Steering damper rod O-ring (After '07 )
Shock arm nut threads and flange surface Engine oil
Shock link nut threads and flange surface
Throttle grip sliding area
1-23
GENERAL INFORMATION
lOCATION MATERIAL REMARKS
Front engine hanger-la-engine contacting a rea Molybdenum disulfide
paste (Dow Corning@ 321
or equivalent)
Diffuser 1'05 '07) Sealant
Spark arrester mounting bolt th reads (After '07) Molybdenum disulfide
g rease (TBl 901 o r equ iva-
lent)
•
•
1-24 •
GENERAL INFORMATION
CABLE & HARNESS ROUTING ('05 - '07)
STARTER SWITCH 2P eLlHe:H CABLE
I BLACKI COI'NECTClR/:;::::;=::::::",,/-.. START CABLE
STARTER SWITCH WIRE

ENGINE STOP BUTTON WIRE
THROTTLE CABLES
FRelNT BRAKE HOSE

TRIPMETER CABLE
~$J!
WIRE HARNESS
ENGINE STOP BUTTON/CLUTCH
SWITCH 3P (BLACK) CONNECTOR
HE"DLIG'1T3P (BLUE) CONNECTOR
CLUTCH CABLE THROTTLE CABLES
HOT STAAT CABLE
STARTER SWITCH WIRE
ENG INE STOP BUTTON WIRE
, FUEL TANK BREATHER HOSE
1-25
GENERAL INFORMATION
THAonlE CABLES
CLUTCH CABLE
SIPHON HOSE
OVERFLOW HOSE TAIPMETER CABLE
HOT START CABLE
ENGINE STOP BunON WIRE
IGNITION PULSE GENERATOR 2P

(BLACK) CONNECTOR
ALTERNATOR 4P (BLACK)
•
CONNECTOR
FRONT BRAKE HOSE
1-26 •
GENERAL INFORMATION
HOSE
CARBURETOR OVERFlOWI
DRAIN HOSE
RADIATOR
SIPHON HOSE
CRANKCASE
BREATHER HOSE
RADIATOR
OVERFLOW HOSE
ALTERNATOR WIRE "",=::::...--- AlA VENT HOSES
BRAKE HOSE
1-27
GENERAL INFORMATION
'05, '06:
T HROTTl_E CABLES
RADIATOR HOSES
CLUTCH CABLE
SPARK PLUG WIRE
HOT START CABLE
MAIN WIRE HARNESS --\1~i~~~~

THRODLE POSITION SENSOR RADIATOR HOSES
CONNECTOR
CRANKCASE
BREATHER HOSE TRANS M ISSION BREATHER HOSE
'05 a nd '06 Ca lifornia type, '07:

SIPHON HOSE
THROTIlE CABLES
CLUTCH CAB LE
SPARK PLUG WIRE
HOT STAAT CABLE
MAIN WIRE HARNESS
THROTIlE POSITION SENSOR

•
CONNECTOR
PAIR AIR SUCTION HOSE

•
CRANKCASE
BREATHER HOSE TRANSMISSION BREATHER HOSE
1-28 •
GENERAL INFORMATION
'os, '06:
.- ~
VUTCHCABLE
TRANSMISSION
BREATHER HOSES
CARBURETOR OVERFLOWI
DRAIN HOSE
ALTERNATOR WIRE
CRANKCASE
BREATHER HOSE o
'OS and '06 California type, '07:
CRANKCASE
BREATHER HOSES ~=:::::::::::;:;:"'fi!i~41:f1\{ PAIR AIR SUCTION HOSE
AIR VENT HOSES

),
) AIR VENT HOSES
CLUTCH CABLE
"'i==rn:--:::::o;. TRANSM
'r
ISSION
BREATHER HOSES
CARBURETOR OVERFLOWI
DRAIN HOSE
ALTERNATOR WIRE
CRANKCASE
, BREATHER HOSE o
1-29
GENERAL INFORMATION
BATIERY NEGATIVE H
CABLE
BATIERY
MAIN WIRE HARNESS
TAil
I,""""'., -____ leM 6P (NATURAL)

1~7~~'~~~ CONNECTOR
STARTER RELAY SWITCH
,,
IGNITION CONTROL MODULE oeM)
leM 6P (BROWN) CONNECTOR

WIRE
1-30 •
GENERAL INFORMATION
SECONDARY AIR SUPPLY SYSTEM ('05 and '06 California type, '07)
, CRANKCASE
BREATHER
HOSES
TRANSMISSION AIR SUPPLY PIPE PAIR CONTROL VALVE

BREATHER HOSES
AIR SUPPLY HOSE
1-31
GENERAL INFORMATION
CABLE & HARNESS ROUTING (After '07)
FRONT BRAKE HOSE CLUTCH CABLE HOT START CABLE
ENGINE STOP BUTTON WIRE
ENGINE STOP BUTTON/ CLUTCH

STARTER 'WITCH WIRE -t+- SWITCH 3P (BLACK) CONNECTOR
THROTTLE CABLES STARTER SWITCH 2P

(BLACK) CONNECTOR
TRIPMETER CAl""
I WIRE HARNESS
HEADLIGHT 3P (NATURAL) CONNECTOR
CABLE THROTTLE CABLES
HOT CABLE
ENGINE BUTTON WIRE
•
20
(0.8 in )
- li--ffl'-- , _
- , •
FUEL BREATHER HOSE
1-32 •
GENERAL INFORMATION
r,,,,,-, CABLE
THROTTLE CABLES
SIPHON HOSE
ENGINE STOP BUTTONI START CAB LE

CLUTCH SWITCH 3P
(BLACK) CONNECTOR
ENG'"IE STOP
BUnONWIRE
CLUTCH S"'ITIC" 'WII<F

CONNECTOR
FRONT HOSE
1-33
GENERAL INFORMATION
HOT START CABLE

•
0-3 mm (O-O.1 in)
RADIATOR SIPHON HOSE
IGNITION PULSE GENERATOR

2P(BLACK)CDNNECTOR
J,;,,~~:::~ CRANKCASE
P BREATHER HOSE
ALTERNATOR4P
(BLACK)CQNNECTOR
RADIATOR OVIERF'lO'W
REAR BRAKE HOSE

•
1-34 •
GENERAL INFORMATION
SIPHON HOSE
THAOTILE CABLES
RADIATOR HOSES
~~ CLUTCH CABLE
SPARK PLUG WIRE
HOT START(:AB ILE
,
MAIN W IRE HARNESS --11~j~~~1J;1I
RA(JlAlrOR HOSES
THROTILE POSITION SEr'SCIR

3P (BLACK) CONNECTOR
PAIR SUCTION HOSE

CRANKCASE
BREATHER HOSE TR,'N'5MISSION BREATHER HOSE
CRANKCASE
BREATHER HOSES -=::::::::;;j;;;;:VF~~~m PAIR AIR SUCTION HOSE
AIR VENT HOSES
il'-i---7A1R VENT HOSES

'f(::<q-;..;....
CLUTCH CABLE
, TRANSMISSION
·~#'k/;'l' BREATHER HOSES
CARBURETOR OVERFLOW!
DRAIN HOSE
ALTERNATOR WIRE
, CRANKCASE
BREATHER HOSE
1-35
GENERAL INFORMATION
BATIERY NEGATIVE H CABLE
BATTERY
MAIN WIRE HARNESS
- - - - leM 6P (NATURAL)
CONNECTOR
ST"RllER RELAY SWITCH
IGNITION CONTROL MOOUlE (lCM)
REIGULAlrOFVR"Cl"1F1'III'R WIRE
leM 6P (BROWN) CONNECTOR
CRANKCASE
BREATHER HOSE
COINTflOLVALVE
CRANKCASE
BREATHER HOSE
TRANSMISSION
BREATHER HOSES
AIR HOSE
•
AIR Y PIPE
1-36 •
GENERAL INFORMATION
OPTIONAL PARTS
ITEM REMARKS
MAINTENANCE:
Work stand For maintenance
Pin spanner
~ Pin spa nner A j( 2
For shock absorber spring installed length (preload)
adjustment (two required)
Air gauge
DRIVE CHAIN & SPROCKET:
Driven sprocket /chain link Standard 51T (Aluminum)1114
Optional 50T (Aluminum)/114
52T (Alum inum)/116
HANDLEBAR LOWER HOLDER:
Standard 3 mm offset
Optional no offset
1-37
GENERAL INFORMATION
ITEM REMARKS
FORK ('05 - '07):
Spring TYPE SPRING RATE OIL CAPACITY
light 2 scribe marks 0.45 kgf/mm Standard
(25.20 Ibflin) 338 em' (11.4 US OZ, 11.9 Imp oz)
0 Standard N o mark (fact ory 0.47 kgf/mm

Maxi mum
407 em] (13.8 US OZ, 14.3 Imp ozl
Minimum
311 em] (10.5 US OZ, 10.9 Imp oz)
Standard
products) or 1 scribe (26.32 Ibflin) 332 em' (11.2 US OZ, 11.7 Imp oz)
0
mark (after market Maximum
parts) 402 em' (13.6 US OZ, 14.2 Imp oz)
Minimum
306 em' (10.3 US OZ, 10.B Imp ozl
0'
0 Heavy 3 scribe marks 0.49 kgf/mm

(27.44 Ibfli n)
Standard
335 em' (11.3 US OZ, 11.8 Imp ozl
0
FORK (After '07 :
Maximum
405 em' ( 13.7 US OZ, 14.3 Imp ozl
Minimum
309 em ' (10.5 US OZ, 10.9 Imp oz)
Spring TYPE SPRING RATE OIL CAPACITY

light 2 scribe ma rks 0.45 kgf/mm Standard
(25.20 Ibt/in ) 330 eml (11.2 US OZ, 11.6 Imp oz)
0
Maximum
407 cm l (13.8 US OZ, 14.3 Imp oz)
Minimum
31 1 cm 3 (10.5 US OZ, 10.9 Imp oz)
Standard No mar~ ,(factory 0.47 kgf/mm Standard
products) or 1 scribe (26.32 Ibflin) 324 cm 3 (11.0 US OZ, 11.4 Imp oz)
0
mark (aher market Maximum
pa rt s) 402 cm' (13.6 US OZ, 14.2 Imp oz)
Minimum
306 cm 3 (10.3 US OZ, 10.8 Imp oz)
0'
0
Heavy 3 scribe marks 0.49 kgf/mm
(27.44 Ibflin)
Standard
327 cm 3 (11.1 US OZ, 11.5 Imp oz)
0 Maximum
405 cm 3 (13.7 US OZ, 14.31mp oz)
M inimum
309 cm 3 (10.5 US OZ, 10.9 Imp oz)
The standard fork springs mounted on the motorcycle when it leaves the factory are not marked. Before replacing the
springs, be sure to mark them so they can be distinguished from other optional springs.
1-38 •
GENERAL INFORMATION
Spring
paint (after pans)
Silver paint
The standard shock spring mounted on the motorcycle when it leaves the factory is not marked. Before replacing the
spring, be sure to mark it so it can be distinguished from ot her optional springs.
1-39
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA), and the California Air Resources Board (CAR B) require that off-road
motorcycle comply with applicable exhaust emissions standa rds during it useful life, when operated and maintained
according to the instructions provided.
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide, oxides of nit rogen and hydrocarbons. Control of hydrocarbons and
oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when sub-
jected to sunlight. Carbon monoxide does not react in the sarna way, but is toxic.
Honda Motor Co., Ltd. util izes appropriate carburetor settings as well as other systems, to reduce carbon monoxide and
hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of lean carbu retor setting, no adjustments should be made except for
high altitude setting and idle speed adjustment with the throttle stop screw. The exhaust emission control system is sepa-
rate from the crankcase emission control system.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow·by gas is returned to the combustion chamber th rough the air cleaner and carburetor.
AIR CLEAN I'R
•
~ FRE$HAIR
_ BLOW-BY GAS •
•
1-40 •
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) :
'05 and '06 California type, After '06
The exhaust emission control system includes a secondary air supply system which introduces filt ered ai r into the exhaust
gases in the exhaust port. Fresh air is drawn i nto 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.
This model has a pulse secondary air injection (PAIR ) control valve. A PAIR check valve prevents reverse air fl ow through
the system. The PAIR control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during
r- engine deceleration, thereby preventing aherburn in the exhaust system.
No adjustment to the PAIR system should be made, although periodic inspection of the components is recommended.
PAIR COIN!'lOLVALVE
VACUUM HOSE
AIR CLEANIER
AIR HOSE
¢:J FRESH AIR
'-
•... EXHAUST GAS
VACUU M AlA
SERVICING THE HONDA

U.S.A. Only
Maintenance, replacement or repair of the emission control devices and systems may be performed by any motorcycle
repair establishment or individ ual using parts that are "certified " to EPA standards.
PROHIBITED ACTIONS
The following prohibitions apply to everyone with re spect to the engine's emission control system.
You may not remove or disable any device or element of design that may affect an engine's emission levels. Th is restric-
tion applies before and after the engine in placed in service.
Vehicles that are u sed only for competition are exempt from this prohibition.
1-41
GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE EMISSION CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian pro·
vinciallaw may prohibit 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
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use; or (2) the
use of any 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 LI STED BELOW:
, . Removal of or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those
specified by the manufacturer.
FUEL PERMEATION EMISSION CONTROL SYSTEM (After '07)

This motorcycle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection
Agency (E PA) , the California Air Resources Board (CARB). and Environment Canada. The fuel tank, fuel hoses, and fuel
vapor charge hoses used on this motorcycle inco rporate fuel permeation control technologies. Tampering with the fuel
tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effect iveness of the fuel permeation technologies is
prohibited by federal regulations.
REBUILT ENGINE
When you rebuild your engine including a major overhaul in which you replace the engine's pistons or power assemblies
or make other changes that significantly increase the service life of the engine, your Honda will continue to comply with all
emissions regulations if you:
- Make sure you are technically qualified to rebuild the engine and have the proper tools
- Use only Genuine Honda parts or equivalents
- Make sure to maintain al l specifications as described in this Service Manual
1-42 •
2. TECHNICAL FEATURE
AUTO-DECOMPRESSION SYSTEM HPSD (Honda Progressive Steering Damper):

(After '07) ..................................... ............... 2-2 After '07 ................................. ..................... 2-3
c.
2-1
TECHNICAL FEATURE
AUTO-DECOMPRESSION SYSTEM (After '07)
DURING STARTING CAMSHAFT
(WHEN ENGINE IS OFF): DECOMPRESSOR PLUNGER
DEC:OMIPRE'SS,)R SHAFT
)AI
ROCKER ARM
AFTER THE ENG INE STARTS:
VALVE
DEC:O.,PRESE:OR WEIGHT
DURING STARTING (WHEN ENGINE IS OFF)

The decompressor plunger protrudes from the exhaust cam lobe, and depresses the exhaust valve via the rocker arm.
The exhaust valve is slightly opened, end releases some cylinder compression for easy starting .
AFTER THE ENGINE STARTS

After the engine starts, the decompressor weight moves outward by centrifugal force.
The decompressor weight turns pin (A) on the decompressor shaft.
Pin (8) on the decompressor shaft turns with the decompressor shaft, and pulis the decompressor plunger into the exhaust
cam lobe.
2-2 •
TECHNICAL FEATURE
HPSD (Honda Progressive Steering Damper): After '07
The steering damper is installed on the steering head pipe and the top bridge.
HPSD utilizes the angle change of the top bridge relative to the steering head pipe to compress or extend the damper rod.
The steering damper can be serviced, however the damper rod/piston is not serviceable.
Each component of HPSD functions as follows:
- Damper rod / pist on
The damping force is generated by the extension or the compression of the damper rod.
- Adjust e r piece/ Plug b o tt
The damping force can be adjusted with the adjuster piece by turning the plug bott. The adjuster piece adjusts the
dampi ng force of both compression and extension. Turning the plug bolt clockwise will increase damping force and
turning it counterclockwise will decrease damping force.
- Free piston / Reservoir/ Spri ng
When compressing the damper rod, damper oil moves temporari ly into the reservoir. The damper oil stored in the
reservoir is pushed back by the free piston. The free piston is moved by the spring tension and damper oil pressure.
- Damper case
There is a groove ins ide t he damper case. Progressive damping force is controlled by the configuration of the groove
within the damper case .
DAMPER ROD/PISTON PLUG BOLT
SPRING
GROOVE
FREE PISTON
ADJUSTER PIECE
RESERVOIR
2-3
TECHNICAL FEATURE
HPSD CHARACTERISTICS
• The required steering torque when turning the handlebar fully (within angle BJ is greater than the required steering
torque when turning the handlebar slightly (within angle Al.
St roke: C <: 0
Angle: A = B NEUTRAL POSITION
A
Stroke when angle B
Stroke when angle A
• When the steering is in the neutral position, HPSD generates no dampi ng f orce and has no effect on steering t orque.
• The steering torque differs between the extension and compression of the damper rod.
• The required damping force is controlled w hen the damper piston travels across the groove in the damper case.
• The required steering torque differs between high and low damper rod speed.
•
extension across the groove
extension outside the groove
2-4 •
TECHNICAL FEATURE
Turning the handlebar from neutral position to full angle (extension) .
When the damper rod is extended outside of the groove:
Damping force is generated when the oi l flows th rough the valves and adjuster piece in the dampe r case.
: High damper rod speed

: Low damper rod speed
ADJUS TER PIECE
Hard
.." •• c
0
-- ----
-•
cr
B ~
c
a
~
c c .. -
~
'0
• 0
ti ••• ~
0
•
E
0
u
Hard
Full .. a
(Steering angle) VALVES
When the damper rod is extended across the groove:

Damping force is controlled when the oil flows through the groove in the damper case.

Hard
\
.. c
Q~ -
--
0
••c
l -•
"cr
B ~
\\
.-----~
a
'"c c . . ----7
--
~
.~ 0
§ •••~ 0
~
E
0
u
,/
/'
Hard
Full - ._ . - - - - - a
(Steering angle)
2-5
TECHNICAL FEATURE
Turning the handlebar from full angle to neutral position (compression).
When the damper rod is compressed across the groove:
Damping force is controlled w hen the oi l flows through t he groove in the damper case.

Hard
GROOVE
.., ••
!!
c
a
c , ,
-,
S
~ "
• 0
--
c c
-
~
a
-
'0
§ ••~a -
•
E
a0 ®
Hard
Full ... 0
(Steering angle)
When the damper rod is compressed outsid e of the groove:

Damping fo rce is generated w hen t he oi l flows through the valves and adju st er piece in the d am per case.

:l ow damper rod speed
Hard ADJUS TER PIECE •

.., ••
!!
c
a
c , ,
-, •
-"
a
• 0
'-- ,
- ----G
~
c c
~
'0
• •••a
3l •"a
E
a0
Hard
•
Full ... 0
(St eering angle) VALVES •
2-6 •
3. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION ·· .. ·...... ····· .. ········· 3-2 ENGINE GUARD .. ...................................... · 3-5
TROUBLESHOOTING .............. .......... ......... 3-2 FRONT VISOR .. ...................... ................ .... 3-5
SEAT · .... · ........ · .. ·· .. .. ·· .. · .. · .. · .... · .... · .... · .. ·.. · .. · .. 3-3 SUB-FRAME ...................... ......................... 3-6
SIDE COVER .. ·.... ·.... ··· .. ·...... ·.. · .. · .. ·· .. · ........ ·· 3-3 FUEL TANK .. · .... · .. ·.... · ................ · .......... · .... ·3-8
RADIATOR SHROUD .................................. 3-4 EXHAUST SYSTEM .................................. · 3-9
3-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels, fuel tank and exhaust system.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all of the exhaust system fasteners. Always tighten the exhaust pipe
joint nuts, then tighten the mounting fasteners.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Seat mounting bolt 26 N'm (2.7 kgf·m, 19Ibf·ft )
Sub·frame upper mounting bolt ('05 - '07) 30 N·m (3.1 kgf·m , 22 Ibf·ft)
Sub-frame lower mounting bolt ('05 - '07) 49 N·m (5.0 kgf·m, 36 Ibf·ft)
Sub· frame upper/lower mounting bolt (After '07) 49 N·m (5.0 kgf·m, 36 Ibf.ft)
Exhaust pipe joint nut 21 N·m (2.1 kgf·m, 15Ibf·ft)
Muffler joint band bolt 21 N·m (2.1 kgf·m, 15Ibf·ft)
Muffler mounting bolt 26 N·m (2.7 kgf·m , 19Ibf.ft)
Heat shield bolt 12 N·m (1.2 kgf·m, 9 Ibf.ft)
Exhaust pipe protector bolt 12 N ·m (1.2 kgf·m, 9 IbHt)
Diffuser mounting torx screw ('05 - '07) 11 N·m ( 1. 1 kgf·m, 8 Ibf. ft)
Rear fender mounting bolt 13 N'm (1.3 kgf·m, 10 Ibf·ft)
Radiator shroud upper mounting bolt 5 N'm (0.5 kgf·m, 3.7 Ibf·ft)
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Po or perform ance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
3-2 •
FRAME/ BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL
Remove the bolts and seat.
INSTALLATION
Align the seat hook with the seat bracket screw on
the fuel tank and the seat prongs with the sub~ SEAT HOOK
frame.
Install and tighten the seat mounting bolts to the
specified torque.
TORQUE: 26 N ·m (2.7 kgf·m, 19 Ibf.ftl
SCREW BOLTS
SIDE COVER
REMOVALIINSTALLATION
Le ft side only: Open t he air cleaner housing caver.
l eft side: SEAT MOUNTING BOLT
Remove the seat mounting bolt, side cover bolt and
side cover.
AlA CLEANER
HOUSING COVER SIDE COVER BOLT
3-3
Be careful nor to Instal l the side cover by inserting it s tabs into the air
damage rile tabs. cleaner housing slit s.
Tighten the side cover bolt securely.
Tighten the seat mounting bolt to the specified
torque.
TORQUE: 26 N'm !2.7 kgf·m, 19 Ibf·ft)
Left side only: Close the air cleaner housing cover.
SIDE BOLT SEAT BOLT
RADIATOR SHROUD
REMOVAL/INSTALLATION
Remove the seat (page 3-3).
Remove the bolts, collars and radiator shroud.
Install the radiator Installation is in the reverse order of removal.

shroud tab onto the
sub-frame. TORQUE:
Radiator shroud upper mounting bolt:
5 N'm (0.5 kgf·m, 3.7 IbUt)
3-4 •
FRAME/ BODY PANELS/EXHAUST SYSTEM
ENGINE GUARD
LEFT/RIGHT ENGINE GUARD
Remove the bolt, coliar and engine guard.
Install the engine guard, collar and tighten the bolt
securely.
CENTER ENGINE GUARD

Remove the bolts and collars.
Remove the center engine guard from the reserve
tank.
Install the center engine guard by aligning its tabs
with the reserve tank groove.
Install the collars and bolts.
Tighten the bolts securely.
BOlTS/COLLARS
FRONT VISOR
REMOVAL/INSTALLATION ('05 - '07)
Remove the bolts and front visor.
3-5
Release the headlight 3P connector from the wire
clamp and disconnect it.
Install the from Installation is in the reverse order of remova l.
visor by all{1ning its
grommets with the
tabs on the steering
stem.
REMOVALIINSTALLATION (After '07)

Remove the bolts and front visor.
FRONT VISOR
Disconnect the headlight 3P (Natural) connector.

Install the front Installation is in the reverse order of removal.
visor by alIgning its
grommets with the
tabs on the sreering
slem.
SUB-FRAME
REMOVAL
Remove the following:
- Seat (page 3-3)
- Side covers (page 3-3)
- Muffler ('05 - '07: page 3-9, After '07: page 3-11)
- Battery (page 17-6)
- Ai r cleaner housing (page 6-7)
Remove the wi re bands and battery term inal cover.
3-6
Oisconnect the taillight connectors and starter relay • •~C
switch 4P connector.
Remove the starter relay switch and ignition control
module (leM) from the rear fender.
Remove the bolts and rear fender.
Remove the sub-frame upper mounting bolts and

sub-frame.
INSTALLATION
Do not righlen the Install the sub-frame and upper mounting bolts.
sub-frame upper
mounting botrs yer.
Install the rear fender and bolts.

Tighten the bolts to the specified torque.
TORQUE: 13 N 'm (1.3 kgf·m , 10 Ibf-ttl
l
3-7
ROUfe the wire Connect the ta il light connectors and starter relay
harnesses properly switch 4P connector.
('05 - '07: page 1- Install the starter relay switch and leM onto the rear ~;:::....~~=:
25. Ahar '07: page fender. ii
1-32) Be careful
not to damage the
wires.
Install the wire bands and banery terminal cover.

Insta ll the following :
- Air cleaner housing (page 6-9)
- Battery (page 17·6)
- Muffler ('05 - '07: page 3-9, After '07: page 3-'1 )
- Seat (page 3-3)
FUEL TANK
Remove the radiator shrouds (page 3-4).
Turn the fuel valve to ·O FF" and disconnect the fue l
valve side of the fu el hose.
• Place an approved gasoline container and catch
the gasoline.
• Wipe o ff spilled out gasoline.
Remove the bolt and fu el valve.
Di sconnect the breather hose from the steering

stem.
Unhook the band and air cleaner case cover from
the fu el tank.
Remove the bolt, collar and fuel tank.
Installation is in the reverse ord er of removal.
NOTE:
• Insert the breather hose into the steering stem as
shown.
• After installation, make sure there are no fuel
leaks.
• Route the wire harnesses properly.
- '05 - '07: (page 1-25)
- After '07: (page 1·32)
3-8
5 N·m (0.5 kgf·m, 3.7 Ibf.ft)

~ RADIATOR SHROUDS
;After '07:
FU EL TANK
: After '07: ""
FUEL VALVE
•
I ••.••.• .. •..•.•.•••.•••••• • ••••••••••
EXHAUST SYSTEM
MUFFLER REMOVAUINSTALLATION
('05 - '07)
Remove the right side cover (page 3-3).
Loosen the muffler joint band bolt.
3-9
Remove the muffler mounting bolts, washer and
muffler.
Remove the bolt, washer and heat shield from the

muffler.
BOlTIW,'SH!,R
Remove the torx screw, washer and diffuser from
the muffler.
DIFFUSER TORX sCfiEW'IWI\S H;ER

Apply muffler sealant to the diffuser as shown.
DIFFUSER
Install the diffuser, washer and torx screw to the
muffler.
Tighten the tao( screw to the specified torque.
TORQUE: 11 N'm (1 .1 kgf·m, 8 Ibf.ft)
,.
TORX SCREW
3-10
Align the muffler Install the heat shield and washer, tighten the bolt
tabs lind hear shield to the specified torque. HEAT SHIELD
grommets.
TORQUE: 12 N'm (1.2 kg f·m , 9 Ibf.ftl
BOLTtvVASHER
Install a new gasket onto the exhaust pipe.
Install the muffler to the exhaust pipe.
Install the washer and muffler mounting bolts.

Tighten the muffler joint band bo lt to the specified
torque.
TORQUE: 21 N'm (2. 1 kgf·m , 15 Ibf.ft)
Tighten the muffler mounting bolts to the specified
torque.
TORQUE: 26 N'm /2.7 kgf·m, 19 Ibf-tt)
Install the right side cover (page 3-3 ).
MUFFLER REMOVAL/INSTALLATION
(After ' 07)
Remove the right side cover (page 3-3).
Loosen the muffler joint band bolt.
3-11
Remove the muffler mounting bolts, washer, muf-
fler, gasket and muffler joint band.
Remove the bolt and heat shield from the muffler.

HEAT SHIE LD
AI'9n the muffler Install the heat shield and tighten the bolt to the
labs 8nd heBt shield speCified torque.
grommets.
TORQUE: 12 N'm (1.2 kgf·m, 9 Ibf.ft)
BOLT
Install the muffler joint band and new gasket onto r~~~~
the exhaust pipe.
Install the muffler by aligning the tab of the muffler ~~-~~~~~~~~~~:::::::::::~

joint band with the cut-oul of the muffler.
TAB
3-12 •
Install the washer and muffler mounting botts.
ii
Tighten t he muffler mounting bolts to the specified ·'::':;;;. .
torque.
TORQUE: 26 N'm (2.7 kgf·m , 19Ibf.ft)
Tighten the muffler joint band bolt to the specified

torque.
TORQUE: 21 N·m (2. 1 kgf ·m , 15 Ibf·ft )
Install the right side cover (page 3-3) ,
EXHAUST PIPE REMOVAL

Remove the muffler.
- '05 - '07: (page 3-9)
- After '07: (page 3-1 1)
Remove the exhaust pipe joint nuts, exhaust pipe f1~~~:r.;;P;Ei::l

and gasket.
Remove the bolts and protector from the exhaust

pipe.
EXHAUST PIPE
3-13
INSTALLATION
26 N'm 12.7 , 19Ibf·ft)
After '07:
21 N'm (2,1 kgf·m, 15Ibf.ft)
Install the protector and tighten the bolts to the

specified torque.
TOROUE: 12 N'm (1.2 kgf·m , 9 Ibf.ft)
Install a new gasket to the cylinder head .

• Always replace the exhaust pipe gasket with a r
new one.
3-14 •
Install the exhaust pipe but do not tighten the nuts
yet.
Install the muffler ('05 - '07: page 3-9, After '07: page
3-11) but do not tighten the bolts yet.
Tighten the exhaust pipe joint nuts to the specified
torque.
TORQUE: 21 N 'm (2, 1 kgf·m , 15 Ibf.ft)
Tighten the muffler fasteners.

- '05 - '07: (page 3-9)
- After '07: (page 3-'1'
3-15
MEMO
•
4. MAINTENANCE
SERVICE INFORMATION ····· .... ·...... ··········· 4-2 TRANSMISSION OIL ······ ·························· 4-22
MAINTENANCE SCHEDULE ('05. ·061 ······· 4-4 DRIVE CHAIN ············································ 4-24
MAINTENANCE SCHEDULE (After ·061 ···· 4-5 DRIVE CHAIN SLIDER .............................. 4-27
COMPETITION MAINTENANCE DRIVE CHAIN ROLLER ............ ...... ..... ...... 4-28
SCHEDULE ....................... .............. ............. 4-6
DRIVE/ DRIVEN SPROCKET ..................... 4-28
ADDITIONAL ITEMS REQUIRING FREQUENT
REPLACEMENT··························· ············ ···· 4-7 BRAKE FLUID ........................................... 4-29
FUEL LINE ..................... ...... ........ ................ 4-8

BRAKE PAD WEAR· ··· ··················· ············ 4-30
FUEL STRAINER SCREEN ............. ............. 4-8 BRAKE SYSTEM ........................... ............ 4-30
THROTTLE OPERATION ····························· 4-9 HEADLIGHT AIM ........ .... .. ..... ................... 4-31
HOT START ······ ···································· .... · 4-10 CLUTCH SYSTEM ·······························.... ·4-31
AIR CLEANER································· ··········· 4-10 CONTROL CABLES .................................. 4-32
CRANKCASE BREATHER· ························4-11 EXHAUST PIPE/ MUFFLER ...................... 4-33
SPARK PLUG ....................................... ..... 4-12

SPARK ARRESTER ···································4-33
RADIATOR COOLANT .............................. 4-13 SIDESTAND ····· ····· ··········· ················· ········ 4-34
l COOLING SYSTEM ································ .. · 4-14 SUSPENSION ........................................... 4-34
- SECONDARY AIR SUPPLY SYSTEM SWINGARM / SHOCK LINKAGE ............... 4-35

('05 and ' 06 California type. After ·061 ···· 4-14
NUTS. BOLTS. FASTENERS···················· 4-36
VALVE CLEARANCE/ DECOMPRESSOR
SYSTEM ............. ....................................... 4-1 5
WHEELS/ TIRES ........... ... .......................... 4-36
ENGINE OIL/ OIL FILTER ··········· ······ ···· .... · 4-19 STEERING HEAD BEARINGS .................. 4-37
I. ENGINE IDLE SPEED .. .............................. 4-22
4-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
• Place the motorcycle on a level ground before starting any work.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored
can cause a fire or explosion.
• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an
enclosed area.
• The exhaust contains poisonous carbon monoxide gas th at may cause loss of consciousness and may lead to death .
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
SPECIFICATIONS
•
equivalent m otor oil
API service classi fication : SG or Higher
~~~~----~ ~~~~
equivalent motor oil
o,
API service classification : SG or Higher
stan,d"d, MA
~~~------~~
•
pressure
•
4-2 •
MAINTENANCE
TORQUE VALUES
Engine oil drain bolt 16 N·m (1.6 kgf.m, 12 Ibf.ft) Apply oil to the threads
and seating surface
Transmission oil drain bolt 16 N'm (1.6 kgf·m, 12Ibf·ft) Apply oit to the threads
and seating surface
Transmission oil check bolt 10 N'm (1.0 kgf·m, 7 Ibf.ft)
Crankshaft hole cap 15 N'm (1.5 kgf·m, 11 Ibf·ft) Apply grease to the
threads
Spark plug 22 N'm (2.2 kgf·m, 16Ibf·ft)
Throttle cable adjuster lock nut (throttle side) 4.0 N 'm (0.4 kgf·m, 3.0 Ibf·ft)
(carburetor side) 4.0 N'm (0.4 kgf·m, 3.0 Ibf.ft)
Brake lever adjuster lock nut 5.9 N 'm (0.6 kgf·m, 4.4 Ibf·ftl
Rear axle nut 128 N 'm (13. 1 kgf·m,94lbf.ft) U-nut
Drive chain roller bolt 12 N'm (1.2 kgf·m, 9 Ibf·ftl
Drive chain roller nut 12 N'm (1.2 kgf·m, 9 Ibf·ftl U·nut
Drive sprocket bolt 31 N'm (3.2 kgf·m, 23 Ibf·ft)
Driven sprocket nut 32 N'm (3.3 kgf·m, 24 Ibf·ft) U-nut
Front master cylinder reservoir cover screw 1.0 N'm (D.l kgf·m, 0.7 Ibf.ft)
Rear master cyl inder reservoir cover bolt 1.0 N·m (D.l kgf.m, 0.7 Ibf·ft)
Exhaust pipe joint nut 21 N'm (2. 1 kgf·m, 15 Ibf·ft)
Muffler joint band bolt 21 N'm (2.1 kgf.m, 15 Ibf·ft)
Spark arrester mounting bolt r05 ~ '07) 12 N·m (1.2 kgf·m, 9 IbUt)
(After '07) 6 N·m (0.6 kgf.m, 4.4 Ibf·ft) Apply molybdenum dis-
ulfide grease (TB1901 or
equivalent) to the
threads
Front spoke 3.68 N'm (0.4 kgf·m, 2.7 Ibf·ft)
Rear spoke 3.7 N'm (0.4 kgf·m, 2.7 Ibf.ft)
Front/rear rim lode 12 N' m ( 1.2 kgf·m. 9 Ibf·ft)
Pressure release screw 1.2 N'm (0.1 kgf·m, 0.9 IbUt)
Sidestand pivot bolt See page 4·34
Sidestand pivot nut 39 N' m (4.0 kgf·m, 29 Ibf·ft) U-nut
Brake pedal adjuster lock nut 5.9 N'm (0.6 kgf·m, 4.4 Ibf·ft)
Drive chain adjuster lock nut 27 N'm (2.8 kgf.m, 20 Ibf·ft)
Decompressor adjuster lock nut (,05 - '07) 10 N'm (1.0 kgf·m, 7 Ibf·ftl Apply oil to the threads
TOOLS
Drive chain too l set Spoke wrench, 6.1 mm Spoke wrench , 6.6 mm
07HMH-MR10103 07JMA-MR60100 070MA·KZ30100
or 7HMH-MR1010C (U.S.A. only) or 07701·0020300 (6.1 mm)
4-3
MAINTENANCE
MAINTENANCE SCHEDULE ('05, '06)
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
1: Inspect and Clean, Adjust. lubricate or Replace if necessary. C: Clean. A: Replace. A: Adjust. L: Lubricate.
WHICHEVER COMES
FIRST
~~,'~~~- REGULAR MAINTENANCE
INTERVAL
NANCE REFER TO
mi ,200
~ ~ 4~
',BOO 12, PAGE
~
}:
tfB:::
<f)
:;
· : ~llif LINE
rlQ!'
C
I
4-B
4-B
4-9
r-
r- ~
w
t:
I
" PARK PLUG I
~
w IV~~
I I I 4-'5
"z
0 •
,N(I . FILTER R
I I
<f)
<f) I , IDL" 'P' I I I 4-22
:; I
w
I I
• I
r- ~I
I INCTE 21
R R 4-22
" NUI." I. L I, L' .,e;;: ~u~,:~~o"u km)
<f)
4-24
:;
w IUKIV. CHAIN <NUI., 1 I <, L' .ve;;: ~u.::,:~~ouu km ) 4-27
t:
"w I I
~
)BRAKE PAC I I 4-,
w I I 4-,
"z
0-
<f)
~~ I I
<f)
:; I 4-
'\' Mnno"on
C, .ve"l "O~~O mi 1 ' ,6~~~::::", ev.,y 4-33
z
~
0
z
I < 4j =
<
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qual ified.
** In the interest of safety, w e recommend these items be serviced only by an authorized Honda dealer.
NOTES:
•
1. Service more frequently when ridden in wet or dusty conditions.
2. California type only.
3. Replace every 2 years. Replacement requires mechanical skill.
4-4 •
MAINTENANCE
MAINTENANCE SCHEDULE (After '06)
I: Inspect and Clean, Adjust. lubricate or Replace if necessary. C: Clean. A: Replace. A: Adjust. L: lubricate.
WHICHEVER COMES
FIRST
,;;~,~~E. REGULAR MAINTENANCE
INTERVAL
NANCE REFER TO
m; _,~O PAGE
~q ~ PI!
1, ,200
12 ' ' ;
~
I IFUElliNE 4·8
FUEL 51 EEN C 4·8
1 1
1 1 4·'2
1
1 [----
f- 1 all FILTER
1 1 1 1
IA;~:;O~.'!'9
1
~
1 1 1 4· '
1
[----
1 1 1 1 1 4·'
~RSUPPlY I (NCTE 2) 1 1
I I NUI.', I, L
R
L• .,0;;-; 3 mon~~O< Ikm,
R :TIC 4-24
,, :g=
I,
~FLUIO (NOTE 3) ,
1
1
1
1
1
1 , 4·30
I BRAK~ 1 1
i--
~ :H SYI , , 1
1 1 ,
1
1 1 4-34
r-.- ~ L • • vo", :O~uu

1 1
" ; I,~ '.U~;:::: 0' eve", 4-33
~ ~
1 1
I •• 1 1 1 1
I •• 1 1 4-37
.. Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qualified .
.... In the interest of safety. we recommend these items be serviced only by an authorized Honda dealer.
L NOTES:
1. Service more frequently when ri dden in wet or dusty conditions.
2. U.S.A. and California type only.
3. Replace every 2 years. Replacement requires mechanical skill.
4-5
MAINTENANCE
COMPETITION MAINTENANCE SCHEDULE
Check all items before each race.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. A: Replace. A: Adjust. l; Lubricate.
NOTE ,~0:ut,!.5 a~~~t,:-5 ab~~~;:.O hou"

•
I
I
{NCTE
(NC TE 2) I 4-1
(NOTE 4) 4-15
~ I
IRINGS R -6
~'~ I
; SYSTEM I 4-t4
IDRIVECHAIN ~~==t===t=3'~==R~E===t===3====E~4-~24~3
I ~KET ~
I '::~'D {NCTE2: I 4
(NCTE 5)
4-
4-
L
(NOTE 3) R
IFORKOIL •
I I
I i HEAD I I 4-
This maintenance schedule is based upon average riding conditions. Machines subjected to severe use require more fre -
quent servicing .
NOTES:
1. Clean after every moto for dusty riding conditions.
2. Replace every 2 years. Replacement requ i res mechanical ski ll.
3. Replace after the fi rst break-in ride.
4. Inspect after the first break-in ride.
5. Replace the transmission oi l, if the clutch discs and plates are replaced.
4-6 •
MAINTENANCE
ADDITIONAL ITEMS REQUIRING FREQUENT REPLACEMENT
ENGINE
Ite m Cause Remark
Cylinder head gasket Compression leak Replace whenever disassembled
Clutch disc Wear or discoloration
Cylinder gasket l eakage Replace whenever disassembled
Right crankcase cover gasket Damage Replace whenever disassembled
FRAME
' ,m Cause Remark
Front/rear brake pad Wear Minimum thickness: 1.0 mm (0.04 in)
Sub-frame mounting bolt Fatigue or damage
Chain guide plate Wear or damage
Side cover Damage
Front visor Damage
Front/rear fender Damage
Clutch lever/holder Freeplay or damage
Brake lever Freeplay or damage
HOi start lever Freeplay or damage
Handlebar Bends or cracks
Thronle housing Damage
Grip rubber Damage
Gearshift pedal Damage
Brake pedal Damage
Chain adjuster/bolt Damage
Air clea ner Damage
NOTE:
• These parts and their possible replacement schedule are based upon average riding conditions .
• Machines subjected to severe use require more frequent servicing.
4-7
MAINTENANCE
FUEL LINE
Check the fuel tine for deterioration, damage or
leakage.
Replace the luelline if necessary.
FUEL STRAINER SCREEN

Remove the fuel tank (page 3-8).
'05 - '07 shown: FUEL JOINT
Drain the fuel from the fuel tank into an approved
gasoline container.
Disconnect the fuel lines from the fuel joint.
Remove the bolts and fuel joint.
After '07 shown: FUEL JOINT
Wash the fuel filter in high flash-point cleaning sol-

vent.
r:"::~~~~~~~~~~~~~~~~~
FUEL FILTEA O~~~--- D-RING
Check that the O-ring is in good condition and

install it ont o the fuel valv8.
Install the fuel joint in the reverse order of removal.
Aher ins talla tIOn, Install the fuel t ank (page 3-8).
make sure there IJre
no fuel leaks.
4-8 •
MAINTENANCE
THROTTLE OPERATION
Check for smooth throttle grip at full opening and
automatic full closing in all steerin g positions.
Check the throttle cables and replace them if they
are deteriorated, ki nked or damaged.
Lubricate the throttle cables if throttle operation is
not smooth .
Measure the freeplay at the throttle grip flange.
FR EEPLAY: 3 - 5 mm (l I B - 3/ 16 in )
Throttle grip freeplay can be adjusted at either end

of the throttle cable. '05 - '06 shown: LOCK NUT
Minor adjustments are made w ith the throttle side
of the adjuster.
Remove the dust cover from the adjuster.
Adjust the freeplay by loosening the lock nut and
turning the adjuster.
After adjustment, tighten the lock nut to the speci-
fied torque .
TORQUE: 4 N 'm (0.4 kg f·m , 3.0 Ibf.tt )
Install the dust cover.
Recheck the t hrottle operation.
If the adjuster cannot reach the correct free play,
turn the adjuster all the way in and then turn it out
one turn.
Make the major adjustment w ith the carburetor side
of the adjuster,
Major adjustments are made with the carburetor
side of the throttle cable.
turning the adju ster.
After adjustment, tighten the lock nut to the speci-
fied torque.
TORQUE: 4 N'm 10.4 kgf·m , 3.0 Ibf·ft)
Recheck the th rottle operation.
l Install the fuel tank (page 3·8).
,
\
4-9
MAINTENANCE
HOTSTART
Check for smooth hot start lever operation and
lubricate the cable if necessary.
Inspect the casing for cracks w hich cou ld allow
mois1ure to enter.
Replace the hot start cable if necessary.
Measure the hot start lever freeplay at the lever end.
FREEPLAV: 2 - 3 mm (1116 -118 in)
2-3 mm (1/16-118 i n)
Hot start lever freeplay can be adjusted at the hot

start cable.
:==================;
COVER USTER
Remove the dust cover.
turning the adjuster.
Tighten the lock nut.
Install the dust cover.
Recheck the freepley at the lever end.
AIR CLEANER
Open the eir cleaner housing cover.
Remove the air cleaner retaining bolt.
Remove the air cleaner assembly while turning it as
shown.
Remove the air cleaner element from the element

holder.
~~~~~~~~~~=========~
TAB AIR CLEANER
ri
elEMENT
Thoroughly
mabie wash
or high flashthe air cleaning
-point cleaner insolvent.
clean nonflam- \~~r )'--::----l:
Then wash the element again in a solution of hot
water and dishwashing liquid soap.
Clean the inside of the air cleaner housing.
Aher clea ning, be sure there is no dirt or sand
trapped between the inner and outer layer of the
cleaner.
Wash again if necessary.
Allow the air cleaner to dry thoroughly.
Aher drying, soak the air cleaner in clean Pro Honda
ELEM ENT
HOLDER
•
Foa m Filter Oil or an equivalent.
4-10 •
MAINTENANCE
Apply air filter oil to the entire surface of the air
cleaner and rub it with both hands to saturate the
element with oil.
Gently squeeze out excess oil. It is important not to
over-oil, or under-oil the element.
Squeeze
_~_ D~~_~
I"'';;''''''l , ,
Wash in Soak
non-flammable (Pro Honda Foam Filter
solvent Oil or equivalent)
Apply a thin coat of Pro Honda Filter Grease or an ~===================~

equivalent to the sealing surface. TAB
Assemble the air cleaner element and element
holder.
Hook the element hole onto the holder tab.
ELEMENT
HOLDER
After '07: Apply 3.5 ± 2 9 grease to the air cleaner assembly

contacting arBa of the air cleaner housing . RETAINING BOLT
Install the air cleaner assembly into the air cleaner

housing.
Carefully position the sealing flange of the element
to prevent dirt intrusion.
Align the air deaner tab with the ~f::::." mark of the air
cleaner housing by rotating the air deaner counter-
clockwise.
Install and tighten the retaining bolt securely.
NOTICE
If the air cleaner assembly is nor installed correcrty,
dirt and dust may enter the engine resulting in wear L.:A~I~R~::-~':.'~A~S~S~E~M':'."B~L~Y~________ J
of rhe piston ring and cylinder.
I
( CRANKCASE BREATHER
Remove the breather hose drain plug, then drain
any fluids or dirt from the hose into a proper con-
tainer.
Reinstall the drain plug.
4-11
MAINTENANCE
SPARK PLUG
REMOVAL
Remove the fuel tank (page 3-8),
Disconnect the spark plug cap from the cylinder
head.
Clean around the Remove the spark plug and inspect it for damage. ,
spark plug base
Inspect or replace as described in the maintenance
with compressed
schedule.
81f before
removmg, and be - '05, '06: (page 4-4)
sure that no debfls - After '06: (page 4-5)
IS allowed 10 enter
the combustion
chamber,
INSPECTION
Check the following and replace if necessary
CENTER ELECTRODE
• Insulator for damage
• Electrodes for wear
• Burning condition, coloration;
This motorcycle's If the electrode is contaminated with accumulated
~~~
spark pJug IS objects or dirt, repla ce the spark plug .
equipped with an
SIDE ELECTRODE
iridium center
electrode Replace INSULATOR
the spar/( plug if the
electrode ;s
con/ammated.
Replace the plug if the cent er electrode is rounded

as shown in the illustration. ROUNDED ELECTRODE
Always usa rna RECOMMENDED SPARK PLUG lOR EQUIVALENT)

specrfied spark plug Standard NG K: IFR8Hll
on rhls motorcycle. DENSO: VK24PRZ11
Optional NGK: IFR9Hll
r
DENSO: VK27PRZll
4·12 •
MAINTENANCE
To prevent Check the gap between the center and side elec-
WIRE TYPE FEelER GAUGE
x
trodes with a wire type feeler gauge.
o
damagmg the
iridium center
electrode, USB a SPARK PLUG GAP: 1.0 - 1.1 mm (0.039 - 0.043 in)
WIre type feeler
gauge to chacl: the
spark plug gap.
Do not adjust the Make sure that the 1.2 mm (0.05 in) diameter feeler
spark plug gap. If gauge does not insert between the gap.
the gap is out of If the gauge can be inserted into the gap, replace the
specification, plug with a new one.
replace with a new
one.
INSTALLATION
Install and hand tighten the spark plug to the cylin-
der head, then tighten the spark plug to the speci·
fied torque.
TORQUE: 22 N 'm 12.2 kg f·m , 1S lbf.ft)

Connect the spa rk plug cap securely_
Install the fue l tank (page 3-8),
RADIATOR COOLANT
Check the coolant level of the reserve tank with the , - - - - - - - - - -- - - - -- - - - ,
engine running at normal operating temperature,
"UP'PE" '" LEVEL LINE
The level should be between the "UPPER" and
"LOWER " level lines.
If necessary, add recommended coolant.
RECOMMENDED ANTIFREEZE:
Pro Honda HP coolant or a n equiva lent hig h qu al-
ity ethylene glycol a ntifreeze containin g silicate
free corrosion inhibitors
Remove the filler cap and f ill the "UPPER " level line
with 1 : 1 mixture of distilled water and antifreeze.
Install the filler cap. "LOWER " LEVEL LINE
4-13
MAINTENANCE
COOLING SYSTEM
Remove the radiator grill (page 7-B),
Check the radiator air passages for clogging or dam-
age.
Straighten bent fins, and remove insects, mud or
other obstructions w ith compressed air or low
water pressu re.
Replace the radiator if the ai r flow is restricted over
more than 20% of the radiating surface.
Inspect the radiator hoses for cracks or deteriora- L::;;;;;;;;;;;;;;;;;;;;;;;;~:;;;;;:::-:;;;;;;::-_ _ __

tion, and replace them if necessary.
Check the tightness of all water hose clamps (page
1-17).
SECONDARY AIR SUPPLY SYSTEM ('05

and '06 California type, After '06)
Remove the right radiator shroud (page 3-4).
Check the ai r supply and PAIR air suction hoses for
damage or loose connector.
Check the vacu um hose between the cylinder head
vacuum joint and PAIR control valve for deteriora-
tion, damage or loose connection.
Also check that the hose is not kinked or pinched.
4-14 •
MAINTENANCE
VALVE CLEARANCE/OECOMPRESSOR
SYSTEM
VALVE CLEARANCE INSPECTION
Inspec t and adjusr Remove the cvlinder head cover (page 9·7) .
the valve clearance
Remove th e crankshaft hole cap and O-ring .
while the engine is
cold (below 35"C/
95~)
Turn the crankshaft clockwise t o align the punch ~.......: :'::....-==----=-~~=--.:::::~~-,

mark with the index mark on the right crankcase
cover.
Make sure the piston is at TOC (Top Dead Center) on
the compression stroke.
This position can be obtained by confirming that
there is slack in the rocker arms. If there is no slack,
rotat e the crankshaft clockwise one full turn and
align the punch mark on the primary drive gea r with
the index mark on the right crankcase cove r again.
Check that the index line on the cam sprocket al igns
with the "/:::,." mark on the camshaft holder.
PUNCH MAR K
,
r
Intake side:
Insen a feele r gauge between the valve liher and
cam lobe.
Record the Check the lIallle clearance for the intake valves
clearBnce for eBch using a feeler gauge.
vailifl for (eference
m sturn selectiOn if VALVE CLEARANCE:
ad,ustment IS
IN : 0.16 ± 0.03 mm (0.006 ± 0.001 in)
required.
4-15
MAINTENANCE
Exhaust side:
Insert a feele r gauge between the rocker arm and
shim.
Record the Check the valve clearance for the ex haust va lves
clearance for each using a feeler gauge.
valve for reference
VALVE CLEARANCE:
in shim selection if
adjustment is EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)
required.
VALVE CLEARANCE ADJUSTMENT

Remove the camshaft holder assembly.
- '05 - '07: (page 9-8)
- After '07: (page 9-16)
• The shims may stick to the inside of the valve
lifter. Do not allow the shims to fall i nto the
crankcase.
Remove the shims.
• Mark all valve lifters and shims to ensure correct
reassembly in their original locations.
• The shims can be easily removed with tweezers
or a magnet.
Clean the va lve shim contact area in the valve lifter

with compressed ai r. VALVE LIFTER
•
4-16 •
MAINTENANCE
Measure the shim thickness and record it.
Ssvent,..lhf88 Calculate the new shim thickness using the equa-
dlfferenl rhickness tion below.
shims lire 8vailable A=(B-C\+D
'rom 1.200 mm 10
A: New shim thickness
3.000mm in B: Recorded valve clearance
Increments of
C: Specified valve clearance
O.025 mm. D: Old shim thickness
• Make sure of the correct shim thickness by mea-
suring the shim using a micrometer.
• Aefaea the intake valve seat if carbon deposits
result in a calculated dimension of over 2.450
mm .
• Retaee the exhaust valve seat if carbon deposits
result in a calculated dimension of over 3.000
mm.
SH IM
.\
eeee
1.80 mm 1.82Smm 1.85mm 1.875mm
InS/811 the shims in Install the newly sel ected sh ims on the valve sprin g
thelf original retainers.
locations.
Install the camshaft holder assembly.
- '05 - '07: (page 9-37)
- After '07: (page 9-39)
Rotate the camshaft by rotating the crankshaft
clockwise several times.
Recheck the valve clearance.
Check that the 0- Apply oil to the O-ring and install it onto crankshaft
MfJ IS In good hole cap.
condition, rep/Bcelf Apply grease to the crankshaft hole cap threads.
l If necessary. Install and tighten the crankshaft hole cap to the

specified torque,
TORQUE: 15 N 'm (1 .5 kgf·m, 11 Ibf.ft)
Install the cylinder head cover (page 9-42 ).
4-17
MAINTENANCE
DECOMPRESSOR CLEARANCE
INSPECTIONI ADJUSTMENT ('05 - ' 07)
Inspect and adjus t Always inspect and adjust the decompressor clear-
the decompressor ance after adjusting the r ight exhau st valve clear- INDEX MARK
CleBrBnCe while fhe
engine is cold
(be/ow 35"C/95'f).
ance.
- Cylinder head cover (page 9-7)
•
- Crankshaft hole cap (page 9-8)
Turn the crankshaft clockwise to align the punch
ma rk on the primary drive gear wi th the index mark
on the right crankcase cover. Make sure that the pis-
ton is at TDC (Top Dead Center) on the compression
stroke.
there is slack in the rocker arms. If there is no slack,
rolate the crankshaft clockwise one full tu rn and
align the punch mark on the primary dr ive gear wi th
t he index mark on the right crankcase cover again.
Check that the index line on the cam sprocket aligns
with the "6." mark on the camsh~ft holder.
Measure the decompressor arm clearance by insert -
ing a feeler gauge between the decompressor lifter
arm adjuster and right side rocker arm .
DECQMPRESSQR CLEARANCE:
RIGHT SIDE EXHAUST VALVE CLEARANCE
+
0.35 mm (0.014 in)
EXAMPLE:
If measured ri ght exhaust valve clearan ce is 0.28
mm (0.0 11 in ), decompressor clearance is;
0.28 mm (0.011 i n) ... 0.35 mm (0.014 in) '" 0.63 mm
(0.025 in)
If decompressor clearance needs adjustment, see
following procedure.
Measure the right exhaust valve clearance by insert-
ing a feeler gauge between the r ight side rocker arm
and shim.
VALVE CLEARANCE :
EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)
Pull out the feeler gauge between the rocke r arm
and shim.
4-18 •
MAINTENANCE
Insert a feeler gauge (r ight exhaust valve clearance
+ 0.35 mm (O.014 in)) between the adjuster and right
side rocker arm.
Loosen the lock nut and turn the adjuster until there
is a slight drag on the feeler gauge.
Hold the adjuster and tighten the lock nut.
TORQUE: 10 N -m (1.0 kgf-m . 7 tbf.ft)
Recheck the decompressor clearance.
Install the fo ll owing:
- Crankshaft hole cap (page 9-39)
- Cyl i nder head cover (page 9-42)
DECOMPRESSOR SYSTEM (After '07)

Remove the cyl i nde r head cove r (page 9-7).
Make sure of the plunger operation using the fol -
lowing procedure:
,. Move the decompressor weight outwa rd with
your finge r.
- The plunger operation is normal if it is
retracted.
2. Release the decompressor weight.
- The decompressor weight shou ld move inward
automatically.
- T he plunger ope ration is normal if it is pro-
truded.
ENGINE OIL/OIL FILTER

OIL LEVEL INSPECTION
St art th e engine and let it idle for 3 minutes.
Stop the engine and wait 3 m inutes.
Support the motorcycle u pright on a level surface.
Remove the oi l fille r cap/dipstick and wipe the oil
with a clean cloth.
Insert the dipstick without screwing it in, remove it
and check the oil level.
If the oil level is below or near the lower level line
on the dipstick, add the recommended engine oil to
the upper level line through the oil filler hole.
Add the recommended engine o il to the upper level

line.
Orher viscosities RECOMMENDED ENGINE OIL:
shown in rhe eIlan Pro Honda GN4 4·stroke oil (U.S.A . and Canada) or
may be used when equ ival ent motor oil
the average API s ervice classification : SG or Higher
temperature in your JASO T 903 standard: MA
riding area IS within
Viscosity: SAE 10W·30
the mdlcared range.
OIL CAPACITY:
0.67 liter (0.71 US qt, 0.59 Imp qt) at draining
0.70 liter (0.74 US qt, 0.62 Imp qtl at oil filter change
Install the oil filler cap/dipstick.
4-19
MAINTENANCE
ENGINE OIL & FILTER CHANGE
Remove the left engine guard (page 3-5),
Change the engine Start the engine and let it idle for 3 minutes.
oil with the engine Stop the engine and wait 3 minutes.
warm and rhe Support the motorcycle upright on a level surface.
motorcycle on level
Remove the oil filler cap/dipstick.
ground to assure
complete dr8ining.
Place an oit pan under the engine to catch the oil. 1;--:};--!~~~~~~~~~3~EEl
Remove the engine oil drain bolt and sealing
washer.
Drain the engine oil.
10 Operate the kickstarter pedal five times or more
while pushing the engine stop switch, so the
engine oil completely drains.
Remove the bolts, oi l filter cover and O-ring.
Remove the oil filter and spring.
4-20 •
MAINTENANCE
Apply oil to the engine oil drain bolt threads and
seating surface.
Install the engi ne oil drain bolt with a new sealing
washer.
Tighten the engine oil drain bolt to the specified
torque.
Apply grease to the oil fil t er spring contact area.

Install the spring into a new oil filter.
Install the oil filter with the "OUT SIDE " mark facing
out.
I NOTICE I
Installing the 0;1 filter reverse side will result in
severe engine damage.
Apply engine oi l to a new O-ri ng and install it to the
oil filter cover.
Install the oi l filter cover and tighten the bolts
securely.
Fill the engine with the recommended oil.
OIL CAPACITY:
l 0.67 liter (0.71 US qt, 0.59 Imp qtJ at draining

0.70 liter (0.74 US qt, 0.62 Imp qt) at oil filter change
Install the oil filler cap/dipstick.
Recheck the oil level (page 4-19).
Make sure there are no oil leaks.
Install the left engine guard (page 3-5).
4-21
MAINTENANCE
ENGINE IDLE SPEED
• Inspect and adjust the idle speed after all other
engine adjustments are within specifications .
• The engine must be warm for an accurate idle
inspection and adjustment. Ten minutes of stop
and go riding is sufficient.
Warm up the engine, shift the transmission into
neutral, and hold the motorcycle upright.
Connect a tachometer according to its manufac-
turer's instructions.
Turn the throttle stop screw to obtain the specified
idle speed.
IDLE SPEED: 1.700 ± 100 rpm
TRANSMISSION OIL
OIL LEVEL INSPECTION
1. Start the engine and let it idle for 3 minutes.
2. Stop the engine and wait 3 minutes.
3. Support the motorcycle upr ight on a level sur-
face.
4. Remove the oil filler cap, oil check bolt and seat-
ing washer from the right crankcase cover. A
small amount of oi l should flow out of the check
bolt hole.
5. If no oil flows out of the check bolt hole, add rec-
ommended transmission oil slowly through the
oil filler hole until oil starts to flow out of the
check bolt hole. Install the oil check bolt with the
sealing washer and filler cap.
6. Repeat steps 1 - 5.
7. After checking the oil level or adding oil, install f~~;;~;~~

the oil check bolt with a new sealing washer.
Tighten the oil check bolt to the specified torque.
TORQUE: 10 N'm (1.0 kgf·m, 7 [bf.ft)
Install and tighten the oil filler cap securely.
4-22 •
MAINTENANCE
TRANSMISSION OIL CHANGE
• Transmission oil should be changed at least
every 15.0 hours of operation to ensure consis- J.,..:!lf~~~
tent performance and maximum service life of
both transmission and clutch components .
• Warm-up the engine before draining the oil. This
wi l l ensu re complete and rapid draining.
1, Support the motorcycle in an upright position on
a level surface.
2. Remove the oil filler cap from the right crankcase
cover.
3. Place an oil pan under the engine to catch the oil, !!I.......
then remove the transmission oil drai n bolt and
sealing washer.
4. After the oil has drained completely, apply trans-
mission oil to the transmission oil drain bolt
threads and seating surface, then install the drain ;,-.
bolt with a new sealing washer.
Tighten the transmission oil drai n bolt to the
specified torque.
TORQUE: 16 N'm (1 .6 kgf·m, 12Ibf.ft )
5. Fill the engine with the recommend ed transmis-
sion oil.
RECOMMENDED TRANSMISSION OIL:
Pro Honda GN4 4-stroke oil (U.S.A. and Canada )
or equivalent motor oil
API service classification: SG or Higher
Viscosity: SAE 10W·30
Oil CAPACITY:
0.65 liter (0.69 US qt, 0.57 Imp qt) at drain ing
0.75 liter (0.79 US qt. 0.66 Imp qt) at d isassembly
Check the oil level by following steps 1 - 4 in the oil .~..,.....,-""..,,=
level check procedure (page 4-22).
4-23
MAINTENANCE
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
Never inspect and Raise the rear w heel off the ground by placing a
adjust the drive workstand under the engine.
chain while the
Measure the chain slack, on the upper chain run,
engine is running.
midway between the sprockets.
CHAIN SLACK: 25 - 35 mm (1 .0 - 1.4 in)
I NOTICE I
Excessive chain slack, 60 mm (2.4 in) Of more, may
damage the frame.
ADJUSTMENT
If the chain needs adjustment, loosen the axle nut I"'..,,...r:;:;;:~';.';::;;:;"
and adjuster lock nuts, and turn the adjusters.
Check that the index marks are in the same position
on each side, then tig hten the axle nut to the speci-
fied torque.
TORQUE: 128 N 'm (13.1 kgf·m, 94lbf.ft)
After torquing the axle nut, seat the adjusters
snugly against the adjusting blocks and tighten the
adjuster lock nuts to the specified torque.
TOROUE: 27 N'm (2.8 kgf·m, 20 Ibl·ft)
CLEANING AND LUBRICATION

Clean the dri ve chain in non-flammable or high , - - - -- - - - - - - - - - - - -,
flash-poin t solvent and wipe it dry. SOFT BRUSH
SOLVENT
Be sure the chai n has dried completely befo re lubri-
cating.
Inspect the chain for possible wear or damage;
replace any chain that has damaged railers or loose CLEANIN G
fitting links.
Replace any chain that has damaged rollers, loose
fining links, or otherwise appea rs unserviceable. WIPE AND DRY D Q DC
Installing a new chai n on badly worn sprockets will

cause the new chain to wear quickly.
Inspect and replace sprocket as necessary. LUBRICATE :~ ~
Measure the drive chain inner plate width.

SERVICE LIMIT: 13.4 mm (0.53 in)
SERVICE LIMIT: 13.4 mm (O.53 in)
If the measurement exceeds the service limit,
replace the chain.
o o o o
•
4-24 •
MAINTENANCE
lubricate the drive chain with #80 - 90 gear oil or
drive chain lubricant designed specifica lly for use LUBRICATE
with O-ring chains. Wipe off the excess oil or chain
lubricant.
#80 - 90 GEAR Oi l OR
DRIVE CHAIN LUBRICANT
REPLACEMENT
This motorcycle uses a drive chain with a staked
master link.
loosen the drive chain (page 4-24),
When using the Assemble the speciel tool as shown.
special tool, foJlovv
1M manufacture, 's TOOL:
instruction_ Drive chain tool set 07HMH-MR10103 or
07HMH-MR1010C
(U.S.A . only)
DRIVE CHAIN TOOL SET
l l ocate the crimped pin ends of the master link from

the outside of the chain , and remove the link with MASTER LINK
the drive cha in tool set.
TOOL:
Drive chain tool set 07HMH·MR10103 or
07HMH·MR101OC
(U.S.A. only)
Remove the drive chain.
4-25
MAINTENANCE
Include rhe master Remove the excess drive chain links from a new
) ID
Imt wflen you drive chain with the drive chain tool set.
count Ihe drive
ctJ4in links STANDARD LINKS: 114 LINKS
REPLACEMENT CHAIN: DI0520MXV

, LINK
• Never reuse the old drive cha in, master li nk,

master link plate and D-ri ngs.
~==================
Q·RINGS PLATE
Insert rhe master Assemble the new master link, O-rings and plate.
link from the inside
of the drive cham.
and Ins/all the pleTe
with rhe
ICIemlflCBllOfI mart
fBCing The OUTSide.
Assemble and set the drive chain tool set.

TOOL:
Drive chain tool set 07HMH· MR10103 or
07HMH· MR101OC
(U.S.A . only)
Make sure that the master link pins are installed ;::=================~
properly. MASTER LINK PINS
Measure the master link pin length projected from
the plate.
STANDARD LENGTH:
1.15 -1 .55 mm 10.045 - 0.061 in)
Stake the master link pins.
4-26 •
MAINTENANCE
Make sure that the pins are staked properly by mea-
suring the diameter of the staked area using a slide SLIDE CALIPER
caliper.
DIAMETER OF THE STAKED AREA:
5.50 - 5.80 mm (0.217 - 0.228 in)
A drive chain with iI After staking, check the staked area of the master ~=================~
eli/Hype master/mk link for cracks.
mUSl nOI be used. If there is any cracking, replace the master link, 0-
rings and plat e. GOOD NO GOOD
~v CRACKED
DRIVE CHAIN SLIDER

CHAIN SUDER
Inspect the drive chain slider for excessive wear.
SERVICE LIMIT: 5.0 mm (0.20 in ) from upper surface
I NOTICE I
If the chain slider becomes worn through to the
5wingarm, the chain will wear against the
swingarm, damaging the chain and swingBrm.
CHAIN SLIDER
l Check the chain guide and chain guide slider for
alignment, wear or damage.
~=:=::::::===============~
'05 - '07 shown:
INSPECTION WINDOW
Replace the chain guide if it is damaged or worn.
Replace the chain guide slider if the slider is worn to
the bottom of the wear limit indicator.
( CHAIN GUIDE
4-27
MAINTENANCE
DRIVE CHAIN ROLLER
Remove the lete step bracket (page 15-30).
Inspect the drive chain roilers for excessive wear or ~- ~ MARK
binding.
SERVICE LIMIT:
Minimum roller 0 .0 .: Upper: 39 mm 11.5 In)
Lower: 35 mm (1 .4 In )
Install the dnve Replace the rollers if necessary. and tighten the
dlsm rollers With roller bolt and nut to the specified torque.
the '- ' mark factnQ
TORQUE:
""t. Drive chain roller bolt: 12 N'm 11 .2 kgf-m, 9 rbl·tt)
Dri\l8 ch ain roller nut : 12 N 'm (1.2 kgf-m , 9 rbf·tt)
NOTE:
• Upper roller: Green
• Lower roller: Black
DRIVE/DRIVEN SPROCKET
Inspect the drive and driven sprocket teeth for wear , - - - - - - - - - - - - - - - - - - ,
or damage, replace them if necessary.
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condi-
tion. or the new replacement chain will wear rap-
idly.
NORMAL
Check the bolts and nuts on the drive and driven

sprockets.
If any are loose, torque them.
TORQUE:
Drive s procket bolt:
31 N'm (3.2 kgf·m, 23 IbUtl
Driven sprocket nut:
32 N 'm (3.3 kgf·m. 24 Ibf.ftl
4-28 •
MAINTENANCE
BRAKE FLUID
I NOTICE
Spilled fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
• Do not mix different types of fluid, as they are
not compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
FLUID LEVEL INSPECTION
When the flu id level is low, check the brake pads for
wear (pa ge 4-30), A low flu id level may be due to
wear of the brake pads. If the brake pads are worn,
the caliper piston is pushed out, and th is accounts
for a low reservoir level.
If the brake pads are not worn and the fluid level is
low, check the entire system fo r leaks (page 4-29).
FRONT BRAKE:
Turn th e handlebar so that the reservoir is level and
check the front brake fluid level.
If the level is near the lower level line, check the
brake pad wear (page 4-30),
REAR BRAKE:
Support the motorcycle in an upright position on a
level surface,
r--
If the level is near the lower level l ine, check the
brake pad wear (page 4-30),
FLUID FILLING
• Inspect the brake ' hose and fittings for deteriora-
tion, cracks or signs of leakage, Tighten any
loose fittings,
• Replace the hose and fittings as required,
FRONT:
Remove the screws, cover and diaphragm,
Fill the reservoir with DOT 4 brake fluid to the upper UPPER LEVEL LINE
level li ne.
Install the diaphragm and cover.
Tighten the screws t o the specified torque.
TORQUE: 1.0 N,m (0.1 kgf·m , 0.7 Ibf.ft)
Check the entire system for leaks.
4-29
MAINTENANCE
REAR:
Remove the bolts, cover, plate and diaphragm .
Fill the reservoir with DOT 4 brake fluid to the upper
level line.
Do not bend the Install the diaphragm, plate and cover.
diaphragm during Tighten the bolts t o the specified torque.
installation.
TORQUE: 1.0 N'm (0.1 kgf·m , O.7Ibf.ft)
Check the entire syst em for leaks.
BRAKE PAD WEAR

Check the brake pads fo r wear.
Front ('05 - '07 shown):
:'U
Replace the brake pads if either pad is worn to the '.0 mm (0.04 in)
bottom of the wear limit groove. I
For brake pad replacement (page 16-10)' . .
LIMIT GROOVE
1.0 mm
(0.04 in
1.0mm
(0,04 in)
LIMIT GROOVE
BRAKE SYSTEM
LEVER POSITION INSPECTION
The brake lever position can be adjusted by 1005en-
ing the lock nut and turning the adjuster. LOCK\,T ADJUSTER
Turning the adjuster clockwise moves the brake
lever farther away from the grip; turning the A-
V 5) L-
adjuster counterclockwise moves the brake lever
closer to the grip.
.-i-J
-- ,.
Apply grease to the
contact faces of the
After adjustment, hold the adjuster and tighten the
lock nut to the specified torque.
1-1
~~~ .---T
adjuster and piston.
f--', LESS THAN 20 mm
'©'
TORQUE: 5.9 N'm 10 .6 kgf·m , 4.4 Ibf.ft)
, (0.8 i n)
If the brake lever f reeplay exceeds 20 mm (0.8 in), ,,
there is ai r in the system that must be bled .
For brake system bleeding (page 16-7).
AiSiII
4-30 •
MAINTENANCE
BRAKE PEDAL HEIGHT
Adjust the brake pedal to the desired height by 1005- r - - - - - - -- - - - - - - - -- - ,
eni ng the lock nut and turning the b r ake pedal
adjuster.
STANDARD LENGTH : 79 .6 mm (3.13 in)
Tighten the lock nut to the specified torque.

TORQUE: 5.9 N'm (0.6 kgf·m , 4.4 Ibf.ft)
mm
(3.13
in)
LOCK
HEADLIGHT AIM
Adjust the headlight beam vertically by turning the
adjusting screw on the front visor.
CLUTCH SYSTEM
Measu re the clutch l ever freeplay at the lever end.
FREEPLAY: 10 - 20 mm (3 / 8 - 13 / 16 in)
10-20mm (318-13116 i n)
l
Minor adjustments can be made with the cable end
adjuster.
Turning the cable end adjuster in direction A will
increase freeplay and turning it in direction B wi ll
decrease freeplay.
If the adjuster is threaded out near its limit and the
correct freeplay cannot be reached, turn the
adjuster in di rection A u ntil it seats lightly and then
turn it out one turn in direction B.
Make the major adjustment with the in-line cable
adjuster.
CABLE END ADJUSTE R
4-31
MAINTENANCE
Major adjustments can be made with the in-tine
cable adjuster.
loosen the lock nul and turn the adjuster.
Tighten the lock nut.
If proper freeplay cannot be obtained using both
procedures or the clutch slips during the test ride,
disassemble and inspect the clutch (page 11-9).
CONTROL CABLES
Remove the dust cover and throttle housing bolts.
Turn the handlebar to the right fully and remove the
throttle housing from the handlebar.
Disconnect the throttle cable end from the throttle
pipe.
If is nor necessary Thoroughly lubricate the cable ends with a commer-
to lubricafe the cially available cable lubricant.
entire cable. If the throttle operation is not smooth, replace the
cable.
Be sure the throttle returns freely from fully open to
fu l ly closed automatically, in all st eering positions.
Turn the adjuster and remove the clutch cable.

Disconnect the clutch cable upper end and hot start HOT CABLE CABLE ENDS
cable upper end from the levers.
It;s nor necessary Thoroughly lubricate the cable ends with a commer-
to lubricate the cially available cable lubricant.
entire cable.
If the clutch lever and hot start lever operation is not
smooth, replace the cable.
CIIHCH CABLE
Apply grease to the clutch cable end adjuster inside

su rface.
CABLE END ADJUSTER

•
4-32
MAINTENANCE
EXHAUST PIPE/MUFFLER
EXHAUST SYSTEM INSPECTION
Check the muffler joint band bolt and exhaust pipe 1~~~~J!.~
joint nuts for looseness and exhaust gas leaks. .,.:;; _.,....
Tighten the bolt and nuts of the exhaust system to
the specified torque.
TOROUE:
, Exhaust pipe joint nut:
21 N'm !2. 1 kgf·m , 15lbf·ftJ
Muffler joint band bolt:
21 N'm 12.1 kgf·m , 15 Ibf.ft)
SPARK ARRESTER
REMOVAL
Remove the bolts, spark arrester assembly and gas-
ket.
INSPECTION/ CLEANING
Check the mesh screen is in good condition.
'05 - '07 shown:
Use a soft brush to remove carbon deposits from
the spark arrester screen. Be careful to avoid dam-
aging the spark arrester screen.
The spark arrester must be free of breaks and holes,
replace it if necessary.
4-33
MAINTENANCE
INSTALLATION
'05 - '07: Install a new gasket, spark arrester assembly and r::~-::~,:",,-
bolts.
TORQUE: 12 N'm (1.2 kgf·m, 9 [bUt)
After '07: Apply molybdenum disulfide grease (T8 1901 or

equivalent) to the bolt threads.
Install a new gasket, spark arrester assembly and
bolts.
TORQUE: 6 N'm (0.6 kgf·m. 4.4 Ibf.ft)
SIDESTAND
INSPECTION
Support the motorcycle u pright on a level surface.
Check the sidestand spring fo r damage or loss of
tension.
Check the sidestand assembly for freedom of move-
ment and lubricate the sidestand pivot sl iding sur-
face if necessary.
Check the pivot bolt and nut on the s idestand.
Tight en the pivot bolt to the specified torque.
Loosen the pivot bolt cou nterclockwise 45" - 90",
and tighten the pivot nut t o the specified torque
while holding the pivot bolt.
TORQUE:
Sidestand pillot bolt:
10 N'm (1.0 kgf·m. 7 IbHt) - 45" to 90"
Sidestand pillot nut:
39 N'm (4.0 kgf'm , 29 Ibf·it)
SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the f orks by operating the front
brakes and compressing the front suspension sev-
eral times.
Check the entire assembly for signs of leaks, dam-
age or loose fasteners.
Make su re the fork protectors and dust seals are
clean and not packed with mud and dirt.
Remove any di rt that has accumulated on the bot-
tom of the fork seals.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolt s.
For fork service (page 14-13).
4-34
MAINTENANCE
Air pressure acts as a progressive spring and affects
the entire fange of fork travel.
Air is an unstable gas; it increases in pressure as it
is worked (such as in a fork), so the fork action on
this motorcycle will get stiffer as the race
progresses.
Release built -up air pressure from the fork legs after
practice and between motos.
Be sure the fork is fully extended with the front tire
off the ground.
, Loosen the pressu re release screws fully, then
tighten them.
TORQUE: 1.2 N·m (O.l kgf·m. 0.9 IbUt)
REAR SUSPENSION INSPECTION

Check the action of the shock absorber by com-
pressing it several times.
Lift the sub-frame (page 6-11).

Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
For shock absorber service (page 15·14).
l ower the sub-frame (page 6-25).
SWINGARM/SHOCK LINKAGE
Raise the rear wheel off the ground by placing a
workstand or equiva lent under the engine.
Check for worn swingarm bea r ings by grabbing the
rear swingarm and attempting to move the
swingarm side-to-side.
Replace the bearings if excessively worn (page 15·
39).
Check the shock linkage and replace any damaged
needle bearings.
4-35
MAINTENANCE
Disassemble, clean, inspect the swingarm and
shock linkage pivot bearings and related seals about
7.5 hours of operation (page 15-32).
Lubricate and reassemble.
NUTS,BOLTS,FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page ' -14).
Check that atl safety clips, hose clamps and cable
stays are in place and properl y secu red.
WHEELS/TIRES
Raise the front wheel off the ground by placing a
workstand or equivalent under the engine.
Hold the fork leg and move the front w heel side-
ways wi th force to see jf the wheel bearings are
worn.

Hold the swingarm and move the rear wheel side-
ways with force to see if the wheel bearings are
worn.
4-36
MAINTENANCE
Check the tires for cuts, embedded nails, or other
damage.
Check the front (page 14-9) and rear (page 15-9 )
wheels for trueness.
Tire pressure Check the cold tire pressure.
should be dJOCked
when the tires are TIRE PRESSURE:
cold. FRONT: 98 kPa (1.0 kgf/c m ~, 14 psi)
REAR: 98 kPa (1.0 kgf/cml. 14 psi)
Inspect the wheel rims and spokes for damage.

Tighten any loose spokes and rim locks to the speci-
fied torque.
TOOLS:
FRONT:
Spoke wrench, 6.1 mm 07JMA·MR60100 or
0770'-0020300 {6.1
mml
REAR:
Spoke wrench, 6.6 mm 070MA·KZ30100
TORQUE:
Front spoke:
3.68 N'm (0.4 kgf·m , 2.7 Ibf.ft)
Rear spoke:
3.7 N'm (0.4 kgf·m, 2.7Ibf.ft)
Front/ rear rim Lock:
12 N'm 11.2 kgf-m , 9Ibf.ft)
STEERING HEAD BEARINGS

Raise the front wheel off the ground by placing a
8e sure the control Check that the handlebar moves free ly from side-to-
cables do nor side.
interiere with
handlebar roration.
4-37
MAINTENANCE
Check the steering stem bearings by grabbing the
fork legs and attempti ng to move the front fork for-
1
ward to backward.
If the handlebar moves unevenly, binds, or has ver-
tical movement, inspect the steering head bearings
(page 14-48).
If excessive play has detected, check the steering
stem fo r cracks.
4-38 •
5. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM ·········· 5·2 PRESSURE RELIEF VALVE .............. .......... 5·5
SERVICE INFORMATION ........................... 5·3 OIL JET ························································5·6
TROUBLESHOOTING ....................... .......... 5·3 OIL PUMP ..................................... .............. 5·7
OIL STRAINER ············································ 5·4
5-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
'05 - '07 shown:
PISTON
MAINSHAFT
OIL JET
OIL PUMP _ _--.&
PRESSURE REUEF
VALVE
Oil PUMP GEAR
CRANKSHAFT
OIL STRAINER SCREEN
5-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Used engine oi l may cause skin cancer if repea tedly left in contact with the skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is st ill advisable to thorough ly wash you r ha nds with soap and
water as soon as possi ble efter handling used oi l.
• The oil pump service requires engine removal.

• The service procedures in this section must be preformed with the engine and transmission oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
SPECIFICATIONS
Canada) or equivalent motor oil

MA
Canadal or equivalent motor i

SAE lOW~30
pump
TORQUE VALUE
Oil jet mounting bolt 10 N'm (1.0 kgf·m, 7 Ibf·ft) Apply locking agent to the th reads
TROUBLESHOOTING
Oil level too low- high o il consumption
• Oil not changed often enough
l • External oil leaks
• Worn piston rings or incorrect piston ring installation
• Worn valve guide or seal
Oil contami nat io n
• Oil not cha nged often enough
• Worn piston rings or incorrect piston ring installation
• Worn valve guide or seal
• From coolant mixi ng with oil
- Fau lty mechanical seal
- Faulty head gasket
- Water leak in crankcase
5-3
LUBRICATION SYSTEM
OIL STRAINER
REMOVAL/INSPECTION
Remove the foHowing:
- Left crankcase cover (page 12-4)
- Flywheel (page 12·5)
- Balancer (page 13-8)
Remove the snap ring and oi l pump driven gear.
Remove the drive pin.
Remove the bolts, gu ide plates, oil st rainer and

grommet.
Remove the O-ring from the oil strainer.

Check the oil strainer for damage or clogs.
Clean the oil strainer screen.
Oil STRAINER
Check the oil pump driven gear for wear or damage.
Oil PUMP DRIVEN GEAR
5-4
LUBRICATION SYSTEM
INSTALLATION
Apply oil to a new O-ring and install it onto the oil
strainer.
Install the grommet onto the oil strainer.
Install the oi l strainer to the crankcase.
Insta ll the guide plates and tighten the bolts

securely.
Insta ll the dri ve pin into the oi l pu mp shatto

Install the oil pump driven gear aligni ng its cut-outs
with t he drive pin.
Install the snap ring securely.
Insta ll the following:
- Ba lancer (page 13-8)
- Flywheel (page 12-6)
PRESSURE RELIEF VALVE

l REMOVAL/INSPECTION
Remove the left crankcase cover (page 12-4),
Remove the snap ri ng and pressure relief valve
from the left crankcase cover.
5-5
LUBRICATION SYSTEM
Check the pressure relief valve for damage or clogs.
Remove the O-ring from the pressure relief valve .
INSTALLATION
Apply oil to a new O-ring and install it onto the
pressure relief valve.
Instal l the pressure relief va lve into the left
crankcase cover.
Ahar installing 8 Install the snap ring securely.
snap ring, a/ways Install the left crankcase cover (page 12-6).
rotate it in its
groove /0 be sure it
IS fully seated.
OIL JET
REMOVAL/INSPECTION
Separate the left and right crankcase halves (page ,..~~~'O:
13-10).
Remove the bolt and oil jet from the left crankcase.
Check the left crankcase oil passage fo r clogg i ng.
Clean the oil passage.
Check the oil jet for damage or clogging.

Blow the oil passage in the oil jet w ith compressed OIL JET
air.
5-6 •
LUBRICATION SYSTEM
INSTALLATION
Install the oil jet onto the left crankcase.
Apply locking agent to the oil jet mounting bolt and
tighten it to the specified torque.
TORQUE: 10 N'm 11.0 kgf·m . 7 Ibf.ft)
Assemble the left and righ t crankcase halves (page
13·25).
OIL PUMP
DISASSEMBLY
Remove the engine from the fra me (page 8-5).
Separate the left and right crankcase halves (page
13-10).
Remove the oil pump inner/outer rotors and shaft.
Remove the one-way valv8.
INSPECTION
Check the one-way valve for wear or damage.
Check the oil pump shaft for wear or damage.
Check the left cra n kcase cover oil seal f or damage

o r deterioration.
Replace the oil seal if necessary.
After installing B Check that the washer and snap ring are inst alled in
snap ring. always the left crankcase cover securely.
rotate It in irs
groove to b6 sure ir
IS fully seared.
5-7
LUBRICATION SYSTEM
Temporarily install the oil pump shaft.
Install the outer and inner rotors into the cr ankcase.
Measure the tip clearance.
SERVICE LIMIT: 0.20 mm 10.008 in)
Measure the body clearance.

STANDARD: 0.15 - 0.21 mm (0.006 - 0.008 in)
Me8sure rhe Measure the side clearance using a straight edge

c/tMrance with the and feele r gauge.
r;askef instslled.
STANDARD: 0.05 - 0.13 mm (0.002 - 0.005 In)
ASSEMBLY
Apply oil to the oil pump inner/outer rotors sliding
surlaces.
Install the oi l pump inner/outer rotors and shaft.
Install the one-way valve onto the left crankcase as
shown.
Assemble the left and right c rankcase ha lves (page
13-25).
Insta ll the engine to the frame (page 8-8),
5-8
6. FUEL SYSTEM
COMPONENT LOCATION .......................... 6·2 CARBURETOR DISASSEMBLy ··············· 6· 13
SERVICE INFORMATION .......... ................. 6·3 CARBURETOR ASSEMBLy · .. ·················· 6·18
TROUBLESHOOTING .................. .......... ..... 6·5 CARBURETOR INSTALLATION ..... ......... . 6·24
CARBURETOR ADJUSTMENT ··················6·6 THROTTLE POSITION SENSOR

REPLACEMENT ................... ..................... 6·26
AIR CLEANER HOUSING ··························· 6·7
PILOT SCREW ADJUSTMENT ................ 6·27
CARBURETOR REMOVAL··········· ·········· ··· 6· 11
SECONDARY AIR SUPPLY SYSTEM
{'05 and '06 California type. After ·061 ·· ·· 6·29
'-
6-1
FUEL SYSTEM
COMPONENT LOCATION
'OS - '07 shown:
3.4 N'm 10.3 2.5Ibf.ft)
r
·
~----.-----------------\
: After '07:
•
.
'
• ••
i~i
!.-------------------
..-;::::::===>:;,-./(
49 . 15.0 kgf·m . 36 Ibf.ft )
6-2
FUEL SYSTEM
SERVICE INFORMATION
GENERAL
• Bending or twisting the control cables will impair smooth operation and could cause the cable to stick or bind, resulting
in loss of vehicle control.
• Work in a well venti lated area. Smoking or allowing flames or sparks in the work area or where gasol i ne is stored can
cause a fire or explosion.
• Before disassembling the carburetor, place an approved gasoline container under the carburetor drain plug, remove the
drain pl ug and drain th e carburetor.
• When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassem-
biV.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with a piece of tape to
prevent any foreign material from dropping into the engine. Be sure to remove the cover when reinstalling the carbure-
tor.
• If the vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause
clogged jets resulting in hard starting or poor driveability.
SPECIFICATIONS
•
; ,
iii
56 kPa (420 mm Hg)
4 - 6k!l
'-.
6-3
FUEL SYSTEM
TORQUE VALUES
Rear fender mounting bolt 13 N·m 0,3 kgf·m. 10 Ibf·tt)
Sub·frame upper mounting bolt ('05 - '07) 30 N·m (3.1 kgf·m, 22 Ibf.ft)
Sub·frame lower mounting bolt ('05 - '07) 49 N·m (5.0 kgf·m, 3S IbHt)
Sub·frame upper/lower mounting bolt (After '07) 49 N'm (5.0 kgf·m, 36 Ibf.ft)
Shock absorber upper mounting nut 44 N·m (4.5 kgf·m, 32 Ibf.ft) U·nut
Throttle drum cover bolt 3.4 N'm (0.3 kgf·m, 2.5 Ibf.ft)
Needle jet 1.8 N·m (0.2 kgf·m, 1.3 Ibf.ft)
Main jet 1.5 N·m (0.2 kgf·m, 1.1 Ibf.ft)
Slow air jet ('05 -'07) 0.9 N'm (0.1 kgf·m, 0.7 lbf.ft)
Starter jet 1.5 N·m (0.2 kgf·m, 1. 1 IbUtl
Slow jet 1.5 N·m (0.2 kgf·m, 1. 1 Ibf.ft)
Ace. pump bypass 0.3 N·m (0.03 kgf·m, 0,2 Ibf·ft)
Carburetor top cover bolt 2.1 N·m (0.2 kgf·m, 1.5 Ibf.ft)
Float chamber screw 2.1 N'm (0.2 kgf·m, 1.5 Ibf·ft)
Carburetor drain plug 4.9 N·m (0.5 kgf·m, 3.S Ibf·ftl
Carburetor drain screw (After '05) 1.5 N·m (0 .2 kgf·m, 1.1 Ibf·ft)
Choke valve lock nut 2.1 N'm (0.2 kgf·m, 1.5 Ibf·ftl
Throttle bolt (carburetor side) 4 N·m (0.4 kgf·m, 3.0 Ibf·ft)
Throttle shaft screw ('05, '06) 2.1 N·m (0.2 kgf·m, 1.5 IbHtl Apply locking agent to the
threads
Throttle shaft torx screw (After '06) 2.1 N'm (0.2 kgf·m, 1.5 Ibf·ftl Apply locking agent to the
threads
Needle holder 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
Accelerator pump cover screw 2.1 N·m (0.2 kgf·m, 1.5 Ibf.ft )
Hot start valve lock nut 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
Throttle position sensor torx screw ('05. '06) 3.4 N·m (0.3 kgf·m, 2.5 Ibf.ft)
Throttle position sensor bolt (After '06) 3.4 N'm (0.3 kgf·m, 2.5 Ibf·h)
PAIR control valve mounting nut 13 N'm (1.3 kgf·m, 10 Ibf·ft)
TOOLS
Carburetor float level gauge Pilot screw wrench ('OS, 'OS) Pilot screw wrench (After '06)
07401-0010000 07908-4730002 07KMA-MSS0102
-'
6-4
FUEL SYSTEM
TROUBLESHOOTING
Engine w ill not start
• Too much fuel getting to the engine
- Air cleaner clogged
- Flooded carburetor
• Intake ai r leak
• Fuel contaminated/deteriorated
• No fuel to carburetor
- Fuel filter clogged
- Fuel line clogged
- Fuel valve stuck
- Float level m isadjusted
- Fuel tank breather hose clogged
• Slow circuit clogged
• No spark at plug (faulty spark plug or ignition system malfunction) (page 4-12)
Lean mixture
• Fuel jets clogged
• Fuel tank breather hose clogged
• Fuel filter clogged
• Fuel hose restricted
• Float valve faulty
• Float level too low
• Air vent hose clogged
• Intake air leak
Misfiring during acceleration
• Ignition system faulty (page ' 8-5)
• lean mixture
Afterburn during acceleration
• Ignition system faulty (page 18-5)
• Lean mixture
• Accelerator pump faulty
Rich mixture
• Choke valve in the "ON " posit ion
• Float va lve faulty
• Float level t oo high
• Air jets clogged
• Air cleaner element contaminated
• Flooded carburetor
Engine stalls, hard to start, rough idling
• Fuel l ine restricted
• Ignition system malfun ction (page 18-5)
• Low cylinder compression
• Fuel mixture too lean/rich
• Fuel contaminated/deteriorated
• Intake air leak
• Float level misadjusted
• Fuel tank breather hose clogged
~ • Pilot screw misadiusted
• Slow circuit or starting enrichment circuit clogged
• Idle speed misadjusted
• Air cleane r clogged
Poor performance (driveability) and poor fuel economy
• Fuel system clogged
• Ignition system faulty (page 18-5)
• Ai r cleaner clogged
Afterfiring
• Ignition system malfunction (page 18-5)
• Carburetor malfunction
• Lean mixture
• Rich mixture
6-5
FUEL SYSTEM
CARBURETOR ADJUSTMENT
IDLE MIXTURE AND IDLE SPEED
STANDARD SETIING:
flOAT LEVEL: 8.0 mm 10.31 in)
PILOT SCREW INITIAL OPENING:
'05 - '07: ' -1/4 turns out
After '07: ' -1/ 8tums out
SlOWJET: ~5
MAIN JET:
'05 - '07: #142
After '07 : .145
JET NEEDLE:
·os, '06: NCVU
'07: NHTU
After '07: NNEU
JET NEEDLE CLIP POSITION :
'05, '06: 2nd position from the top
After '06: Fixed position
1. When the engine is warm enough to run without
the choke, push the choke knob in to its off posi-
tion.
2. Turn the throttle stop screw to obtain the

smoothest idle:
• To decrease idle speed, turn the throttle slop
screw counterclockwise.
• To increase idle speed, turn the throttle stop
screw clockwise.
3. Adjust the pilot screw to obtain the best off-idle

performance.
• If the engine runs rich exiting a corn er, turn the
pilot screw clockwise to lean the mixtu re.
• If the engine runs lean exiting a corner, turn the
pilot screw counterclockwise to fichen the mix-
ture.
6-6
FUEL SYSTEM
AIR CLEANER HOUSING
REMOVAL
- Seat (page 3-3)
Side covers (page 3-3)
Radiator shrouds (page 3-4)
Muffler ('05 - '07: page 3-9, After '07: page 3-11)
Regu lator/rectifier (page 17-8)
Banery (page 17-6)
loosen the air cleaner connecting boot band screw.
Unhook the band and air cleaner case cover from
the fuel tank.
Remove the sub-frame lower mounting bolts and

loosen the upper mounting bolts.
Do not ma ke less Lift the sub-frame as shown.

than 90°, Be care ful
Tighten the sub-frame upper mounting bolts to the
not to damage the
specified torque.
wires and cables.
TORQUE:
'05 - '07: 30 N-m !3.1 kgf·m ,22 lbf·ft) 90·
After '07: 49 N'm 15.0 kgf-m , 36 Ibf.ft)
~
UPPER MOUNTING BOLT
"- Except '05 and '06 Disconnect the crankcase breather hose.
California type,
After '06:
,
\
6-7
FUEL SYSTEM
'05 and '06 Disconnect the breather hose and PAIR air suction
California type, hose.
Aher '06:
Remove the bolt and collar.
Remove the screws and mud guard.

Remove the botts, collars and air cleaner housing.
Check the carbu reto r connecting boot is sealed
properly at the air cleaner housing.
Check the air cleaner housing for damage.
Remove the carbu retor connecting b oot from the ai r
cleaner housing and seal thoroughly if any sign of
inadequate sealing is detected.
6-8
FUEL SYSTEM
INSTALLATION
Install the removed parts in the reverse order of r emoval.
AIR CLEANI'R HOUSING
MUD GUARD
~) AIR CLEANER ElEMENT
_ : ApplV Honda Bond A or

~
'-"~/'---_-_ _
~J ELEMENT HOLDER
Honda HandgripCement
or equivalent
Route the wires Install the air cleaner housing , collars and bolts.
and hoses properly
Tighten the rear fender mounting boilS to the speci-
('05 - '07: page ,.
fied torque.
25, Aha! '07. page
'-32). Be C8reful not TORQUE: 13 N'm (1.3 kgf·m, 10 Ibf.ft) AIR CLE.'NE
to damage the
WIres /Jnd hoses. Install the mud guard and tighten the screws
securely _
I..
Install the collar and bolt.
Tighten the bolt securely.
6-9
FUEL SYSTEM
Except '051100 '06 Connect the crankcase breather hose.
~lrfo(mlJ type,
Aher '06:
'05 and '06 Connect the crankcese breather hose and PAIR air
Caltfoml8 type, suction hose.
After '06:
Lower the sub-frame and connect the air cleaner

connecti ng boot securely.
Tighten the sub-frame mounting bolts to the speci·
fied torque.
TORQUE ('05 - '07):
Upper: 30 N'm (3.1 kgf'm, 22 Ibf.ft)
lower: 49 N'm (5.0 kgf·m, 36 Ibf.ft)
TORQUE (After '07):

Upper/ lower: 49 N 'm (5.0 kgf-m , 36 Ibf.ft'
Tighten the air cleaner connecting boot band screw

securely.
Hook the ai r cleaner case cover and band securely
to the fuel tank.
Install the following:
- Banery (page 17·6)
Regulator/rectifier (page 17-8)
Muffler ('05 - '07: page 3-9, After '07: page 3·11 )
Radiator shroud s (page 3-4)
Side covers (page 3-3)
Seat (page 3-3)
6-10 •
FUEL SYSTEM
CARBURETOR REMOVAL
- Seat (page 3-3)
- Muffler ('05 - '07: page 3-9, After '07: page 3-11 )
- Fuel tank (page 3-8)
Support the motorcycle using a workstand or equiv-
alent under the engine.
Loosen the air cleaner connecting boot band screw.
Remove the sub-frame lower mounting bolts and

loosen the upper mounting bolts.
Do not lift Lift the su b-frame as shown.
past 90·,
Tighten the sub·frame upper mounting bolts to the
Be careful nor to
specified torque. SO"
dllmage the wires
and CtJbles. TOROUE:
'OS - '07: 30 N'm 13.1 kgf·m , 22lbf.ft)
After '07: 49 N·m (5.0 kgf·m, 36 Ibf·ft)
~ UPPER MOUNTING BOLT
Remove the shock absorber upper mounting nut ~:;~---Igiiii~~~~~~~~~

and bolt. ,
Pull back the shock absorber.
Disconnect the throttle position sensor 3P (Black)

u connector.
6-11
FUEL SYSTEM
Turn the handlebar to the right fully.
Loosen the carburetor insulator band screw and
remove the carburetor from the insulator.
loosen the hot start valve lock nut and remove the
hot start valve from the carburetor.
:~iT,~:i~i~~i~~~~~~~~~
Disconnect the hot start cable end from the hot start
valve and remove the valve spring.
Check the hot start valve for nicks, grooves or other
damage.
Check the hot start valve seat for wear.
Remove the bolt and throttle drum cover.
l oosen the lock nut, throttle bolt, adjuster and dis-

connect the throttle cables from the throttle drum.
Remove the carburetor to the rea r.
6-12 •
FUEL SYSTEM
CARBURETOR OISASSEMBL Y
JET NEEDLE/ THROTTLE VALVE
Disconnect the fuel hose, air vent hoses and over-
flow hose.
FUEL HOSE
Release the throttle position sensor wire from the
clamp. TOP COVER
Remove the bolts, clamp, top cover and O-ring.
'05, '06:
After '06:
Remove the needle holder and jet needle .
Remove the jet needle/holder assembly.
-
'05, '06: Check the jet needle for wear, nicks or other dam-
JET NEEDLE
age.
6-13
FUEL SYSTEM
After '06: Check the jet needle for wear, nicks or other dam-
age. After '06:
If necessary. remove the jet needle from the needle JET NEEDLE
holder by removing the needle clip.
t' (.~)
NEEDLE HOLDER
'05, '06: Remove the throttle shaft screw.

After '06: Remove the throttle shaft torx screw.
Lift up the throttle shaft arm and remove the throttle
valve assembly.
Remove the throttle valve plate and roller from the

THROTTLE
throttle valva.
. _ - - - "AlI/E PLATE
Check the throttle valva, throttle valve seal, roller
and throttle valve plate for scratches, wear or dam·
age.
Replace them if necessary.
ROLLER
CHOKE KNOB/THROTTLE SENSOR

Loosen the lock nut and remove the choke knob.
CHOKE KNOB
6-14
FUEL SYSTEM
Check the valve for damage or stepped wear.
'05, '06:
'05, '06 shown: THROTTLE POSITION
Remove the torx screw and throttle position sensor.
SENSOR
After '06:
Remove the bolt and throttle position sensor.
• When removing the throttle position sensor,
mark the sensor position ensure that it is rein·
stalled in the original location.
• The throttle position sensor is factory pre·set and
no adjustment is necessary unless the throttle
position sensor is replaced.
For sensor inspection (page 1S·9) and replace·
ment (page 6·26).
ACCELERATOR PUMP/FLOAT/JETS
Remove the screws and accelerator pump cover.
'05 - '07 shown:
NOTE:
• The accelerator pump cover is under spring pres·
sure.
• Do not lose the screws and O·ring.
Remove the spring, diaphragm, D·ring and O·ring.

O·RING
DIAPHRAGM
6-15
FUEL SYSTEM
Remove the screw and throttle stop screw stay.
FLOAT CH,AMISER STAY
Remove the screws, hose guides, and float cham-
ber.
Remove the O-ring from the float chamber. O-RING
The push rod link Pull out the push rod while holding the push rod l ink
lever adjusting lever.
screw is fac/ory
pre-set. Adjustment
and disassembly
are nor necessary.
Check the diaphragm for deterioration or pin hole.

Check the spring for damage or fatigue. SPRING
Check the push rod for wear, bends or damage .
PUSH ADD
Remove the float pin, float and float valve.

Check the float for damage or fuel in the float.
Replace the float jf necessary.
6-16
FUEL SYSTEM
Check the float valve and valve seat for scoring,
scratches, clogs or damage.
A~nor Check the tip of the float valve where it contacts the
ron/aminated floa t valve seat, for stepped wear or contamination .
valve will not seat
Check the valve seat for wear or damage.
properly and will
e\l8ntually flood the Clean or replace them jf necessary.
carburetor.
Remove the following :

-
-
Main jet
Needle jet
-
BAFFLE PLATE PILOT SCREW
- Baffle plate
- Starter jet
- Slow jet
Damage to the pilot Before rem oving the pilot screw, turn it in, counting
screw saar will the number of turns until it seats tightly so you can
occur" rhe PliOt return the pilot screw to its original position when
screw IS tightened reassembling .
agamst the sear
Remove the pilot screw, spring , washer and O-ring.
'05 - '07: Remove the slow ai r jet.
Remove the acc. pump bypass from the float cham-

ber.
Blow open the acc. pump bypass and fuel passage
l with compressed air.
Check the acc. pump bypass for clogs or damage.
6-17
FUEL SYSTEM
Blow open all jets with compressed air.
SLOW JET
Inspect each jet for clogs, wear or damage and
replace them if necessary.
Check the pilot screw for stepped wear or damage. PilOT SCREW
Check the spring for fatigue or damage.
'),,-- .~ ;-
.'~
)' SLOWAIRJET
""- ('05 - '071
/ \ NEECLE JET
MAIN JET STARTER JET
Blow open all carburet or body openings with com-
pressed air.
CARBURETOR ASSEMBLY
TOP COliER ,um A'" JET ('05 - '07) THROTTLE pn,<ITlnN SENSOR
THROTTLE VALVE
CHOKE KNOB
NEEDLE
HOLDER
FLOAT VALVE
FLOAT
O·RING "
FLOAT CHAMBER
THROTTLE
Ace. PUMP STOPSCAEW
BYPASS
NEEDLE HOLDER
PUSH ROD BAFFLE

NttOLtClIP PLATE
STARTER JET
,,-,-- DIAPHRAGM
NEEDLE JET
O·RING $-' •
SLOW
PILOT SCREW ADCEl.ER,UClR PUMP COVER
6-18
FUEL SYSTEM
Ins tall the throttleInstall the thranle position sensor by aligning the
poSlfion S9flSf)f to tabs of the throttle position sensor with the flat side THROTTLE POSITION
jlS original position of the shah as s hown.
as marked during
'05, '06:
remollal.
Tighten the torx screw to the specified torque.
TORQUE: 3.4 N'm (0.3 kgf·m, 2.5 Ibf.ft)
After tightening the After '06:

boll 10 the specified Tighten the bolt to the specified torque.
torque, brea/( the
bolt head. TORGUE: 3.4 N'm (0.3 kgf·m , 2.5 Ibf.ft)
• The throttle position se nsor is factory pre-set and
no adjustment is necessary unless the throttle
position sensor is replaced.
• For sensor inspection (pag e 18-9) and replace-
ment (page 6-26) .
Damage to the pilot Install the O-ring, washer, spring and pilot screw.
screw seat Will
SLOW JET
Perform pi lot screw adjustment if a new pilot scr ew
occur if the pilot
is instal led (page 6-27).
screw is tightened
against rhe sear • Install the pilot screw and return it to its original PilOT SCREW
position as noted during removal.
Install the slow jet, starter jet, baffle plate, needle jet ~ ,. .. ;-
and main jet.
TORQUE: )'.,~
Z ~LOWAIRJET
~05 - '07)
~EEDLEJET
Slow jet: 1.5 N'm (O.2 kgf·m, 1.1 lbf·ft)
Starter jet: 1.5 N'm (0.2 kgf·m, 1.1 lbf·ft)
Needle jet: 1.8 N'm (0.2 kgf·m, 1.3 Ibf.ft)
Main jet: 1.5 N'm (0.2 kgf·m, 1.1 Ibf·ft) MAIN JET BAFFLE PLATE STARTER JET
'05- '07: Install and tighten the slow air jet to the specified
torque.
TORQUE: 0.9 N·m (0.1 kgf·m , 0.7 lbf·ft)
Install the float valve, float and float pin.

l
6-19
FUEL SYSTEM
Set the float level gauge so it is perpendicular to the
float chamber face and in·line with the main jet. FLOAT LEVEL GA.UG;E
Set the carbu retor so the float valve just contacts

the float arm lip. Make sure the float valve lip is
securely in contact with the valve seat.
Make su re the float is level with the float level
gauge.
TOOL:
Carburetor float level gauge 07401·0010000
FLOAT LEVEL: 8.0 mrn 10.31 in)

If the float level is oul of specification. adjust it by
bending the lip.
Install the push rod while holding the push rod link
lever.
Install the acc. pump bypass into t he float chamber

and tighten it to the specified torque.
Install a new O-ring to the float chamber.

Install the float chamber to the carburetor.
6-20 •
FUEL SYSTEM
Install the hose guides and f loat chamber screws.
Tighten the screws to the specified torque .
TORQUE: 2.1 N'm (0.2 kgf·m , 1,5 Ibf.ft)
Install the throttle stop screw stay and tighten the
screw securely.
Install a new D·ring with it flat side facing forward r------::;~~:ru;NG

the accelerator pump cover. ~~
Install the diaphragm, spring, new Q· rings and ItiijiIII
accelerator pu mp cover.
Install and tighten the screws to the specified

torque. '05 - '07 shown:
TORQUE: 2.1 N 'm (0.2 kgf·m , l .5Ibf.ft)
Install the choke knob and tighten the lock nut to the
CHOKE
specified torque.
TORQUE: 2. 1 N·m (0.2 kgf·m , 1.5Ibf.ftl
6-21
FUEL SYSTEM
Note the installation Assemble the roller and throttle valve plate on the
directionofrhe throttle valve.
throttle valve plate. • Install the throttle valve plate with the seat side
facing towa rd the throttle valve.
•
VALVE
Install the throttle valve assembly into the ca rbure -
tor with the valve plate facing towards the engine t;';:~iil~~~~E
side .
• Make sure the throttle valve moves smoothly.
Align the holes in the throttle shaft arm and throttle
shaft .
'05, '06: Apply locking agent to the screw threads.
Install and tighten the throttle shaft screw to the
specified torque.
TORQUE: 2.1 N 'm (0.2 kg'·m, 1.5 IbHt)
After '06: Apply locking agent to the torx screw threads .

Install and tighten the throttle shaft torx screw to
the specified t orque.
TORQUE: 2.1 N'm (0.2 kgf·m, 1.5Ibf·ft)
'05, '06: Install the jet needle clip to the jet needle.
'05, '06: NEEDLE CLIP
STANDARD CLIP POSITION:
2nd pOSition from the top
JET NEEDLE
Afrer '06: Install the jet needle to the needle holder and then
install the needle clip to the jet needle, if it was After '06:
•
removed. JET NEEDLE
/ IC$
NEEDLE HOLDER
•
6-22 •
FUEL SYSTEM
'05, '06: Install the jet needle and needle holder into the
throttle valve.
-
'05, '06 shown:
Tighten the needle holder to the specified torque. NEEDLEHOLDER ~-;iI""'~
TORQUE: 2. 1 N -m (0.2 kgf·m , 1.5 IbUt)
Aher '06: Install the jet needle/holder assembly into the throt-
tle valve.
Tighten the jet needlelholder assemblv to the speci-
fied torque.
TORQUE: 2. 1 N ·m (0.2 kgf·m . 1.5 Ibf.ft)
Install a new D-ring and top cover.

TOP COliER
Install the clamp and bolts.

Tighten the bolt s to the specified t orque.
TORQUE: 2. 1 N'm (0.2 kgf·m , 1.5 rbf·tt l
Clamp the throttle position sensor wire as shown.
ROllla the hoses Connect the overflow hose. air vent hoses and fuel
property ('05 - '07: hose.
pag9 1-25, After
l '07: page 1-32).
OVERFLOW
FUEL HOSE HOSE
6-23
FUEL SYSTEM
CARBURETOR INSTALLATION
Connect the throttle cables to the throttle drum but
do not tighten the adjuster and lock nut yet.
Tighten the th rottle bolt to the specified torque.
TORQUE: 4 N 'm (0.4 kgf·m , 3.0 Ibf.ftl
Install the throttle d rum cover and bolt.

Tighten the bolt to the specified torque.
Install the valve spring over the hot start cable and
connect the cable end to the hot start valve.
Insta ll the hot start valve to the carburetor body,
and tigh t en the lock nut to the specified torque.
TORQUE: 2.1 N·m (0.2 kgf·m, 1.5 Ibf.ft)
Align the lug on the carburetor with the groove in

the carburetor insulator.
•
Tighten the insulator band screw (page 1-17),
6-24 •
FUEL SYSTEM
Connect the throttle position sensor 3P (Black) con·
nector.
Install the shock absorber upper mounting bolt and

nut.
Tighten the upper mounting nut to the specified
torque.
TORQUE: 44 N'm 14.5 kgf·m , 32 Ibf.ft)
Lower the sub-fram e and connect the air cleaner !1'.;,:~

connecting boot securely. ~,
Tighten the sub-frame mounting bolts to the speci·
fied torq ue.
TORQUE ('05 - '07):
Upper: 30 N'm (3.1 kgf·m, 22 Ibf.ft)
lower: 49 N'm (5.0 kgf·m, 36 Ibf.ft)
TORQUE (After '07):

Upper/lower: 49 N'm (5.0 kgf·m, 36 IbUt)

secu rely.
P--"
(
'- - Muffler ('OS - '07: page 3·9, After '07: page 3-11)
- Seat (page 3-3)
After installation, ch eck the followi ng:
- Secondary air leak around the in sulator and co n-
necti ng boot
- Fuel leaks around the fu el hose and carburetor
- Route the overflow hose, air vent hoses and fuel
hose properly ('05 - '07: page '-25, After '07:
page 1·32).
- Throttle ope ration (page 4-9)
- Hot start lever (page 4-10)
6-25
FUEL SYSTEM
THROTTLE POSITION SENSOR
REPLACEMENT
Remove the carburetor from the engine (page 6-11).
CLAM P
Remove the clamp, tone screw and throttle position
sensor.
In sta ll the throttle position sensor by aligning the

tabs of the throttle position sensor with the flat side f'o".l~_
of the shaft es shown.
'05, '06: Loosely install the screw.

'05, '06 shown :
After '06: Loosely install the bolt.
THROTIlE POSITION SENSOR
Measure the resistance between the Blue and Black

wire terminals of the sensor side connector. 3P CONNECTOR
STANDARD: 4 - 6 kO (20 c C/ 68"F)

Calculate the throttle position sensor resistance at
idle speed using the equation below.
Ax (O.13-0.15j""B ••
A: Blue and Black wire terminals resistance
B: Throttle position sensor resistance at idle speed
(Ex.)
If the Blue and Black wire terminals resistance is 5
kfl, then the thronle position sensor (YeJlow - Black)
resistance at idle speed is:
5 kfl x (0.13 - 0.15) '" 650 - 750 n
6-26 •
FUEL SYSTEM
Adjust the throttle position sensor position so the
resistance between terminals Yel low and Black is BLUE YellOW
resistance calculated.
'OS, '06:
Tighten the torx screw to the specified torque. BLUE
After rigl'llening the After '06:
bolt to the specified Tighten the bolt to the specified torque.
torqlJfl, break the
bolt head.
BLACK
Connect the throttle position sensor connector.
Install the carburetor (page 6-24), BLACK
PILOT SCREW ADJUSTMENT

NOTE :
• The pi lot screw is factory pre-set and no adjust-
ment is necessary unless the pilot screw is
replaced .
• Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate a 50 rpm
change.
BEST IDLE (,05, '06: 49 States and
Canada type only)
DamaQ8 to the pilot 1. Turn the pilot screw clockwise until it seats
screw sea t will lightly, then back it out the specified number of
occur if the pilor turns.
screw is tightened
against the seat. TOOL:
Pilot screw w rench 07908·4730002
STANDARD OPENING: 1·114 tums out

2. Warm up the engine to operating temperature.
Ride the motorcycle for approximately 10 m in·
utes.
3. Stop the engine and attach a tachometer accord·
ing to its manufacturer's instruction.
4. Start the engine and adjust the engine idle speed
to the specified rpm with the throttle stop screw.
IDLE SPEED: 1,700 ± 100 rpm
5. Turn the pilOt screw in or out slowly to obtain the
l highest engine speed.

S. Readjust the idle speed to the speci fied rpm with
the throttle stop screw.
6-27
-------------
FUEL SYSTEM
IDLE DROP PROCEDURE ('05 and '06
California type, '07, After '07)
Damage to the pilot 1. Turn the pilot screw clockwise until it seats
screw seal will lightly, and then back it out to the specification
occur if the pilot given.
screw is tightened TOOL:
against the seat. Pilot screw w rench 1'05, '06) 07908-4730002
(After '06) 07KMA-MS60102
INITIAL OPENING:
'05 and '06 California type, ' 07:1-114 turns out
After '01: 1- 118 turns out
2. Warm the engine up to operating temperaturB.

Stop and go riding for 10 minutes is sufficient. VACUUM HOSE
3. Stop the engine and connect a tachometer
according to its manufacturer's instruction.
4. Disconnect the PAIR control valve vacuum hose
and plug it to keep air from enteri ng, then con-
nect the vacuum pump to the PAIR control valve
vacuum hose joint.
5. Apply the specified vacuum to the PAIR control
valve vacuum hose more than 56 kPa (420
mmHg).
6. Start the engine and adjust the idle speed with
the throttle stop screw.
IDLE SPEED: 1,700 ± 100 rpm PAIRC:ONTR(iLVALVE
6-28
FUEL SYSTEM
7. Turn the p ilot screw in o r out slowly to obt ain the
highest engine speed.
8. Lig htly open the throttle 2 or 3 times, then adj ust VACUUM
the idle speed with the throttle stop screw. PUMP
PAIR CONT ROL VALVE
9. Turn the pilot screw in until the engine speed
drops by 50 rpm.
AIRSUPPLY
I O.Turn the pilot screw counterclockwise to the final
opening from the position obtai ned in step 9. HOSE
FINAL OPENING: 112 turns out PAIR AIR

l1.Remove the plug from the vacuum hose, then I HOSE
disconnect the vacuum pump and con nect the
vacuum hose to the PAIR control valve.
12.Readjust the idle speed with the throttle stop
screw.
IDLE SPEED: 1,700 ± 100 rpm

Disconnect the tachometer.
SECONDARY AIR SUPPLY SYSTEM ('05

and '06 California type, After '06)
SYSTEM INSPECTION
Warm up the engine to normal operating tempera·
ture.
Check that the secondary ai r intake port is clean and
free of carbon deposits. tt~jjj~
Check the pu lse secondary air injection (PAIR) con-
trol valve.
(
'-.
6-29
FUEL SYSTEM
Disconnect the PAIR air suction hose from the air
cleaner housing. VACUUM PUMP
Disconnect the PAIR control valve vacuum hose and
plug the vacuum hose. PAIR CONTIROl VALVE
Connect a vacuum pump to the PAIR control valve.
Start the engine and open the throttle slightly to be PAIR AIR
certain that air is sucked in through the PAIR ai r suc- HOSE
tion hose.
If the air is not drawn in, check the PAIR air suction
hose for clogs.
With the engine funning, gradually apply vacuum to
the PAIR control valve.
Check that the PAIR air suction hose stops drawing
air. and that the vacuum does not bleed.
SPECIAEO VACUUM: 56 kPa (420 mmHg)
If the air is drawn in, or if the specified vacuum is

not maintained, install a new PAIR control valve.
VAIOULIM HOSE
PAIR CONTROL VALVE REMOVALI

INSTALLATION
Remove the right radiator shroud (page 3-4). ~~[!§:SIJ~~~!EE
Disconnect the vacuum, air supply and PAIR air sue- •
tion hoses.
Remove the bolts, nuts, stay and PAIR control valve. I~~~~~~
Installation is in the reverse order of remova l.
TORQUE:
PAIR control valve mounting nut:
13 N-m (1 .3 kgf·m, 10 Ibf.ft)
PAIR CHECK VALVE INSPECTION

Remove the PAIR control valve (page 6-30),
Remove the screws, PAIR check valve cover and
PAIR check valve.
.
PAIR CHECK VALVE
6-30 •
FUEL SYSTEM
Check the reed for damage or fatigue.
Replace the PAIR check valve if the rubber seat is VALVE STOPPER
cracked, deteriorated or damage, or if there is clear-
ance between the reed and seat.
Installation is in the r everse order of removal.
RUI'B'HSEAT
AIR SUPPLY PIPE REMOVAL!

INSTALLATION
Remove the radiator shroud (page 3-4),
Remove the bolt.
Disconnect the ai r supply hose.
Remove the air supply pipe and O-r ing.
Check the ai r supply pipe for damage or deforma-

AIR SU PPLY PIPE
tion.
Install a new O-ring onto the ai r supply pipe.

Installation is in the reverse order of removal.
6-31
MEMO
•
7. COOLING SYSTEM
SYSTEM FLOW PATTERN ......................... 7-2 COOLANT REPLACEMENT ........................ 7-6
SERVICE INFORMATION ...... ..................... 7·3 RADIATOR .................................................. 7·8
TROUBLESHOOTING ........................... ...... 7-4 RADIATOR RESERVE TANK ............ .......... 7·9
SYSTEM TESTING ...... · ............................ ·.. 7-5 WATER PUMP ............................................ 7-9
7-1
COOLING SYSTEM
SYSTEM FLOW PATTERN
••
: .,
~
,: ., ,
o ~
a 0 ~
RES I'R~ETANK
WATER PUMP
7-2
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
Removing the radiator cap while the engine is hot can the coolant to spray Qut, seriously scalding you.
Always let the and radiator coot down before the
[ NOTICE [
Using coolant with silicate inhibitors may cause premature wear of water pump seals or bloclcage of radiator passages.
USing tap wafer may cause engine damage.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• All cooling system services can be done wi th the engine in the frame.
• Avoid spilling coolant on painted su rfaces.
• After serviCing the system, check for leaks with a cooling system tester.
SPECIFICATIONS
or an I
antifreeze containing silicate-free
TORQUE VALUE
Water pump impeller 12 N-m !1.2 kgf·m, 9Ibf.ft)
TOOLS
Mechanical seal driver Bearing remover set, 12 mm Remover weight

07945-4150400 07936-1660101 07741 -0010201
not available in U.S.A. or 07936-371020A (U.S.A. only)
7-3
COOLING SYSTEM
Remover head, 12 mm Beari ng remover, 12 mm Remover shaft

07936· 1660110 07936-166010A (U. S.A. only) 07936-1660120
not available in U.S.A. not available in U.S.A.
Remover handle Driver Attachm ent, 28 x 30 mm

07936·3710100 (U.S.A. only) 07749·001000 0 07946-1870100
Pilot, 12 mm
07746-0040200
TROUBLESHOOTING
Engine temperature too high
• Faulty radiato r cap
• Insufficient coolant
• Passage blocked in radiator, hoses or water jacket
• Radiator ai r passage clogged with dirt
• Air in syst em
• Faulty water pu mp
Coolant leak
• Faulty wa t er pu mp oi l seal and m echanical seal
• Deteriorated water pump oil seal and mechanical seal
• Damaged or deteriorated D-ring
• l oose hose connection or clamp
• Damaged or deteriorated hose
• Faulty radiator cap
• Damaged radiator
• Passage blocked in radiator sip hon hose
7-4
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Make su re the engine is cool, remove the radiator
cap.
Test the coolant specifi c gravity u sing a hyd rome-

ter.
STANDARD COOLANT CONCENTRATION: 1 : 1
Look for contamination and replace the coolant if Io.....,;ol:...-

necessary.
COOLANT GRAVITY CHART
"-.
7-5
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cap.
Wet the sealing Install the radiator cap on the tester.
surface with wafer.
Pressure test the radiator cap.
Replace the radiator cap if it does not hold pressure,
or if the relief pressure is too high or too low.
It must hold the specified pressure for at least 6 sec-
onds.
RADIATOR CAP RELIEF PRESSURE:
108 - 137 kPa (1 .1 - 1.4 kgf/cml, 16 - 20 psi)
Pressure test the radiator, engine and hoses, and

check for leaks.
I NOTICE I
Excessive pressure can damage the cooling system
components. Do not exceed 137 kPa (1.4 kgfknr. 20
psi).
Repair or replace components if the system will not
hold the specified pressure for at least 6 seconds.
After checking the pressure, install the radiator cap
securely.
COOLANT REPLACEMENT
PREPARATION
• If any coolant gets in you r eyes, rinse them with , - - - - - -- - - - - - - - -- - - ,
water and consult a doctor immediately.
• If any coolant in swallowed, induce vomiting,
gargle and consult a physician immediately.
• If any coolant gets on your skin or clothes, rinse
thoroughly with plenty of water.
• The effectiveness of coolant decreases with the
accumulation of rust or if there is a change in the
LOW M INERAL
mixing proportion during usage. Therefore, for
(ETHYLENE OR DISTILLED
best performance, change the coolant regularly
as specified in the maintenance schedule. GLYCOLBASE WATER
• Mix only distilled, low mineral water with the SOLUTION)
antifreeze.
RECOMMENDED ANTIFREEZE: COOLANT
Pro Honda HP coolant or a n equivale nt high qual-
ity ethylene glycol a ntifreeze containing si licate-
free corrosion inhibitors
RECOMMENDED MIXTURE:
1 : 1 1distilled water a nd recomme nded antifreeze)
7-6
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
Remove the right and center engine guard (page 3-5),
Remove the radiator cap.
,.
Drain the coo lant from the system by removing the

drain bolt and sealing washer on the water pump
cover.
Insta ll the drain bolt with a new sealing washer.
Tighten the drain bolt securely.
Disconnect the siphon hose from the reserve tank.

Remove the reserve tank cap and reserve tank.
Drain the reserve tank coolant.
Empty the coolant and rinse the inside of the
reserve tank w ith water.
Rou te the hoses Reinstall the reserve tank and connect the radiator
properly ('05 - '07: siphon hose.
page 1-25, A fter
Install the right and center engine guard (page 3-5),
'07: page 1-32J.
Fill the system with the recommended coolant

through the filler opening up to the filler neck.
CAPACITY:
1.21 liter (1.28 US qt, 1.06 Imp qt) at change
Lean the machine approximately 20 to the right
Q
and left several times to bleed any air trapped in the

cool ing system. If the coolant level drops, add more
coolant and repeat the air bleeding procedure.
7-7
COOLING SYSTEM
Remove the radiator reserve tank cap and fill the
reserve tank to the upper level line. "UPPER " LEVEL LINE
Bleed air from the system as follow:
CAP , ,,,,
1. Shift the transmission into neutral. Start the
engine and let it idle for 2 - 3 minutes.
2. Snap the throttle three to four t imes to bleed air
from the system.
3. Stop the engine and add coolant up to proper
level if necessary. Reinstall the radiator cap.
4. Check the level of coolant in the reserve tank and
fill to the · UPPER " level line if it is low.
RADIATOR
Drain the coolant (page 7-7),
Remove the fue l tank (page 3-8),
Remove the radiator grills.
Note the direction Disconnect the following:

of the wa ter hose
- Siphon hose
clamp.
- Connecting hose
8e careful not to
- Upper and lower radiator hoses
damage the radiator
core.
Remove the upper and lower mounting bolts.

Remove the radiator from the frame.
7-8
COOLING SYSTEM
Be Cllrsful not to Installation is in the reverse order of removal.
damage the radia lor
Fill the system with the recommended coolant and
core. bleed the air (page 7-7) .
After installation, check the radiator and radiator
hoses for leaks.
RADIATOR RESERVE TANK

Remove the right and center engine guard (page 3-5).
Remove the reserve tank cap and reserve tank.
Disconnect the radiator siphon and reserve tank
overflow hoses from radiator reserve tank.
Drain the reserve tank coolant.
Route tile hoses Installation is in the reverse order of removal.
Pf0p8r/y ('05 - '07:
page 1-25. Aher
'07: page 1..J2}.
WATER PUMP
MECHANICAL/OIL SEAL INSPECTION
Check for signs of seal leakage.
If water leaks through the bleed hole, replace the
mechanical seal (page 7-12).
If oil leaks through the bleed hole, replace the oil
seal (page 7-12).
A small amount of "weeping" from the bleed hole is
normal.
l
HOLE
7-9
COOLING SYSTEM
REMOVAL
Remove the bolts, water hose joint and O-ring .
Remove the drain bolt and sea ling washer.

Remove the bolts and water pump cover.
Remove the O-ring and dowel pin.
Loosen the impeller.

Remove the right crankcase cover (page 11-5).
7-10
COOLING SYSTEM
Remove the impeller, washer and water pump shaft
from the right crankcase cover.
WATER PUMP SHAFT

RIGHT CRIINKCA'5E COVE R
Check the water pump shaft for wear or damage.
WATER PUMP SHAFT
"
Turn the inner race of the water pump shaft bearing

with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the right crankcase cover.
Replace the water pump shaft bearing if the inner
race does not turn smoothly, quietly, or if the outer
race fi ts loosely in the right crankcase cover.
Check the mechanical seal for damage or deteriora-

tion. ME·CH',NI'<:AlSEAl
Replace the mechanical seal if necessary (page 7-12).
7-11
COOLING SYSTEM
BEARING/MECHANICAL SEAL/OIL
SEAL REPLACEMENT
Remove the water pump shaft bearing using the r::::!':o::::-:::~
special tools.
TOOLS:
Bearing remover set, 12mm 07936-'660101
not available in U.S.A.
- Remover weight 0774'-0010201
- Remover head, 12 mm 07936-1660"0
- Remover shaft 07936-'6601 20
TOOLS, U.S.A. only:
Bearing remover, 12 mm 07936-166010A
Remover handle 07936·3710100
Remover weight 07741-0010201 or
07936-371020A
Check the oil seal for damage or dete ri oratio n,
replace it if necessary (page 7- 12),
Remove the mechanical and oil seals from the right

crankcase cover.
Apply grease to the oil seal lips.

Install II new oil seal into the right crankcase as
shown.
7-12 •
COOLING SYSTEM
Be careful not toDrive i n a new mechanica l seal using the special
damage the tools as shown.
mechamcal seal
lips. TOOLS:
Driver 07749·0010000
Mechanical seal driver 07945·4150400
Apply grease to new mechanical seal lips.
Drive in a new Drive in a new bearing i nto the r ight crankcase

bearing squarely cove r using the special tools as shown .
with the marking
side facing toward TOOLS:
the inside of the Driver 07749-0010000
right crankcase Attachment. 28 x 30 mm 07946· 1870100
cover. Pilot. 12mm 07746·0040200
Apply oi l to new oil seal lips.
INSTALLATION
WATER PU MP SHAFT
BEARING
L QILSEAL ~
~.¥jjffi ~
MECHANICAL SEAL
WATER PUMP COVER
IMPELLER
12 N' m (1.2 kgf-m, 9Ibf·ft) SEALING WASHER
D -RING ~
(
7-13
COOLING SYSTEM
Install the water pump shaft into the right crankcase
cover.
Insta ll the washer and impeller onto the water pump
shaft.
WASHER
IMPELLER "\.
~o
WATER PUMP SHAFT
RIGHT CRANKCASE COVER
Install the right crankcase cover (page 11 -6).

Tighten the impeller to the specified torque.
TORQUE: 12 N'm 11.2 kgf·m, 9Ibf.ft)
Install a new O-ring onto the water pump cover.

Install the dowel pin.
•
Install the water pump cover and tighten the bolts :;~:;;;
securely.
Install the drain bolt and a new sealing washer.
Tighten the drain bolt securely.
•
7-14
COOLING SYSTEM
Install a new D-ring into the water hose joint
groove.
Install the water hose joint onto the water pump
cover and tighten the bolts securely.
bleed the air (page 7-7l.
7-15
MEMO
8. ENGINE REMOVAL/INSTALLATION
,-
COMPONENT LOCATION ....................... ... 8-2 ENGINE REMOVAL·· ···· ······· ······················· 8-5
SERVICE INFORMATION ···························8-3 ENGINE INSTALLATION .. ············· ············· 8-8
DRIVE SPROCKET ······································ 8-4
8-1
ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
'05 - '01 sh own :
26 N-m (2.7 kgf·m, 191bf·hl
. (9.0 kgf.m, 65 Ibf.ftj
After '07:
54 N'm (5.5 kgf·m, 40 Ibf.ft)
54 N'm 15.5 kgf.m . ~
38 N·m (3.9 kgf·m, 28 Ibf.ft)
31 N' m (3.2 23Ibf.ft)
21 (2.1 kgf·m , 15Ibf·ft)
8-2
ENGINE REMOVAL/ INSTALLATION
SERVICE INFORMATION
GENERAL
• During engine removal and Installation , support the motorcycle using a workstand or equivalent.
• The following components require engine removal for service.
- Crankcase (page 13· lO)/Crankshaft (page 13-14)fTransmission (page 13-11)
- Oil pump (page 5-7)
• The following components can be serviced with the engine instal led in the frame.
- Cylinder head (page 9-24)Nalves (page 9-27)
- Cylinder (page 10-5)/PiSlon (page 10-6)
- Clutch (page 11 -7)/Kickstarter (page' '-15)/Gearshift linkage (page 1' -24)
- Carburetor(page6-11j
- Secondary air supply system ('OS and '06 California type, After '06: page 6-3 1)
- Water pump (page 7-9)
- Balancer (page 13-8)
- Starter clutch (page 11-19)
- Starter motor (page 19-6)
SPECIFICATIONS
equ;val,nt motor
service classification: SG or Higher
T903 standard: MA
SAE 10W-30
0'
equivalent motor oil
JASO T903 standard: MA
TORQUE VALUES
Engine hanger plate bolt 26 N·m (2.7 kgf·m , 19 Ibf.ft)
Engine mounting nut (front ) 54 N·m (5.5 kgf·m, 40 Ibf.ft)
( (upper ) 54 N·m (5.5 kgf·m, 40 Ibf.ft)
(lower) 54 N·m (5.5 kgf·m , 40 IbUt)
Drive sprocket bolt 31 N·m (3.2 kgf·m , 23 IbUt)
Kickstarter pedal bolt 38 N·m (3.9 kgf·m , 28 Ibf·h)
Swingarm pivot nut 88 N·m (9.0 kgf·m, 65 Ibf·h) U· nut
Exhaust pipe joint nut 21 N·m (2.1 kgf·m, 15 Ibf·h )
8-3
ENGINE REMOVALIINSTALLATION
DRIVE SPROCKET
REMOVAL
Raise the rear wheel off the ground by placing a ~"'!'l'
Loosen the axle nut.
loosen the drive chain adjuster lock nuts and turn
the adjusters clockwise fully.
Remove the botts, sprocket cover and spacer.
Shift the transmission other than neutral position.

Remove the bolt. collar, washer and drive sprocket.
,.
INSTALLATION
Install the drive chain to the drive sprocket.
Install the drive sprocket onto the countershaft with
the · OUT" mark facing out.
8-4
Install the washer and coliar with their "OUT-SIDE "
marks facing out.
Tighten the drive sprocket bolt to the specified
torque.
TORQUE: 31 N 'm (3.2 kgf·m , 23 Ibf.ft)
Install the spacer, sprocket cover and tighten the

bolts securely.
Adjust drive chain slack (page 4-24).
ENGINE REMOVAL
Drain the engine oil (page 4-20).
Drain the transmission oil (page 4-23),
Drain the coolant (page 7-7) .
- Seat (page 3-3)
left/rig ht/center engine guards (page 3-5)
Fuel tank (page 3-8)
Spark plug cap (page 4-12)
Ignition coil (page 18-8)
Exhaust system (page 3-13)
Carburetor (page 6-1 1)
Drive sprocket (page 8-4)
Kickstarter pedal (page 11 -5)
Gearshift pedal (page 1' -24)
Brake pedal (page 16-24)
Radiator reserve tank (page 7-9)
'05 and '06 Remove the PAIR control valve (page 6-30).
California type, Disconnect the breather hoses,
A fter '06;
Remove the bolt and ground cable.
Remove the nut and starter motor cable.
Remove the bolt and clutch cable stay, then discon-
nect the clutch cable from the clutch lifter lever.
8-5
Remove the wire band.
Disconnect the alternator 4P (Black) and ignition
pulse generator 2P (Black) connectors.
Loosen the hose band screws and disconnect the

radiator hoses.
Remove the bolt, water hose joint and O-ring from
the cylinder head.
Remove the nut, bolts, fuel hose guide, clu tch cable
guide and engine hanger plates.
loosen the swing arm pivot nut.

Loosen the engine front and lower mounting nuts.
Remove the swing arm pivot nut, washer and bolt.
Remove the engine front and lower mounting nuts,
washers and bolts.
During engine Remove the engine.
removal, hold the
• A workstand or equivalent is need to support the
engine securely and
swing arm when removing the engine.
be careful not to
damage the frame
snd engine.
•
8-6
ENGINE REMOVAL/INSTALLATION
Before engine Turn the engine 90 degrees in the frame so that the
removal, rape the left crankcase cover is facing rearward using the fol·
cornefsofrhe lowing procedures:
cylinder head cover
to protect it from
damage.
OS' - '07 shown:
NOTE 1'05 - '07):

Be careful not to damage the
cylinder head cover with the
ignition coil stays.
NOTE (After '07):

Be careful not to damage the
cylinder head cover with the
ignition coil stay (upper only).
2. Move the fBa r end of the engine over 1. Position the water hose joint inside
the swingarm pivot of the frame. of the front engine hanger.
Remove the engine from the right side of the frame

using the following procedures:
'05 - '07 show n:
1. Lift the bottom of the engine and pass t he water hose
joint under the front engine hanger.
(
2. Pass the engine rear end over the right side of the frame,
and then remove the engine.
8-7
Note the direction of the engine h anger plates and
mounting bolts.
Temporarily install the swingarm pivot bolt so the
chassis can be moved and stored safely.
ENGINE INSTALLATION
Apply molybdenum disulfide paste to the engine
contact area of the front engine hanger.
Carefully align the Install the engine in the frame.
mounting poims to Apply thin coat of grease to the swing arm pivot bolt
prevent damage to sliding surface.
englnB, frame, wire loosely install the swingarm pivot bolt, washer and
andcsb/es. nut.
Loosely instal l the engine mounting bolts, washers
and nuts .
• Route the wires and cables properly ('05 - '07:
page 1-25, After '07: page 1-32).
• Do not tighten the swingarm pivot nut and
engine mounting nut s yet.
Install the engine hanger plates, fuel hose guide,

clutch cable guide, upper engine mounting bolt,
washer, nut and engine ha nger plate bolts.
Tighten the engine mounting nuts, engi ne hanger
plate bolts and swingarm pivot nut t o the specified
t orque.
TORQUE:
Sw ingann pivot nut: 88 N'm (9.0 kgf·m , 65 Ibf.ft)
Engine hanger plate bolt:
26 N 'm (2.7 kgf·m , 19Ibf·ft)
Engine m ounting nut:
(front): 54 N'm (5.5 kgf·m . 40 Ibf·ftl
(upper) : 54 N·m 15.5 kgf·m , 40 fbf·ft l
(low er) : 54 N ·m (5.5 kgf·m . 40 Ibf·ft)
Install the water hose joint to the cylinder head.

Connect the radiator hoses and tighten the band
screws securely.
8-8
Route the wife
harness properly
Connect the alternator 4P (Black) and ignition pulse
generator 2P (Black) connectors.
r-
('05 - '07: page /.
Install the wir e b and.
25, A fter '0 7: PBge
1-32).
Connect the starter motor cable and tigh t en the nut

securely.
~~~~~~~
Connect the clutch cable to the clutch tifter lever.
Install the cl utch cable st ay and ground cable and
tighten the bolts secu rely.
Connect the b reather hoses.

- Ignition coi' (page 18-8)
Radiat o r reserve t ank (page 7-9)
Brake pedal (page 16-24)
Gearshift pedal (page' 1-27)
Kickstarter pedal (page 11-7)
Drive sprocket (page 8-4)
Carburetor (page 6-24)
Exhaust system (page 3-14)
Spark plug cap (page 4- 12)
Fuel tank (page 3-8)
Left/right/canter engine gua rds (page 3-5)
Seat (page 3-3)
'05 and '06 Install the PAIR control valve (page 6-301.
callfom~ type.
After '06'
bleed the ai r (page 7-71.
Fill the engine with the recommended engine oil
(page 4-19) .
Fil l the t ransmission with the recommended trans-
mission oil (page 4-23).
After installing the engine. perform the following
inspections and adjustments:
- Thronle grip freeplay (page 4-91
- Drive chain slack (page 4-24)
- Clutch lever freeplay (page 4-31)
Check the exhaust system for leaks.
8-9
MEMO
•
9. CYLINDER HEAD/VALVES
COMPONENT LOCATION .. ················ ········9·2 CYLINDER HEAD INSPECTION ............... 9·28
-
SERVICE INFORMATION ··························· 9·3 VALVE GUIDE REPLACEMENT ··············· 9·29
TROUBLESHOOTING ................................. 9·6 VALVE SEAT INSPECTIONI

REFACING ·················· ····················· ·········· 9·30
CYLINDER COMPRESSION TEST·············· 9·7
CYLINDER HEAD ASSEMBLy· ················ 9·33
CYLINDER HEAD COVER REMOVAL .. ······ 9·7
CYLINDER HEAD INSTALLATION ......... .. 9·36
CAMSHAFT REMOVAL 1'05 - '07) ............. 9·8
CAMSHAFT INSTALLATION
CAMSHAFT REMOVAL IAfter '07) .......... 9· 16 ('OS - ' 07)-·················································· 9·37
CYLINDER HEAD REMOVAL ················· ··9·24 CAMSHAFT INSTALLATION

IAfter '07) .... .............................................. 9·39
CAM CHAIN TENSIONER/ CAM CHAIN

GUiDE ································ ························ 9·25 CYLINDER HEAD COVER
INSTALLATION ......... ............................... 9-42
CYLINDER HEAD DiSASSEMBLy············ 9·27
9-1
COMPONENT LOCATION
'05 - '07 sh own:
~ 10 N'm 11.0 'gf·m, 7 Ibf·ftJ
After '07:
, ,
._-----------------------------
66 N'm (6.7 kgf·m, 49 Jbf.ft)
20 N'm (2.0 kgf·m, 15 Ibf·ft)
9-2
SERVICE INFORMATION
GENERAL
• This section covers service of the camshaft, cyl inder head and valves. These services can be done with the engine
installed in the frame.
• During disassembly, mark and store the disassembled parts to ensure that they are reinstalled in their original loca-
tions.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed ai r before
inspection.
• Camshaft lubrication oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the
cylinder head .
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
SPECIFICATIONS
valve guide
" EX 17.9 - 18.1 (0.70-0.71)
I .
( TORQUE VALUES
l_ Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7 Ibf.ft)
Camshaft holder mounting bolt 14 N·m (1.4 kgf.m , 10 Ibf·ft) Apply oil to the threads
Decompressor cam mounting bolt 24 N·m (2.4 kgf·m, 18 Ibf·ft) Apply oil to the threads
('05 - '07)
Cam sprocket bolt 20 N'm (2.0 kgf·m, 15 Ibf·ft) Apply locking agent to the th reads
Decompressor lifter arm mounting
nut (,OS - '07) 22 N·m (2.2 kgf·m, 16Ibf.ft) Apply oil to the threads and seati ng surface
Cylinder head nut 66 N·m (6.7 kgf·m, 49 Ibf.ft) Apply oil to the threads and seating surface
Cam chain tensioner bolt 12 N ·m (1.2 kgf.m , 9Ibf·ft ) Apply loC\C::ing agent to the threads
Crankshaft hole cap 15 N·m (1.5 kgf·m , 11 Ibf·ft) Apply grease to the threads
Engine mounting nut (upper) 54 N·m (5.5 kgf·m, 40 Ibf·ft)
Engine hanger plate bolt 26 N·m (2.7 kgf·m, 19 Ibf·ft)
Spark plug 22 N·m (2.2 kgf·m, 16Ibf·ft)
l
9-3
TOOLS
Valve spring compressor Valve spr ing compressor attach· Valve guide remover, 5.0 mm
07757·0010000 ment 07942-MASOOOO
07959-KM30101
•
Valve guide remover, 5.5 mm Valve guide driver Va lve guide reamer, 5.5 mm
07742-0010100 07743-0020000 07984-2000001 or
not available in U.S.A. 07984-2000000 (U.S.A. only)
Valve guide reamer, 5.0 mm Valve seat cutter, 35 mm (45°, IN ) Valve seat cutter, 33 mm (45", EX)
07984-MASOOOl o r 07780-0010400 07780-0010800
07984-MA6000D (U.S.A. only) or equiva lent commercially avail- or equivalent commercia lly avail-
able in U.S.A. able in U.SA
Flat cutter, 33 mm (32°, EX) Flat cutter, 36 mm (32", IN) Interior cunet, 37.5 mm (60°, IN )
Q7780'()012900 07780-0013500 07780-0014100
or equivalent commercially avail- or equivalent commercially avail- or equivalent commercially avail-

able in U.S.A. able in U.S.A. able in U.SA
9-4 •
Interior cutter, 34 mm (60 0 , EX ) Cutter holder, 5.0 rnm Drive r
07780·0014700 07781-0010400 07749-0010000
or equivalent commercially avail- or equivalent commercially avail-

able in U.S.A. able in U.S.A.
Attachment, 37 x 40 mm Pilot, 20 mm Cutter holder, 5.5 mm

07746-0010200 07746-0040500 0778'-0010101
or equivalent commercially avail-

able in U.S.A.
Tensioner stopper Cam sprocket holder ('05 - '07)

070MG·0010100 07AMB-MEBA 100 (U.S.A. only)
or 07AMG-001A 100 (U.S.A. only)
9-5
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test
or by tracing top-end noise with a sounding rod stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If t he hose is smoky,
check for a seized piston ring.
Compression too low, hard starting or poor performance at low speed
• Valves:
- Incorrect valve adjustment
- Burned or bent valves
- Incorrect valve timing
- Weak valve spr ing
- Uneven valve seating
- Valve stuck open
• Cylinder head:
- leaking or damaged cylinder head gasket
- Warped or cracked cylinder head
• loose spark plug
• Faulty cylinder. piston or piston rings
• Faulty decompressor system
Compression too high
• Excessive carbon build-up in cylinde r head or t op of piston
Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Cylinder, piston or piston rings problem
Excesslv, noise
• Incorrect valve adjustment
• Sticking valve or broken valve spring
• Worn or damaged camshaft
• Worn or damaged valve lifter
• Worn or loose cam chain
• Worn or damaged cam chain tensioner
• Worn cam sprocket teeth
• Cylinder, piston or piston rings problem
Rough idle
• l ow cylinder compression
9-6 •
CYLINDER COMPRESSION TEST
Warm up the engine .
Stop the engine and remove the spark plug (page 4- COMPRESSION GAUGE
12).
Connect a compression ga uge.
Open the th rottle fully.
To avoid discllargingCrank the engine with the electric starter or
the barrery. do notkickstarter until the gauge needle stops moving.
operate the starter The maximum reading is usually reached within 4-7
motor for more seconds when using electric sta rt er.
than 7 seconds.
COMPRESSION : 402 kPa (4.1 kg /cm2, 58 psi)
at 360 rpm
low compression can be caused by:
- Improper valve adjustment
- Valve leakage
- Blown cylinder head gasket
Worn piston ring or cylinder
- Faulty decompressor system
High compression can be caused by:
- Carbon deposits in combustion chamber or on
piston head
- Faulty decompressor system
CYLINDER HEAD COVER REMOVAL

Remove the fuel tank (page 3-8) .
Disconnect the spark plug cap and crankcase
breather hose.
Remove the bolts, cylinder head cover and packi n g.
I
\
9-7
Remove the plug hole seal.
•
CAMSHAFT REMOVAL ('05 - '07)
Remove the cylinder head cover (page 9-7 ),
Remove the crankshaft hole cap and O-ring.
Turn the crankshaft clockwise to align the punch ~~~~~~~~~~

mark on the primary drive gear with the "1:::." mark
on the right crankcase cover.
there is slack i n the rocker arms. If there is no slack,
rotate the crankshaft clockwise one full turn and
align the punch mark on the primary drive gear with
"t:." mark on the right crankcase cover again.
Check that the index tine on the cam sprocket aligns
with the "I:::," mark on the camshaft holder.
Remove the cam chain tensioner lifter bolt and seal-

ing washer.
~~i~i~i~~~;;.;;;=== •
9-8
Insert the stopper tool into the cam chain tensioner
lifter.
Turn t he stopper tool clockwise fully and lock the
cam chain tensioner lifter by pushing the handle.
TOOL:
Tensionar stopper 070MG-00101DO or
07AMG-001A 100
(U.S.A. only)
r'-,
1
TENSIONER STOPPER
A tool ca n easily be made f rom a thin (1 mm thick)

piece of steel as shown.
~===================;
19 mm
12 mm
i +
8.5 m
m~ 0 3.5 m m
r
Insert the special tool into the sprocket, over the
gasket surface and loosen the one cam sprocket
bolt.
• When the decompresso r cam assembly will be
disassembled, loosen the mounting bolt, but do
not remove it yet.
TOOL:
Cam sprocket holder 07AMB-MEBA100 (U.S.A . only)
Be careful not to Remove the special tool, turn the crankshaft clock- I~;~E;:;~
drop the bolts into wise one turn and reinsert the spedal tool into the
the crankcase. sprocket. Remove the other cam sprocket bolt.
Then remove the another cam sprocket bolt using
the same procedure as removal of the other cam
sprocket bolt.
Remove the cam sprocket from the camshaft. and
suspen d the cam chain with a piece of wi re to pre-
l vent it from falling into the crankcase.

Make sure the piston is at TDC (Top Dead Center) on "',.,...."'
Loosen the camshaft holder bolts in a crisscross
panern in two or three steps.
• Valve lifters are insta lled into the camsha ft
holder assembly.
• The shims may stick to the inside of the valve lift-
ers. Do not allow the shims to fall into the crank-
case.
9-9
Be sure to msrk!he Remove the valve lifters from the camshaft holder
VALVE LIFTERS
valve liflers so finly assemblv.
can be Installed III
rhelr onglflai
POSit/MS.
DISASSEMBLY
Remove the circlip and nut.
Remove the decompressor lifter, spring and

decompressor arm. DE<:ONIPR " SSOR ARM
Remove the stopper ring.
9-10
Thread a 6 mm bolt into the rocker arm shaft, and
pull the rocker arm shaft from the camshaft holder.
Remove the rocker arm.
liii-.,..••
Remove the bolt, stopper plate and decompressor

cam assembly. DECOMPRESSOR CAM ASSEMBLY BOLT
Remove the snap ring and camshaft from the cam-

shaft holder.
I NOTICE I
Make sure the intake lobes afe faCing up when
removing the camshaft from rhe holder to prevent
damaging the intake litrer bores.
SNAP RING
INSPECTION
If the camshaft Inspect the camshaft con t act surface of the rocker
COIllect surface of arm for wear or damage.
thB rocker afm is
Measure the rocker arm 1.0.
damaged or
abnormally worn, SERVICE LIMIT: 12.05 mm (0.474 in)
check the cam
lobes for damage
(page 9- 12).
9-11
Inspect the rocker arm shaft for wear or damage.
Measure the rocker arm shaft 0.0.
Calculate the rocker arm·to·shaft clearance.

Turn the outer race of the camshaft bearing wi th , - - - - - - - - - - - - - - -- ---,

you r finger.
Also check that the bea ring inner race fits tightly on
the camshaft.
Replace the camshaft assembly if the bearing does
not turn smoothly, quietly, or if it fits loosely on the
camshaft.
Check the cam lobe surfaces for scoring or evidence

of insufficient lubricant.
Measure the height of each cam lobe.
SERVICE LIMITS:
IN: 36.890 mrn 11 .4524 In)
EX: 35.063 mm (1 .3804 in)
NOTE:
Check the rocker arm if the cam lobe and valve lift-
ers are worn or damage.
Check the decompressor assembly for wear or dam· ' O-E-C-O

-M- P-R-E-S-S-O-R- -A S-S-E-M- e-L-Y---- - - - - ,
age. SPRING
Check the balancer weight and spring for damage or
fatigue.
•
BALANCER WEIGHT
9-12 •
Turn the inner race of the camshaft bearing with
your finger.
the camshaft holder.
Remove and discard the bearing if the race does not
turn smoothly, quietly, or if it fits loosely in the cam-
shaft holder.
-~ ..
Apply oil to a new bearing.

Dnve In a new Install a new bearing into the hub using the special
bearing squa rely tools.
with the markmg
side facmg toward
TOOLS:
the inside of the Driver 07749-0010000
camshaft holder. Attachment , 37 )( 40 mm 07746-0010200
Pilot , 20 mm 07746-0040500
Check the valve lifter bore scoring, scratches or

damage.
Measure each valve lifter bore I.D.
SERVICE LIMIT: 26.04 mm ' 1.025 in )
Check the valve lifter fo r scor ing, scratches or dam-

age.
Measure each varve lifter 0 .0.
SERVICE LIMIT: 25.97 mm (1 .022 in )
9-13
ASSEMBLY
SNAPRING
~
, CAMSHAFT
CAMSHAFT HUW. H
,""~,, ....
¢>"t
BALANCER W EIG HT
DEC:OMIPR£'SSI)R ARM
STOPPER PLATE
ROCKER ARM
--, ~9
22 N'm (2. 2 kgf·m, 16Ibf.ft) S-QI :11 VALVE LIFTER
ROCKER ARM SHAFT

flI CIReliP DECOMPRESSOR LI FTER STOPPER RING
Apply molybdenum oil solution to the camshaft
journal and lobes. INTAKE LOBES
Install the camshaft in the camshaft holder as
shown.
I NOTICE I
Make sure the intake lobes are facing up when
installing the camshaft to prevent damaging the
intake lifter bores.
Make sure the snap Install the snap ring into the groove in the camshaft
ring is firmly seared holder.
in the groove.
Align the dowel pin Insta ll the decompressor cam assembly.

on the
decompressor cam
assembly with the
pin hole in the
camshaft.
•
9-14 •
,
Adjust the stopper plate angle as shown.
ASSEMBLY ...--- BOLT
Apply oil to the decompressor cam mounting bolt
threads.
Install the decompressor cam mounting bolt.
STOPPER PLATE
Apply molybdenum oil solution to the rocker arm

bore and valve slipper surfaces.
Install the rocker arm and rocker arm shaft into the
camshaft holder.
~ .--
Install a new stopper ring into the groove in the

camshaft holder.
Install the decompressor arm, decompressor lifter

and spring .
• Align the decompressor arm and decompressor
lifter as shown .
• Align the spring end and camshaft holder tab 85
sh own.
9-15
Apply oil to the nut threads and seating surface,
then tighten it to the specified torque. NUT ,
TORQUE: 22 N'm (2.2 kgf· m, 16 Ibf.ft)

Install a new circlip.
E'RI:UP eI
CAMSHAFT REMOVAL (After '07)
Remove the cylinder head cover (page 9-7),
Remove the crankshaft hole cap and O-ring.

mark on the primary drive gear with the w,6" mark
there is slack in the rocker arm.
If there is no slack, rotate the crankshaft clockwise
one full turn, and match up the punch mark on the
primary drive gear with "6" mark on the right crank-
case cover again.
Check that the index line on the cam sprocket aligns
with the ~t::.. mark on the camshaft holder.
Remove the cam chain tensioner lifter bolt and

sealing washer.
9-16
Insert the stopper tool into the cam chain tensioner
lifter.
Turn the stopper 1001 clockwise fully and lock the
cam chain tensioner lifter by pushing the handle.
TOOL:
Tens ione r stoppe r 070MG· 0010100 or
07AMG -001A100
(U .S.A . only)
A tool can easily be made from a thin (1 mm thick)

piece of steel as shown.
19mm
12mm
J 0 +
3.5m m
8.Smm
.~
I f
Loosen the one cam sprocket bolt.

Be careful nor fO Turn the crankshaft clockwise one turn, and remove
drop the bolts into the other cam sprocket bolt.
the crankcase.
Turn t he crankshaft clockwise one turn again, and
remove the remaining cam sprocket bo lt.
Be careful not to Remove the cam sprocket from the camshaft and
drop the cam chain.
decompressor shaft
Suspend the cam chain with a piece of wire to
Md decompressOf
prevent it from falling into the crankcase.
plunger,
Make sure the piston is at TOC (Top Dead Center ) on

l l oosen the camshaft holder mounting bolts in a

crisscross panern in two or three steps.
• Va lve lifters are installed into the camshaft
holder assembly.
• The shims may stick to the inside of the valve
lifters. Do not allow the shims to drop into the
crankcase.
• Be careful not to drop the decompressor shaft
and decompressor plunger.
9-17
Ba sure fO mark the Remove the valve lifters from the camshaft holder
valve Mrers so they assembly. VALVE
can be ins/ailed In
their OfIgmal
posmons.
DISASSEMBLY
Remove the decompressor shaft and decompressor
plunger.
SHAFT
Thread a 6 mrn bolt into the rocker arm shaft, and "":~~::::~
pull out the rocker arm shaft from the camshaft
holder.
Remove the rocker arm.
ROCKER ARM
9-18
Remove the snap ring.
Remove the camshaft from the camshaft holder.

CA''.1S'HA''T HOLDER
I NOTICE I
Make sure the intake lobes are facing up when
removing the camshaft from the holder to prevent
damaging the intake lifter bores.
INSPECTION
ROCKER ARM
If the camshaft Inspect the camshaft contact surface of the rocker
contact surface of arm for wear or damage.
the rocker arm is
Measure the rocker arm 1.0.
damaged or
abnormally worn, SERVICE LIMIT: 12.05 mm (0.474 in)
check the cam
lobes for damage
(page 9--20).
c. ROCKER ARM SHAFT

Inspect the rocker arm shaft for wear or damage.
Measure the rocker arm shaft 0.0.
Calculate the rocker arm-te-shaft clea rance.

SERVICE LIMIT: 0.10 mm (Q.OO4 in)
9-19
CAMSHAFT
Turn the outer race of the camshaft bearing with
your finger.
Also check that the bearing inner race fits tigh tly on
the camshaft.
Replace the camshaft assembly if the bearing does
not turn smoothly, quietly or if it fits loosely on the
camshaft.
Check the cam lobe surfaces for scori ng or evidence

of insufficient lubricant.
Measu re the height of each cam lobe.
SERVICE LIMITS :
IN : 36.890 mm (1 .4524 in)
EX: 35.063 mm (1.3804 in)
NOTE:
Check the rocker arm if the cam lobe is worn or
damage.
OECOMPRESSOR SHAFT/ PLUNGER

Check the d ecompressor shaft for bend o r damage.
PLUNGER SHAFT
Check the decompressor plunger fo r wear or dam-
age.
CAM SPROCKET/ DECOMPRESSOR WEIGHT!

SPRING
Check the cam sprocket teeth for wear or damage.
Check the decompressor weight for damage. CAM SPROCKET DE(:O.WRIE SS'ORWEIGHT
Check the spring for fa tigue by moving the
decompressor weight with your finger.
Replace the cam sprocket, decompressor weight
and spring as an assembly if necessary.
9-20 •
CAMSHAFT HOLDER
Turn the inner race of the camshaft bearing with
your finger.
the camshaft holder.
Remove and discard the bearing if the race does not
turn smoothly, quietly, or if it fits loosely in the cam-
shaft holder (page 9-21).
'-
Check the valve lifter bore scoring, scratches or

damage.
Measure each valve lifter bore 1.0.
SERVICE LIMIT: 26.04 mm (1 .025 in)
VALVE LIFTER
Check the valve lifter for scoring. scratches or dam-
age.
Measure each valve lifter 0.0.
SERVICE LIMIT: 25.97 mm 11 .022 in)
l CAMSHAFT HOLDER BEARING

REPLACEMENT
Drive out the bearing.
DRIVER
Install a new bearing into the camshaft holder using
the special tools.
TOOLS :
Driver 07749-0010000
Attachme nt, 37 x 40 mm 07746-0010200
Pilot , 20 mm 07746-0040500
After installing the bearing, lubricate it with engine
oil.
ATIAcf' MENl PI LOT
9-21
ASSEMBLY
-,
!11l! STOPPER RING CAMSHAFT HOLDER
, DECOMPRESSOR PLU NGER
ROCKER ARM SHAFT
--:?t DECOMPRESSOR SHAFT
, CAMSHAFT
, VALVE LIFTER
--:?t ROCKER ARM
Apply molybdenum oil solution to the camshaft

---'SNAP RING 'rp
CAMSHAFT ,
journal and lobes.
Install the camshaft to the camshaft holder.
I NOTICE I
Make sure the intake cam lobes are facing up when
installing the camshaft to prevent damaging the
intake lifter bores.
CAMSHAFT HOLDER
Make sure the snap Install the snap ring into the groove of the camshaft
rmg;s firmly sealed holder.
in the groove.
9-22 •
Apply molybdenum oil so lution to the rocker arm
bore and valve slipper surfaces. , ROCKER
Install the rocker arm and rocker arm shaft into the
camshaft holder.
Install a new stopper ring into the groove of the

camshaft holder.
SH)PPI;R RING ~
Apply molybdenum oil solution to the
decompressor plunger sliding surface and
decompressor shaft 20.9 mm, 14 mm 0.0. areas.
Install the decompressor plunger and
decompressor shaft into the camshaft by aligning
the groove on the plunger and pin on the shaft as
shown.
9-23
CYLINDER HEAD REMOVAL
- Ignition coil (page 18-8)
- Exhaust pipe (page 3- 13)
- Carbu retor (page 6-1 1)
- Camshaft holder assembly ('05 - '07: page 9· 8,
After '07: page 9-16)
- Spark plug (page 4-12)
'05 and '06 Remove the PAIR control valve (page 6-30),
california type.
After '06:
Be careful not to let

Remove the shims.

•
the shims fall into •
The shims can be easily removed with tweezers
the cylinder.
or a magnet .
• Mark all valve sh ims so they can be installed in
their origi nal position.
Remove the u pper engine mounting nut, bolt and ir:'~~'1":'

fuel hose clamp. 010';;;;;;;;;';';';;:;;;;';;; ;;';"
Remove the bolts, clutch cable guide and engine
hanger plates.
Loosen the hose band screw and disconnect the

upper radiator hose.
9-24 •
Remove the cylinder head mounting bolts .
Loosen the cylinder mounting bolt.
,-
Loosen the cyl inder head nuts in a crisscross pat-

tern in two or three steps. r~~~~~~~~~~~~
Be careful not to let Remove the nuts, washers and cylinder head.
the nuts and
washers fall into
the left crankcase.
Remove the gasket and dowel pins.
CAM CHAIN TENSIONER/CAM CHAIN

GUIDE
REMOVAL
- Cylinder head (page 9-24)
Remove the cam chain guide.
9-25
Remove the bolt, washer, collar and cam chain
tensioner.
INSPECTION
Inspect the cam chain tensioner and cam chain
guide for excessive wear or damage, replace them if CAM CHAIN GUIDE
~
necessary.
CAM CHAIN TENSIONER
INSTALLATION
Apply locking agent to the cam chain tensioner bolt [~~~~;~~~~~~E
th reads.
Install the cam chain tensioner, coilar, washer and
bolt.
Install the cam chain guide by aligning the tabs with

the grooves in the cylinder and the guide end with
the groove in the crankcase.
9-26 •
CYLINDER HEAD DISASSEMBLY
Remove the cylinder head (page 9-24).
loosen the i nsulator band screw a nd remove the
i nsulator from the cylinder head.
Remove the bolt, water hose jOint and O-ring.
,
SCR EW O-RING
To prevent loss of Remove the valve sp ring cotters using the special • ~~~'J.=~G
tension. do nor tools. •
compress the valve
spring more than TOOLS:
necessary to Valve spring compressor 07757-0010000
remove the corrers. Valve spring compressor
attachment 07959-KM30101
,
COTTERS
Mark all pans Remove the following:

during disassembly SPRI NG SEAT
- Spr ing retainer
so they can be
- Val ve spring
installed in their
- Valve VALVE
orlglns/iocations .
- Stem seal
- Spr ing seat
"Z JI
VALVE SPRING
9-27
CYLINDER HEAD INSPECTION
CYLINDER HEAD
Use care not to

SCf8fcil the
Disassemble the cylinder head (page 9-27),
Remove the ca rbon deposits from the combustion
chamber and exhaust port.
\~
...
combustion
Check the spark plu g hole and valve areas for
ctl8mber or head
cracks.
gasket surface.
Check the cylinde r head fo r warpage with a straight

edge and feeler gauge.
VALVE SPRING
Check the valve springs for fatigue or damage.
Measu re the free length of the intake and exhaust EX HAUST INTAKE VALVE
valve springs. VALVE SPRING
SERVICE LIMITS:
IN : 39.7 mm (1.56 in)
EX: 41 .9 mm (1.65 in)
Replace the springs if they are shorter than the ser-
vice limits.
VALVEIVALVE GUIDE
Inspect each valve for out-af-round, burns,
scratches or abnormal stem wear.
Check the valve movement in the guide.
Measure and record t he valve st em 0.0.
STANDARD:
IN: 5.475 - 5.490 mm (0.2156 - 0.2161 in)
EX: 4 .965 - 4 .980 mm (0.1955 - 0.1961 in)
SERVICE LIMIT:
EX: 4.96 mm (0.195 in )
9-28 •
Take care nor t D tilt
Ream the valve guid e to rem ove any carbon build-
or lean the reamer up before measuring the guid e 1.0. VALVE GUIDE REAMER
in the guide while Insert the reamer from the combu stion chamber
reaming. side of the head and always rotate the reamer clock-
wise.
TOOLS:
IN : Valve guide reamer, 5.5 mm 07984-2000001 or
07984·2000000
(U .S.A .only)
EX: Valve guide reamer, 5.0 mm 07984-MA60001or
07984-MASOOOO
(U.S.A.only)
Measure and record each valve guide 1.0.
STANDARD:
IN : 5.552 mm (0.2186 in)
EX: 5.052 mm (0.1989 in)
Subtract each valve stem 0.0. from the correspond-
ing guide I.D. to obtain the stem-ta-guide clearance.
STANDARD:
IN: 0.010 - 0.037 mm (0.0004 - 0.0015 in)
EX; 0.020 - 0.047 mm (0.0008 - 0 .0019 in)
Reface the valve If the stem-to-guide clearance exceeds the service

sears whene ver tile limits, determine if a new guide with standard
valve guides are dimensions would bring the clearance within toler-
rep/aced (page 9- ance. If so, replace the guides as necessary and
29). ream to fit.
If the stem-to-guide clearance exceeds the service
limit s with new guides also, replace the valves and
guides.
VALVE GUIDE REPLACEMENT

Mark new valve guides at the proper depth (see
specification page 9-30) using a marker. Chill the VAILVE GUIDE REMOVER
new valve guides in a freezer for about 1 hour.
Using a Toren to Heat th e cylinder head to 100 - 150"C (212 - 300"F)
heat the cylinder with a hot plate or oven. Do not heat the cylinder
head may cause head beyond 160°C (320"F). Use temperatu re ind ica-
warpage. tor sticks, available from welding supply stores, to
be sure the cylinder head is heated to the proper
temperature.
l Support the cylinder head and drive the valve
guides out of the cylinder head from the combus-
tion chamber side.
TOOLS:
IN : Valve guide remover, 5.5 mm 07742·0010100
EX : Valve guide remover, 5.0 mm 07942·MA60000
9-29
-----------------------------------
Adjust the valve guide driver to the valve guide
height.
While the cylinder head is still heated, drive new
valve guides into the cyl i nder head from the top of
the cylinder (camshaft and rocker arm side).
Check that the valve guides are at the proper depth
using a cal iper. adjust the height if necessary.
SPECIFIED DEPTH:
IN: 16.1 - 16.3mm(O.63 - 0.64in)
EX: 17.9 - 18.1 mm (0.70 - 0.71 in)
TOOL:
Valve guide driver 07743·0020000
not available in
U.S.A.
Let the cyli nd er head cool to room temperature.
Use curringoiJon Ream new valve guides.
the reamer during Insert the reamer from the combustion chamber
this operation. side of the cyl inder head and always rotate the
Take care not to tilt reamer clockwise.
or lean the reamer
In the guide while
TOOLS:
(eaming. IN: Valve guide reamer, 5.5 mm 07984-2000001 or
07984-2000000
(U .S.A. onlv)
EX: Valve guide reamer, 5.0 mm 07984-MA60001 or
07984· MA6000D
(U.S.A. onlv)
Clean the cyl i nder head thoroughly to remove any
metal particles after reaming and reface the valve
seats (page 9-30).
VALVE SEAT INSPECTION/REFACING

Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply light coati ng of Prussian Blue to the va lve
seat.
Tap the valves and seats using a rubber hose or
other hand·lapping tool.
Remove the valve and inspect the valve seat face.

The va lve seat contact should be w ithin the speci-
fied width and even all around the circumference.
STANDARD:
IN: 1.1 - 1.3 mm (0.04 - 0.05 in)
,",,, ",."'
EX: 1.3 - 1.5 mm (0.05 - 0.06 in)
f--- ,
SERVICE LIMIT:
IN/ EX : 2.0 mm (0.08 in)
If the seat width is not within specification, reface
, SEATWfDTH
•
the valve seat (page 9-3 1).
9-30 •
Inspect the valve seat face for:
• Uneven seat width:
- Replace the valve and retace the valve seat .
• Damaged face:
- Replace the valve and reface the valve seat.
.0.
,
DAMAGED FACE UNEVEN SEAT WIDTH
The valves cannot • Contact area (too high or too low)

be ground. If B - Refaee the valve seat.
valve fsce is burned
01 badly worn or if it
contacts the sear
unevenly, rep/ace
the valve.
TOO lOW TOO HIGH
VALVE SEAT REFACING

FOllow the reracing Valve seat cutters/grinders or equivalent valve seat
manufaCTurer's refacing equipment are recommended to correct
operating worn valve seals.
9 \45
mstruCf!OfIS.
0
"\ Soo
Q \ 32°
V \
If the contact area is too high on the valve, the seat
'"."~.~:;~'
must be lowered using a 32" flat cutter.
If the contact area is too Iowan the valve, the seat
must be raised using a 60° interior cutter.
CONTACT TOO LOW OLD SEAT
~ . .~WIDTH
L 60°
9-31
Reface the sear Use a 45° seat cutter, remove any roughness or
WIth a 45~cutte, irregularities from the seat. ROUGHNESS
whenever B valve
guide is rep/aced. TOOLS:
Seat cutter, 35 mm liN) 07780·0010400
Seat cutter, 33 mm (EX) 07780·0010800
Cutter holder, 5.5 mm (IN) 07781·0010101
Cutter holder, 5.0 mm (EX) 07781-0010400
or equivalent commercially available in U.S.A .
Use a 32° flat cutter, remove 1/4 of the exist ing

valve seat material.
TOOLS:
Flat cutter, 36 mm (IN) 07780-0013500
- /~EATWIDTH
Flat cutter. 33 mm (EX) 01780·0012900
Cutter holder, 5.0 mm (EX) 07781·0010400
or equivalent commercially available in U.S.A. 32°~
Use a 60° interior cutter, remove 1/4 of the existi ng

valve seat materia l.
-~~...J~OLD
TOOLS:
Interior cutter, 37.5 mm (IN) 07780-0014100
~)SEAT WIDTH
Interior cutter, 34 mm (EX) 07780-0014700
Cutter holder, 5.0 mm (EX) 07781 -0010400
or equivalent commercially available in U.S.A.
Using a 45° seat cutter, cut the seat t o proper width. ~=================~
Make sure all pitting and irreg ularities are removed.
Refinish if necessary.
STANDARD:
IN : 1.1 - 1.3 mm (0.04 - 0.05 in)
EX: 1.3 - 1.5 mm (0.05 - 0.06 in)
,''",
-------' 45°L
•
9-32 •
INTAKE SIDE:
After refacing, wash the cylinder head and valve.
I NOTICE I
• Do not lap the imake valves. They are titanium
and have a thin oxide coating. Lapping will dam-
age this coating.
• Use only new intake valves.
EXHAUST SIDE:
After cutting the exhaust seats, apply lapping com-
pound to the exhaust valve face, and lap the
exhaust valve using light pressure.
After lapping, wash any residual compound off the
cylinder head and valve.
I NOTICE I
• Excessive lapping pressure may deform or dam-
age the seat.
• Change the sngle of the lapping tool frequently
to prevent uneven seat wear.
• Do not allow any lapping compound to enter the
guides.
CYLINDER HEAD ASSEMBLY

VALVE COnERS
~ SPRIN G RETAINER
SPRING - - . \ SPRING SEAT
tI
STEM SEAL
~
~
VALVE GUIDE - - - ,
WATER HOSE JOINT
~ INTAKE VALVE 7~--_=-l EXHAUST VALVE
9-33
Blowout all oil passages in the cylinder head with
SPRING SEAT
compressed air.
Install the spring seat and new stem seal.
Lubricate the valve stem sliding surface with molyb-
-:7J VALVE
denum oil solution.

Insert the valves into the guide while turning it
slowly to avoid damage to the stem seal.
fI=Z , ; VALVE SPRING
Instal l the va lve springs with the tightly wound coils

facing the combustion chamber. EXHAUST INTAKE VALVE
VALVE SPR ING
Install the spring retainer.

NOTE:
IN:
• • EX:
Do not confuse the intake spring retainers and
exhaust spring retainers. The intake spring retainer
has a flat surface and the exhaust spring retainer
has a chamfered edge.
Gresse IlIecolters Install the valve coners using the special tools as
to ease ins/allation. shown.
To preV6n1loss of TOOLS:
16nsion, do nor Valve spring compressor 07751·0010000
compress rhe valve Valve spring compressor
spnngs more than attachment 01959·KM30101
necessary.
NOTE;
Do not confuse the intake cotters and exhaust cot-
ters. The intake cotters are long and exhaust cotters
are short.
,
COTTERS
IN: EX:
00
9-34 •
Suppon the Tap the valve stems gently with two plastic ham-
mers as shown to seat the cotters firmly.
cylinder head SD
the valve heads do
not contact
anything that may
damage them.
Install the carburetor insulator to the cyl inder head

by al igning th e groove of the ca r buretor insulator '05 - '07:
with the tab of the cylinder head.
Tighten the carburetor insulator band screw so the 12.0 ± 1.0mm
distance between the band ends is follow: (0.47 ± 0.04 in)
- '05 - '07: 12.0 ± 1.0 mm (0.47 ± 0.04 in)
- After '07: 9.0 ± 1.0 mm (0,35 ± 0.04 i n)
INSULATOR Align
After '07:
9.0 ± 1,Omm
(0.35 ± 0.04 in )
Install a new D-ring to the water hose joint.

Install the water hose joint to the cylinder head.
Install and tighten the bolt securely.
~ O-RING
9-35
CYLINDER HEAD INSTALLATION
Install the dowel pins and a new gasket.
Install the cylinder head onto the cylinder.

Apply oil to the cylinder head nut threads and seat-
ing surface.
Be careful no r fO leI Install the washers and cylinder head nuts.
the nuts and Tighten the nuts to the specified t orque in a criss-
washers fallimo cross pattern in two or three steps.
the left crankcase.
TOROUE: 66 N'm (6.7 kgf ·m , 49 Ibf.ft)
Install the cylinder head mounting bolts.

Tighten the cyl i nder mounting bolt and cylinder
head mounting bolts secu rely.
I~~~~~~~~~~;~::~
Connect the radiator hose to the water hose joint.

Tighten the hose band screw securely.
9-36 •
Install the upper engine hanger plates, bolts, fuel
hose clamp, clutch cable guide and nut.
Tighten the engine hanger plate bolts to the speci-
fied torque.
TORQUE: 26 N'm (2.7 kgf·m , 19 IbHt)
Tighten the upper engine mounting nut to the spec-
ified torque.
TORQUE: 54 N 'm (5.5 kgf·m. 40 IbUt)
Be careful nor TO ler Install the shims,

the shims fa/l into
rhe left crankcase. Install the following :
Instal/ rhe shims in - Spark plug (page 4-13)
rheiroriginal - Camshaft holder assembly ('05 - '07: page 9-8,
location. After '07: page 9·16)
- Carbu retor (page 6-24)
- Exhaust pipe (page 3- 14)
- Ignition co i l (page 18-8)
'05 and '06 Install the PAIR control valve (page 6-30) .
Californis type,
Fill the cooling system w ith recommended coolant
After '06:
mixtu re (page 7-7).
CAMSHAFT INSTALLATION ('05 - '07)

Apply molybdenum oi l solution to the outer suriace
of each valve lifter. LIFTERS
Install the \lBlve Install the valve lifters into the camshaft holder.
lifters in their
Make sure the dowel pins are installed into the cam-
originslloca tion.
shaft holder.
Apply molybdenum oil solution to the cam lobes

and camshaft bearings,
Install the camshaft holder assembly with the intake
cam lobes facing up.
Apply oil to the camshaft holder mounting bolt
threads.
Install the camshaft holder mounting bolts.
Tighten the bolts in a crisscross pattern in two or
three steps to the specified torque.
TORQUE: 14 N'm (1.4 kgf·m, 10 IbHt )
\.
9-37
Be careful nor to Turn the crankshaft clockwise to align the punch
IBm the cam cham mark on the primary drive gear with the index mark
Bg8tnsr the on the right crankcase cover.
crankcase.
Align
Install the cam chain onlo the cam sprocket.

Install the cam sprocket while alig ning the index l ine
on the cam sp rocket with the ~f:::.. mark on the cam
holder.
Clea n and apply locking agent to the cam sprocket

bolt threads.
Align the cam sprocket bolt holes with the cam
sprocket and camsha ft.
Temporarily install the one cam sprocket bolt.
Turn the crankshaft clockwise 360 0 and insert the
special tool into the sprocket over the gasket sur-
face.
TOOL:
Cam sprocket holder 07AMB·MEBA100 (U.S.A. only)
Tighten the other sprocket bolt to the specified

torque.
l~~~~~~~~~
TORQUE; 20 N·m (2.0 kgf·m , 15 lbf·ft)
Remove the special tool, turn the crankshaft clock-
wise one turn and reinsert the special tool into the
sprocket.
Tighten the another cam sprocket bolt to the speci-
fied torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 Ibf·ft)
9-38
Remo .... e the stopper tool from the cam ch ain
tensioner lifter.
Install the bolt with a new sealing washer.
Tighten the cam cha i n tensioner lifter bolt securely.
If decompressor cam assem bly was disassembled,

tighten it to the specified to rque while holding the
crankshaft.
TORQUE: 24 N 'm 12.4 kgf·m , 18 Ibf.ft)
Check the O-r ing is in good condition, replace it if

necessary.
Apply oil to the O-r ing.
Apply grease to the crankshaft hole cap threads.
Install the crankshaft hole cap and tighten it to the
specified torque.
TORQUE: 15 N 'm 11.5 kgf·m, 11 Ibf·ft)
Install the cyl inder head cover (page 9-42).
CAMSHAFT INSTALLATION (After '07)

"I::," MARK
mark on the primary dri ....e gear with the "I::," mark
'-
9-39
Apply molybdenum oil solution to the outer surface ~ VALVE
of each valve lifter. m
Instal! the valve Install the valve lifters into the camshaft holder.
lifters in their
Make sure the dowel pins are installed in the cam-
originallocarion.
shaft holder.
Apply molybdenum oil solution to the cam lobes.

Install the camshaft holder assembly with the intake
cam lobes facing up.
Apply oil to the camshaft holder mounting bolt
threads, and install them.
Tighten the bolts in a crisscross pattern in two or
three steps to the specified torque.
TORQUE: 14 N·m (1 .4 kgf·m, 10 Ibf.ft!
Install the cam chain onto the cam sprocket.

When installing the When installing the cam sprocket, align the follow-
cam sprocket face ing:
the decompressor
pin to the front
Decompressor weight hole with the setting pin of ~~!";::7:-:f.
the decompressor shaft
side.
- Bolt hole of the cam sprocket with the camshaft
- Index li ne on the cam sprocket with the -D." mark
of the camshaft holder
Clean and apply locking agent to the cam sprocket

bolt threads.
;~~~~~~~~
Temporari ly install the one cam sprocket bolt.
Turn the crankshaft clockwise one turn, then i nstall
and tighten the other cam sprocket bolt to the speci-
fied torque.
TOROUE: 20 N·m (2.0 kgf·m, 15 Ibf.ft)
Turn the crankshaft clockwise one turn again, and
tighten the remaining cam sprocket bolt to the
specified torque.
9-40 •
Make su re of the plunger operation using the fol -
PLUNGER
lowing procedure:
1. Move the decompressor weight outside with
your finger_
- The plunger operation is norma l if it is
retracted .
2. Release the decompressor weight.
- The decompressor weight should m ove inside
automatically.
- The plunger operation is no rmal if it is pro-
truded.
Remove the stopper tool from the cam chain

STOPPER TOOL
tensioner lifte r.
=--c
\
)1:::;'~iF
TENSIONER LIFTER
Install the cam chain tensioner lifter bolt with a new

seal ing washer.
Tighten the cam chain tensioner lifter bolt securely.
Check the O-ring is in good condition, replace it if

necessary.
Apply oil to the O-ring.
Apply grease to the crankshaft hole cap threads.
Install the crankshaft hole cap and tighten it to the
specified torque.
TORQUE: 15 N 'm " .5 kgf·m, 11Ibf·tt)
Install the cylinder head cover (page 9-42).
9-41
CYLINDER HEAD COVER
INSTALLATION
Check the plug hole seal is in good condition,
replace it if necessary.
Apply oil to the circumference of the plug hole seal.
Install the plug hole seal.
Inspect the cylinder head cover packing for damage

or deterioration and replace it with a new one jf nec-
essary.
Install the cylinder head cover packing to the cyl in-
der head cover .
Install the washers to the cylinder head cover with , - - -- -- - - - - - - - - - - - - - ,

their ·UP" mark facing up. "UP· MARK
Install the cylinder head cover and tighten the bolts

to the specified torque.
L--r~ii~iiifiiii~~~i-.::~1
TORQUE: 10 N'm (1 .0 kgf·m, 7 Ibf.tt)
9-42
Connect the spark plug cap and breather hose.
Install the fuel tank (page 3-8).
9-43
MEMO
10. CYLINDER/PISTON
'-- .-
COMPONENT LOCATION ···· .. ·.. ·.. ············ 10-2 PISTON REMOVAL ...... ............................ 10-6
SERVICE INFORMATION ···· ····················· 10-3 PISTON INSTALLATION ......................... . 10-9
TROUBLESHOOTING ................ · .............. 10-4 CYLINDER INSTALLATION .................. .. 10-10
CYLINDER REMOVAL .... ·.. .... .................. · 10-5
10-1
CYLINDER/PISTON
COMPONENT LOCATION
~----------.
'05 - '07: :
,,,
,,
,,
,
10-2
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the cylinder and piston. These procedures can be done with the engine installed in
the frame.
• Before disassembly, clean the engine thoroughly to prevent dirt from entering it.
• Be careful not to damage the mating suriaces when removing the cylinder. For example. do not use a screwdriver to pry
the cylinder.
• Clean all disassembled parts with cleaning solvent before inspection, use compressed air to dry the parts.
• Under racing conditions, the piston and piston rings should be replaced after 15.0 hours of operation. Replace the pis-
ton pin after 30.0 hours of operation .
SPECIFICATIONS
ring
Top 0.065 - 0.100 (0.0026 - 0.0039) 0.115 (0.0045)

gap
0.90 (0.035)
TORQUE VALUE
Cam chain tensioner lift er mounting bolt 12 N·m (1.2 kgf·m, 9lbHt)
10-3
CYLINDER/PISTON
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test
or by tracing engine noise to the top-end with a sounding rod stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky,
check for a seized piston ring.
Compression too low, hard starting or poor performance at low speeds
• Leaking cylinder head gasket
• Worn, stuck or broken piston rings
• Worn or damaged cylinder and piston
• Loose spark plug
Compression too high, over.heating or knocking
• Excessive carbon build-up in cylinder head or on top of piston
Abnormal noise
• Worn cylinder and piston
• Worn piston pin or piston pin hole
• Worn connecting rod sma ll end
• Worn connecting rod big end
Excessive smoke
• Worn cylinder, piston and piston rin gs
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
10-4
CYLINDER/PISTON
CYLINDER REMOVAL
Remove the cylinder head (page 9-24l.
Remove the cam chain guide.
Remove the bolts, cam chain tensioner lifter and

gasket.
Remove the bolt and cylinder.
Prevent the cam Remove the dowel pins and gasket.

chain from f811ing
Into the crankcase.
'-
10-5
CYLINDER/PISTON
PISTON REMOVAL
Places clean shop Remove the pist on pin clips with pliers.
towel ovef the
Press the piston pin out of the piston and remove
crankcase to
prevent the clip
the piston.
from falling into the • Under racing conditions, the piston and piston
crankcase. rings should be replaced according to the com-
petition maintenance schedule (page 4·6).
PISTON RING REMOVAL

Do nor damage the Spread the piston rings and remove them by lifting
piston ring by up at a point just opposite the gap.
spreading the ends
/00 faf.
CYLINDER INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cyl inder tD. in the X and Y axes at
three levels.
Take the maximum readi ng to determine the cylin-
der wear.
Calculate the cylinde r-to-piston clea ran ce.
Take a maximum reading to determine the clear-
ance.
For piston 0.0. (page 10-7).
Calculate the taper and out-of·round at three levels

in the X and Y axes. Take the maximu m reading to
determine the cylinder condition.
\~-Y-~j
SERVICE LIMITS: TOP X
Taper: 0.010 mm (0.0004 in) ......... ..-/
Out-oJ-round: 0.010 mm (0.0004 in)
".::= -=--------
-- ,
MIDDLE
'----'--~/
BonOM "'-------- ;---.......
---_/
'-. /'
10-6
CYLINDER/PISTON
Inspect the top of the cylinder for warpage.
SERVICE LIMIT: 0.05 mm (0.002 in )
-
PISTON/PISTON RING INSPECTION
Never use a wife Remove the carbon deposits from the pi ston head
brush. It will scra tch or piston ring grooves.
PISTON RING
the grooves. Inspect the piston for damage and the ring grooves
for wear.
Temporarily install the top piston ring to its proper

position with the mark facing up.
Measure the piston ring+to·ring groove clearance
with the ring pushed into the groove.
Inspect the piston ring grooves for wear or damage.
Measure the diameter of the piston at 5.0 mm (0.20

I in) from the bottom and 90 degrees to the piston pin
U hole.
SERVICE LIMIT: 95 .94 mm (3.777 in )
If the 0 .0 . is under the service limit or nearly 15.0
hours of ru nning time have elapsed (competition 5.0mm
use only), replace the piston wi th a new one. (0.20 in)
Calculate the cylinder-to-piston clearance.
10-7
CYLINDER/PISTON
Measu re the piston pin bore I.D. ,-.' ....
Check the piston pin for wear and excessive discol-

oration.
Measure the piston pin 0 .0 .
If the 0.0. is under the service limit, discolored, or

nearly 30.0 hours of running t ime have elapsed
(competition use only). replace the piston pin.
Calculate the piston-ta-piston pin clearance.
SERVICE LIMIT: 0.04 mm to.002 in)
Push the ring inro Insert each piston ring into the cylinder and mea-
the cylmder with sure the ring end gap.
the top of the
Piston 10 be sure SERVICE LIMITS:
Top: 0.45 mrn (0.018 in)
,.
the ring is squarely
in rhe cylinder. Oil (side rail): 0.90 mm (0.035 in)
CONNECTING ROD INSPECTION

Measure the connecting rod small end 1.0.
If the 1.0. is over the service limit, repla ce the crank-
shaft (page 13-14).
Calcu late the connecting rod-to-piston pin clear-
ance.
CAM CHAIN TENSIONER LIFTER

INSPECTION
Check the cam chain tensioner lifter operation:
- The tensioner shaft should not go into the body
when it is pushed.
- When it is turned clockwise with a screwdriver,
the tensioner shaft should be pulled into the
body. The shaft should spring out of the body as
soon as the screwdriver is released .
10-8
CYLINDER/PISTON
PISTON RING INSTALLATION
Clean the piston grooves thoroughly.
Install the rop ring Apply engine oil to the piston rings and install them .
on the piston Wilh
.. Do not damage the piston r ing by spreading the
MARK TOP RING
t he marked side
ends too far.
facing up.
.. Be careful not to damage the piston during pis-
ton ring installation .
.. Do not align the oit ring (side rails) gaps .
• Space the piston ring end as shown.
After installation, the rings should rotate freely in
the ring grooves.
OIL RING
PISTON INSTALLATION
When cleaning the Clean any gasket material f rom the cylinder mating or:= ;.. -u
cylinder mating surfaces of the crankcase.
surface, place a
Apply molybdenum solution oil to the connecting
shop rowel over the
rod small end.
cylinder opening to
prevent dust or dirt
from emen'ng the
engine.
l
Place a shop towel around the piston skirt and in the
crankcase to prevent the piston pin clips from falling
into the crankcase.
Apply engine oil to the piston pin outer surface and
piston pin hole of the piston.
Install the piston with the "IW mark facing intake
side.
Be careful not to Install the piston pin and new piston pin cl ips.
drop the piston pin
• Always use new piston pin clips. Reinstalling
cl(o into the
used piston pin clips may lead to serious engine
, crankcase.
damage.
\
Do not align the piston pin clip end gap w ith the pis-
ton cut-out.
10-9
CYLINDER/PISTON
CYLINDER INSTALLATION
Install the dowel pins.
Install a new cylinder base gasket on the crankcase.
Avoid piston ring Coat the cylinder bore, piston and piston rings with l~!l~N]fR'"
damago during engine oil and i nstal l the cyl inder w hile compress-
installarion. in9 the piston rings.
Install the cyl inder mounting bolt.

• After tightening the cylinder head mou nting nut,
tig hten the cylinder mounting bolt securely.
Install a new gasket, cam chain tensioner lifter and
bolts.
Tighten the bolts to the specified to rque.
10-10
CYLINDER/ PISTON
Install the cam chain guide by aligning il s tabs with
the grooves in the cylinder and the guide end with
the groove in the crankcase.
Install the cylinder head (page 9-36).
10-11
MEMO
•
11. CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
-..
COMPONENT LOCATION ··· ····················· " -2 CLUTCH .................................................... " -7
SERVICE INFORMATION ························· "-3 KICKSTARTER ...................... ·................ ·"-'5
..
TROUBLESHOOTING ······························· "-4 STARTER CLUTCH .......... · ............ · .... ·.... "-'9
RIGHT CRANKCASE COVER .. ·.............. ·.. " -5 GEARSHIFT LINKAGE ........................ ·.. · " -24
11-1
COMPONENT LOCATION
12 N'm (1.2 kg f·m, 9 rbf.ft)
22 N·m (2.2 kgf·m, 1 Ibf.ft)
12N·m(1 .2kgf·m, ". ~

9lbfft) / ~
(}.
18 N'm (1.8 kgf·m , 13 Ibf.ftj
108 N'm (11.0 kgf·m, 80 rbf·ft)
80 N'm (8.2 kgf·m,

59Ibf.ft)
12 N'm (1.2 kgf·m , 9 l bf.ftj

•
•
11-2 •
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch , starter clutch, kickstarter and gearshift linkage. All service can be done with the
engine installed in the frame .
• Transmission oil v iscosity and level have an effect on clutch disengagement. Oil additives also affect clutch perfor-
mance and are not recommended . When the clutch does not disengage or the motorcycle creeps with the clutch pulled
i n, inspect the transmission 011 level before servicing the dutch system.
SPECIFICATIONS
I .
gear I .
TORQUE VALUES
Clutch center lock nut 80 N'm (8.2 kgf·m , 59 Ibf·ft) Apply oil to the threads and seating surface
Clutch spring bolt 12 N'm (1.2 kgf·m . 9 Ibf·ft)
Gearshift drum center pin 22 N'm (2.2 kgf·m , 16Ibf.ft) Apply locking agent to the threads
Gearshift drum stopper arm bolt 12 N'm (1 .2 kgf·m , 9 IbUt)
Kid:starter pedal bolt 38 N'm (3.9 kgf·m , 28 Ibf·ft)
Gearshift pedal pinch bolt '2 N 'm (1.2 kgf·m , 9 Ibf·ft)
Gearshift return spring pin 22 N'm (2.2 kgf·m , 161bHt)
Primary drive gear bolt 108 N'm (11.0 kgf·m, 80 lbf.ft) Apply oil to the threads
Starter gear holder mounting bolt 18 N·m (1.8 kgf·m , 13Ibf·ft ) Apply oil to the threads
l TOOLS
Clutch center holder Gear holder, M2 .5
07724-0050002 07724-0010100
or equivalent commercially avail - or 07724-001A 100 (U.S.A. only)

able in U.S.A.
11-3
TROUBLESHOOTING
Hard to shift
• Improper clutch operation
• Improper oil viscosity
• Incorrect clutch adjustment
• l oose stopper plate boll
• Damaged stopper plate and pin
• Damaged gearshift spindle
• Bent shift fork (page 13-13)
• Bent shift fork shaft (page 13-13)
• Bent fork claw (page 13-13)
Transmission jumps out of gear
• Worn shift drum stopper arm
• Weak or broken shift arm return spring
• loose stopper plate bolt
• Bent shift fork shaft (page 13-13)
• Damaged or bent shift fork (page 13-13)
• Damaged shift drum center groove
• Faul.ty ratchet pawl
• Worn gear engagement dogs or slot (page 13-12)
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Bent gearshift spindle
Clutch slips when accelerating
• Worn clutch discs
• Weak clutch springs
• Transmission oil mixed with molybdenum or graphite additives
Motorcycle creeps with the engine Idling
• Clutch plate warped
• Faulty clutch lifter
• Incorrect transmission oil
Starter motor tums, but engine does not tu rn
•
• Faulty starter clutch
• Damaged or faulty starter motor pinion gear, reduction gears, idle gear or starter driven gear.
11-4 •
RIGHT CRANKCASE COVER
REMOVAL
- Brake pedal (page 16-24)
- Right engine guard (page 3-5)
Drain the transmission oil (page 4-23),
Drain the coolant (page 7-71.
c .
; Remove the bolt and kickstarter pedal.
'. Remove the bolts, water hose joint and D -ring.
Loosen the right crankcase cover bolts in a criss-

cross pattern in two or three steps.
Remove the bolts, hose guide, hose clamp and right
crankcase cover.
Remove the water by-pass pipe and D-ring.

Check th e kickstarte r spindle oil seal for deteriora-

tion or damage.
Apply grease to the kickstarter spindle oil seal lips.
11-5
INSTALLATION
Install a new D-ring onto the by-pass pipe.
Install the by-pass pipe into the crankcase.
Install the dowel pins and new gasket.
Install the right crankcase cover while engaging the

water pump shaft securely with the balancer shaft
tab.
Install the hose clamp, hose guide and right crank-
case cover bolts.
nghten the right crankcase cover bolts in a criss-
cross pattern in two or three steps.
Install a new D-ring onto the water hose joint.
11-6
Install the water hose joint to the water pump cover
and tighten the bolts securely.
Inst all the kickstarter pedal and tighten the bolt to
TORQUE: 38 N'm (3.9 kgf·m , 28 Ibf.ft)
Inst all the following:
- Right engine guard (page 3-5)
- Brake pedal {page 16-241
bleed the air (page 7-7),
Fill the transmission with the recommended trans-
mission oil (page 4-22).
Start the engine and check f or oil and coolant leaks.
CLUTCH
CLUTCH REMOVAL
Remove the brake pedal (page 16-24).
Remove the bolts, clutch cover and O-ring.
Remove the clutch spring bolts in a cr isscross pat-

tern in two or three steps.
Remove the clutch springs.
Remove the clutch pressure plate.
,
\....
Remove the washer,
and lifter rod.
11-7
Remove the eight clutch discs and seven clutch
plates.
Bend the tab of the lock washer away from the lock
nut.
Remove the clutch cen t er lock nut using the special

tool.
::=::;;::~:i~~~~~~~~~~~~
TOOL:
Clutch center holder 07724·0050002 or
equivalent com-
mercially avail-
able in U.S.A.
Remove the thrust washer and lock washer.
Remove the clutch center.
Remove the right crankcase cover (page 11-5),

Remove the thrust washer and clutch out er.
11-8 •
Remove the needle bearings and clutch outer guide.
Remove the bolts. drive sprocket cover and spacer.
Disconnect the clutch cable from the clutch lifter

lever.
Remove the bolt, stay and clutch lifter lever from
the left crankcase.
INSPECTION
ClUTCH SPRING
l Clutch springs
should btl replaced
8S 8 set If one or
Measure the clutch spring free length.
SERVICE liMIT: 43.7 mm 11.72 in)

more Is below the
servICe limll.
ClUTCH SPRING
I
\
11-9
CLUTCH DISCS
Check the clutch discs for signs of scoring or discol·
oration. CLUTCH DISC
Replace the clutch Measure the thickness of each disc.

discs and plates as
8 S8t.
CLUTCH PLATES
Check the plates for excessive wa rpage or discolor·
ation.
Check the plate warpage on a su rface plate using 8
feeler gauge.
Re~e the clutch Measure the thickness of the plates.
drSCSBndpJaresBs SERVICE LIMIT: 0.15 mm (0.006 in)
a ser.
CLUTCH CENTER
Check the clutch center for nicks, indentations or
abnormal wear made by the clutch plates.
CLUTCH LIFTER/ NEEDLE BEARING

Check the lifter for wear or damage.
Check the needle bearing for wear or damage.
Assemble the clutch l ifter, needle bearing and
LIFTER
washer.
Turn the washer with you r finger and make sure the
needle beari ng turns smoothly.
WASHER
Replace t he clutch lifter, needle bear ing and washer
as a set if necessary.
,i
LIFTER ROD
CLUTCH LIFTER ROD
Check the clutch lifter rod for damage and straight-
ness. •
NEEDLE BEARING
11-10
CLUTCH OUTER
Check the clutch outer for nicks, indentations or
abnormal wear made by the clutch discs. CLUTCH OU·rER
Check the serrated teeth of the primary driven gear
for wear or damage.
PRIMARY DRIVEN GEAR

CLUTCH OUTER GUIDE
Check the clutch outer guide for abnormal wear or
damage. NEEDLE BEIIR"'GS
NEEDLE BEARING
Check the needle bearing for wear or damage.
Check the mainshaft for wear or damage at the slid-
ing surface of the clutch outer guide.
CtUTCH OUTER GUIDE
CLUTCH LIFTER LEVER

Check the clutch lifter lever for damage.
Check the dust seal and needle bearing for wear or
CLUTCH LIFTER LEVER I~~~~~~~
damage.
Applv grease to the oil seal lips.
11-11
INSTALLATION
THRUST WASHER
CLUTCH
CLLJT(:H DISC A
"7!
CLUTCH DISC B
WASHER
LOCK WASHER ~
....
LIFTER ROD - ,
CLUTCH LIFTER ~
NE"DL.E BEARING --"1
12 N'm (1.2 kgf·m, 91 PRESSU RE PLATE
Apply molybdenum oi l sol ution to the clutch lifter r=::;;:-:,::,~~,~~

lever cam area.
Insta ll the clutch lifter lever into the left crankcase.
Install the clutch lifter lever stay and bolt.
Connect the clutch cable to the clutch lifter lever.
Install the spacer, drive sprocket cover, and bolts.
11-12
Apply molybdenum oil solution to the clutch outer
guide inner surface and clutch ouler needle bearing
rolling area.
Apply transmission oil 10 the needle bearing.
Install the clutch outer guide and needle bearings
onto the mainshaft.
Apply oil to the clutch out er sliding surface.

Install the clutch outer and th rust washer.
Install the right crankcase cover (page 11-6).
Install the clutch center onto the mainshaft.

Install a new lock washer by aligning its grooves
with the clutch center ribs.
Apply transmission oil t o the threads and seating
surface of the clutch center lock nut.
Install the thrust washer and lock nut.
Tighten the lock nut t o the specified torque using

the special tool.
TOOL:
Clutch center holder 07724-0050002 or
equivalent com-
merciallvavail·
able in U.S.A.
TORQUE: 80 N'm 18.2 kgf·m, 59 Ibf·ft)
11-13
Bend the tabs of the lock washer up against the
clutch center lock nut.
Coat the clutch plates and discs with clean transmis- ;~~~~~~~~:":'~~:.:=~~~~~
sicn oil.
Install the clutch disc A at first, then install the seven
clutch plates and six clutch discs B alternately.
Install the clutch disc A at the end.
DISC A: DISC B:
~~
Apply transmission oi l to the clutch lifter and lifter
rod contact surface.
~~Tcii=i~~r:~~~iill~~ji~~~l
r
Insert the clutch lifter rod into the mainshaft.
Inst all the clutch litter.
Apply transmission oil to the needle bearing and
washer.
Install the needle bearing and washer to the clutch
lifter.
Install the pressure plate.

Install the clutch springs and bolt s.
Tighten the bolts to the specified torque in a criss-
cross pattern in two or three st eps.
TORQUE : 12 N'm (1.2 kgf·m, 9 Ibf.ft)
11-14
Apply oil to
cover.
"---.
Tighten the cover bolts in a crisscross pattern in two

or three steps.
Install the brake pedal (page 16-24).
Adjust the clutch lever freeplay (page 4-31).
Fill the cooling system with the recommended cool-
ant and bleed the air (page 7-7).
Fill the engine with the recommended transmission
oil (page 4-23).
Start the engine and check for oil leaks.
KICKSTARTER
REMOVAL
- Right crankcase cover (page' 1-5)
- Clutch (page 11 -71
Remove the snap ring, thrust washer, starter idle
gear and bushing.
Unhook the kickstarter return spring from the crank-
case.
Remove the kickstarter spindle assembly_
OISASSEMBL Y
Disassemble the kickstarter spindle by removing the
SPINDLE PINION GEAR
following:
- Return spring and collar
- Ratchet spring and starter ratchet
SNAP RING
- Snap ring, thrust washe rs and pinion gear
- Pinion gear bushing
INSPECTION SPRING
Check the return spring and ratchet spring for
fJ
COLLAR
fatigue or damage.
Check th e starter ratchet fo r wear or damag e.
WASHERS STARTER RATCHET
11-15
Check the kickstarter pinion for wear or damage.
Check the kickstarter spindle for bend, wear or dam-
age.
Check the kickstarter pinion gear bu shing for dam-
age or excessive wear.
Measure the kickstarter pinion gear 1.0.
Measu re the kicksta rt er pinion gear bushing 1.0. and
0 .0 .
SERVICE LIMIT: I.D.: 20.04 mm (0.789 in)
0 .0 .: 21 .96 mm (0.865 in )
Measu re the kickstarter spindle 0 .0 .
Check the starter idle gear and bushing fo r wear or
damage.
Measu re the starter idle gear 1.0.
Measure and record the starter idle gear bushing
1.0 . and 0.0.
SERVICE LIMIT: 1.0 .: 17.04 mm (0.671 in)
0 .0 .: 19.96 mm (0.786 in)
Measure the countershaft D.D. at the idle gear slid-

ing surface.
11-16 •
ASSEMBLY
RATCHET SPRING
SNAP RING
-:7J PINION GEAR
THRUST WASHER
THRUST WASHER
$
COLLAR
-:7J STARTER RATCHET
~ -:7J KIICK~;TAFm R SPINDLE
Ho ll UHNSPRING
Apply molybdenum oil sol ution to the kickstarter

spindle spline area an d gea r rol ling surface. RETURN SPRING
Install the coll ar aligning jts gap with the spring .
( Install the thrust washer and pinion gear bush i ng

THRUST WASHER
onto the kickstarter spindle.
11-17
Apply molybdenum oil solution to the pinion gear
inner surface. I I SNAP RING
Install the pinion gear and thrust washer.

Set the sharp edge Install the snap ring in the groove of the spindle.
of the snap rmg
faCIng OUI. Check
r118/ lhe snap ring IS
ssated In the
groove.
THI""" WASHER
Align the punch marks and install the starter ratchet.
INSTALLATION
Install the ratchet spring .
Apply transmission oil to the kickstarter spindle
journal.
Be sure the nnchet Install the kickstarter assembly to the crankcase and
spnng did not fall rotate the spindle counterclockwise until the ratchet
oHlhespmdle tab is clear of the stopper plale.
dUflng ins/a/ia/lOft.
Hook the return spring end into the hole in the

crankcase.
11-18
App ly molybde num oil solution to the countershaft
sliding su rface.
Install the bushing and starter idle gear onto the
countershaft.
Install the thrust washer and snap r ing.

Install the f ollowi ng:
- Clut ch (page '1 -12)
- Rig ht crankcase cover ~ p age 11-6)
STARTER CLUTCH
REMOVAL
Remove the follow i ng:
- Right crankcase cover (page 11-5)
- Clutch (page 1'-7)
Remove the reduction gear shaft and reduction gea r B.
l Temporarily install t he clutch ou ter guide, needle

bearings and clu tch oute r.
Install the gear holder between the primary drive
and driven gea rs.
TOOL:
Gear holder, M2.5 07724-0010100 or
01124·001Al00
(U.S.A. only)
Remove the primary drive gear bo lt, washer, clutch
outer, needle bea ri ngs, clutch out er guide and p ri-
mary drive gear.
11-19
Remove the starter clutch assembly.
Remove the bolts. gear holder, reduction gear A and

idle gear.
1ii~~~i~
~
DISASSEMBLY/INSPECTION
Check that the starter driven gear turns counter-
clockwise smoothly and does not turn clockwise. DRIVEN GEAR
Remove the driven gear and needle bearing from
starter clutch outer.
NEEDLE
Remove the snap ring and one-way clutch from
clutch outer. SNAPAING ONE-WAY CLUTCH
CLUTCH ",reFR
"·20
Check the needle bearing for abnormal wear or
damage. NEEDLE BEARING
Check the starter driven gear for abnormal wear or

damage.
Measure the driven gear boss 0.0.
Measure the driven gear boss 1.0.

'.'
,
-- ..;;,.-'
I
Check the one-way clutch sprag for abnormal wear

or damage.
Check the starter clutch outer sliding surface for
wear or damage.
CLUTCH OUfER
Check the reduction gear A and idle gear for wear or

damage.
l Measure the reducti on gear A 1.0.

Measure the idle gear 1.0.

IDLE REDUCTION GEAR A
11-21
Check the gear holder shafts sliding surface for
wear or damage.
Measu re the gear holder shafts 0 .0.
Check the staner reduction gea r B and reduction

gear shaft for wea r or damage.
Measure the reduction gear B I.D.
SERVICE LIMIT: 10.085 mm (0.3970 In )
Measure the reduction gear shaft 0.0.

SERVICE LIMIT: 9 .980 mm (0.3929 in)
ASSEMBLY
Apply transmission oil to the clutch outer slid ing
surface. ON E-WAY CLUTCH
Install the one-way clutch into the staner clutch

outer with the blue paint facing out.
Install the snap ring securely.

SNAPA ING
11-22
Apply transmission oil to the starter driven gear -"711 STARTER DR:!V'" GEAR
sliding surface. . iii
Install the needle bearing and starter driven gear.
Check that the starter driven gear turns counter-
clockwise smoothly and does not turn clockwise.
NEE'DLE BEARING
INSTALLATION
Apply molybdenum oil solution to the starter gear
holder gear rolling surface.
Install the idle gear and reduction gear A onto the
gear holder.
Apply t ransmissi on oil to the gear holder bolt
threads.
Install the gear holder assembly and bolts.
TORQUE: 18 N·m (1.8 kgf·m , 13 Ibf.ft)
Install the starter clutch while aligning its wide cut-

out in the spl ines with the punch mark on the crank-
~~~~~~~~~~~~
shaft.
Ins tall the primary Install the primary drive gear while align ing its wide
drive gesr with the cut-out in the spl ines with the punch mark on the
punch mark facing crankshaft.
out.
Temporarily install the clutch outer guide, needle ~;;~~~~~

( bearings and clutch outer.
Insert the gear holder between t he primary drive
and driven gears.
TOOL :
Gear holder, M2.5 07724-0010100 or
07724-001A100
(U.S.A. only)
Apply transmission oil to the primary drive gear bolt
threads.
Install the washer and tighten the primary drive
gear bolt to the specified torque.
TORQUE: 108 N 'm (11.0 kgf ·m , 80 Ibf.ft)
Remove the clutch outer, needle bearings and
clutch outer guide.
11-23
Install the reduction gear B and reduction gear shaft
securely.
- Clutch (page 11-12)
GEARSHIFT LINKAGE
REMOVAL
- Right crankcase cover (page 11 -5)
- Clutch (page 11-7)
When removing the Remove the bolt and gearshift pedal.
gearshifr pedal,
mark the pedal
position to ensure
correct reassembly
in its original
location.
Before removing Remove the gearshift spindle and washer from the
the g88rshift crankcase.
spindle, clean the
-,.
gearshift spindle
splines at gearshift
Remove the shifter collar.

Do no t le t the Remove the bolts, guide plate and drum shifter as
ratchet pawls fall an assembly.
when removing the
guide piate 8T1d
drum shifter.
11-24
Remove the shift drum center pin and shift drum
center.
Remove the bolt, stopper arm, washer and return

spri ng.
Remove the drum pin from the shift drum.
INSPECTION
GEARSHIFT SPINDLE
Check the gearshift spindle for bend, wear or dam- GEARSHIFT SPINDLE
age.
Check the return spring fo r fatigue or damage.
( RATCHET PAWL
I ~~ I
GUIDE PLATE
- Guide plate DRUM SHlmR
- Dru m shifter
- Ratchet pawls
- Plungers
- Springs
Clean the ratchet pawl A, ratchet pawl B, plungers, RATCHET PAWL B
springs and drum shifter with clean transmission
oil.
~'NG~
Check each part for wear or damage.
Apply clean transmission oil to each parts.
Assemble the drum shifter, springs, plungers,
ratchet pawl A and ratchet pawl B in the guide plate L-"'''--_--' PLUNGER
as shown.
11-25
CLUTCH / STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
INSTALLATION
Install the drum pin into the hole on the shift drum.
Install the return spring, washer and stopper arm
and tighten th e gearshift stopper arm bolt to the
specified torque.
Check the gearshift stopper arm for proper opera-
tion.
M ove the stopper arm out of the way u sing a screw-

driver.
~~=:~~~~~i=:
Align the shift drum center groove with the drum
pin.
Clean and apply locking agent to the gearshift drum

center pin threads and then install it.
Tighten the gea rshift drum center pin to the speci-
fied torque.
TORQUE: 22 N'm (2.2 kgf· m, 16 Ibf.ft)
Set the drum center in a position other than neutral.

Whi le holding the ratchet pawls in pl ace in the
guide plale and drum shifter, Install the drum shifter
assembly by aligning the hole of the drum sh ifter
with the shift drum center pin, and guide plate · UP"
mark facing up.
Install and tighten the guide plate bolts.
Install the shifter collar onto the drum shifter.
11-26
CLUTCH / STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Do nor forgel to Install the washer and gearshift spindle into the
Instllil the washer crankcase while aligning the spring ends with the
OntO the gearshift crankcase stopper pin and the gearshift spindle with
spindle. the shifter coltar.
Apply oil to the gearshift spindle serration area .

Install the gearshift pedal on its original position as
marked during removal.
TORQUE: 12 N·m 0 .2 kgf·m . 9Ibf-ft)
Move the gearshift pedal and check the shift mecha-
nism for smooth operation.
Install the following :
- Clutch (page 11 ·12)
11-27
MEMO
12. ALTERNATOR
COMPONENT LOCATION ···.... ················· 12-2 STATOR ................ .............................. ·.... · 12-5
SERVICE INFORMATION .... ·.. ·...... ·.... ·.... ·12-3 FLyWHEEL ...... · .... .... · ............ · .... · .............. 12-5
LEFT CRANKCASE COVER REMOVAL .. · 12-4 LEFT CRANKCASE COVER

INSTALLATION ............................ ·.... ·...... 12-6
(
~
12-1
ALTERNATOR
COMPONENT LOCATION
5.2 N'm (0.5 • 3.B Ibf·ft)
4.7 N·m (0.5 . 3.5Ibf.ft) 64 N'm (6.5 kgf·m, 47 IbHtl
•
•
16 N 'm (1.6 kgf.m. 12 Ibf·ft)
12-2
ALTERNATOR
SERVICE INFORMATION
GENERAL
• This section covers the removal and installation of the alternator stator and flywheel. These services can be done with
the engine installed in the frame.
• For alternator stator inspection (page 17-8),
TORQUE VALUES
Engine oil drain bolt 16 N-m (1.6 kgf·m, 12 IbHt) Apply oit to the threads and seating sur-
face
Flywheel nut 64 N-m (6.5 kgf·m, 47 lbHt) Applv oil to the threads and seating sur-
face
Ignition pulse generator mounting bolt 5.2 N·m (0.5 kgf·m, 3.8 Ibf.ft) Apply locking agent to the threads
Stator mounting bolt 4.7 N·m (0.5 kgf.m, 3.5 Ibf.ft) Apply locking agent to the threads
TOOLS
Flywheel holder Flywheel puller Flywheel puller adaptor

07725-0040001 070MC-HP10100 070MG-KSE0100
or 07AMB·KANA100 or 07QMC- HP1A 100 (U.S.A. only)
Adapter 12 x 1.25 mm
07AMC·MEBA 110 !U.S.A. only)
12-3
ALTERNATOR
LEFT CRANKCASE COVER REMOVAL
- Left engine guard !page 3-5)
- Gearshift pedal (page '1-24)
Drain the engine oi l (page 4-20).
Remove the wire band .
Disconnect the alternator 4P (Black) and ignition
pulse generator 2P (Black) connectors.
loosen the engine oil drain bolt and left crankcase

cove r bolts in a crisscross pattern in two or three
steps.
Remove the engine oil drain bott, sealing washer,
left crankcase cover bolts and left crankcase cover.

For left crankcase cover oil seal inspection (page 5-
7).
12-4
ALTERNATOR
STATOR
REMOVAL
Remove the left crankcase cover (page 12-4).
Remove the bolts, ignition pulse generator and
grommet from the left crankcase caver.
Remove the bolts and stator.
INSTALLATION
Place the stator/ignition pulse generator into the left
crankcase cover.
Apply liquid sealant to the wire grommet seating
surface and install the grommet into the groove in
the left crankcase cover.
Apply locking agent to the ignition pulse generator
and stator mounting bolt threads.
Tighten the ignition pulse generator and stator
mounting bolts to the specified torque.
TORQUE:
Ignition pulse generator mounting bolt:
5.2 N 'm (0.5 kgf·m, 3.8 Ibf.ft)
Stator mounting bolt:
4.7 N 'm (O.S kgf·m, 3.5 Ibf.ft)
Install the left crankcase cover (page 12-6).
FLYWHEEL
REMOVAL
Remove the left crankcase cover (page 12-4).
Hold the flywheel with the spedal tool and remove
the nut and washer.
TOOL:
Flywheel holder 07725·0040001 or
07AMB-KRNA100
Remove the flywheel using the special tools.
TOOLS:
Flywheel puller 070MC-HP10100 and
Flywheel puller adapter 070MG-KSE0100
U.S.A. TOOLS :
Flywheel pull er 070MC-HP1A100 and
Adapter 12 x 1.25 mm 07AMC· MEBA110
12-5
ALTERNATOR
Remove the woodruff key.
INSTALLATION
Wipe any oil off the mating surface of the flywheel.
Install the woodruff key into the crankshaft groove.
Install the flywheel to the crankshaft by aligning the ~;;;;~

groove in the flywheel with the woodruff key.
Apply oil to the flywheel nut threads and seating
surface.
Install the washer and nut.
Hold the flywheel with the special tool and tighten
the nut to the specified torque.
TOOL:
Flywheel holder 07725·0040001 or
07AMB· KRNA100
TORQUE: 64 N'm (6.5 kgf·m, 47 IbUt)

Install the left crankcase cover (page 12-6),
LEFT CRANKCASE COVER

INSTALLATION
Install a new gasket and dowel pins.
Apply oil to the engine oil drain bolt threads and

seating surface.
'~~~~;~~~E~~ii~ii~~~
Inst all the left crankcase cover and bolts.
Tighten the left crankcase cover bolts in the order as
shown in the illustration.
• First tighten the No.1 bolt temporarily.
• Tighten the No.2 - No.9 bolts securely.
• Tighten the engine oil drain bolt (No.10) to the
specified t orque with a new sealing washer.
TORQUE: 16 N 'm {1.6 kgf·m , 12 Ibf·ftj
12-6
ALTERNATOR
Connect the ignition pulse generator 2P (Btack) and
alternator 4P (Black) connectors.
Route the wires Install the wi re band.
properly ('05 - '07:
page /·25, Afrer
'07: page f-32}. - Gearshift pedal (page 11 -27)
- Left engine guard (page 3-5)
Fill the engine with the recommended engine oil
(page 4-20).
12-7
MEMO
13. CRANKCASE/CRANKSHAFT /TRANSMISSION/BALANCER
COMPONENT LOCATION ························ 13-2 CRANKSHAFT REMOVAL .................... · 13-14
SERVICE INFORMATION ........................ · 13-3 CRANKCASE BEARING

REPLACEMENT ...................................... 13-16
TROUBLESHOOTING .............................. ·13-7
CRANKSHAFT INSTALLATION ............ · 13-21
BALANCER GEAR/ BALANCER ................ 13-8
TRANSMISSION ASSEMBLy ................ 13-22
CRANKCASE SEPARATION .... .......... ·.... 13-10
CRANKCASE ASSEMBLy ...................... 13-25
TRANSMISSION DISASSEMBLY .......... 13-11
\,
13-1
COMPONENT LOCATION
44 N 'm (4.5 kgf·m, 32 Ibf·ft)
10 N'm (1,0 kgf·m, 7 Ibf·ftl
'05 - '07: 10 N'm (1 .0 kgf·m, 7 Ibf.ft)

After '07: 20 N·m (2.D kgf·m, 15Ibf.ft)
10 N·m (1,0 kgf·m, 7 Ibf.tt)
12 N ·m (1,2 9 Jbf·ft )
13-2
CRANKCASE/CRANKSHAFT/ TRANSMISSION / BALANCER
SERVICE INFORMATION
GENERAL
• This section covers crankcase separation for service of the crankshaft, transmission a nd balancer.
• The crankcase must be separated to service the crankshaft and transmission.
• The engine must be out of the frame for this service.
• The following parts must be removed before separating the crankcase.
- Clutch (page 11 -7)/stater clutch(page 11-19J/kickstarter (page 11-151/gearshift li nkage (page 11-24)
r -. - Cylinder (page 10-5)/piston (page 10-6)
- Engine (page 8-5)
- Oil pump drive gear/drive pin (page 5-7)
- Starter motor (page 19-6)
- Drive sprocket (page 8-4)
SPECIFICATIONS ('05 - '07)

Unit· mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Side clearance 0.30 0.75 (0.012 0.030) 0.75 (0.030)
Radial clearance 0.006 0.018 (0.0002 - 0.0007) 0.05 (0.002)
Runout R - 0.03 (0.001)
L - 0.05 (0.002)
Transmission Gear LO. M4 28.007 - 28.028 (1.1026 1.1035) 28.05 (1. 104)
M5 25.020 - 25.041 (0.9850 - 0.9859) 25.07 (0.987)
C1 22.007 22.028 (0.8664 0.8672) 22.04 (0.868)
C2 30.020 30.041 (1.1819 1.1827) 30.07 (1. 184)
C3 25.020 - 25.041 (0.9850 0.9859) 25.07 (0.987)
Bushing 0.0. M4 27.959 27.980 (1. 1007 1.1016) 27.94(1.100)
C2 29.979 30.000 (1.1803 1.1811) 29.95 (1.179)
Bushing LD. C2 27.000 27.021 (1.0630 1.0638) 27.04 (1.065)
Gear-to-bushing M4 0.027 0.069 (0.0011 0.0027) 0.11 (0.004)
clearance C2 0.020 0.062 (0.0008 0.0024) 0.12 (0.005)
Mainshaft 0.0. M5 24.959 24.980 (0.9826 0.9835) 24.94 (0.982)
Countershaft 0.0. Cl bearing 18.987 19.000 (0.7475 0.7480) 18.94 (0.746)
C2 bushing 26.959 26.980 (1.06 14 1.0622) 26.94 (1.061)
C3 24.959 24.980 (0.9826 0.9835) 24.96 (0.983)
Gear-to-shaft M5 0.040 0.082 (0.0016 0.0032) 0.13 (0.005)
clearance C3 0.040 0.082 (0.0016 - 0.0032) 0.082 (0.0032)
Bushing-to·shaft 0.020 - 0.062 (0.0008 - 0.0024) 0.12 (0.005)
clearance
C2
Shift fork, shift Fork ctaw thickness 4.93 5.00 (0.194 - 0.197) 4.8 (0. 19)
fork shaft Shift fork 1.0. C 10.989 11.011 (0.4326 0.4335) nOll (0.4335)
R, L 12.035 - 12.056 (0.4738 0.4746) 12.070 (0.4752)
Fork shaft 0.0. C 10.969 - 10.980 (0.43 19 0.4323) 10.969 (0.4318)
l R, L 11.966 11.984 (0.471' 0.4718) 11.950 (0.4705)
13-3
SPECIFICATIONS (After '07)
clearance
MS, C2 , C3 0.020 - 0.062 (0 .0008 - 0.0024) 0.'2 (0.005)
fork shaft
13-4
TORQUE VALUES
Crankshaft bearing set plate torx scr ew
i'05 - '07) 10 N'm (1.0 kgf·m, 7 rbf·tt) Apply locking agent t o the threads
(Pro Honda Hondalock 3 or equivalent
high strength locking 8gent)
(After '07) 20 N'm (2.0 kgf·m. 15 Ibf.ft) Apply locking agent to the threads
(Pro Honda Hondalock 3 or equivalent
high strength locki ng agent)
r. Balancer shaft bearing set plate bolt 10 N'm (to kg f·m , 7 rbf·tt) Apply locking agent to the th reads
Countershaft bearing set plate screw 10 N'm (1,0 kg f.m, 7 Ibf.ft) Apply locking agent to the threads
Gearshift drum bearing set plate bolt 10 N·m (1.0 kg f·m, 7Ibf.ft) Apply locki ng agent to the threads
Mainshaft bearing set plate bolt 10 N' m (1.0 kgf·m, 7 Ibf.ft) Apply locking agent to the threads
Balancer shaft nut 44 N·m (4.5 kgf·m, 32 Ibf.ft) Apply oil to the threads
Cam chain tensioner bolt 12 N·m (1.2 kgf·m. 9Ibf.ft) Apply locking agent to the threads
Transmission oil drain bolt 16 N·m (1.6 kgf·m , 12 Ibf.ft ) Apply oi l to t he threads and seating
surface
TOOLS
Bearing remover set, 17 mm Bearing remover sel, 20 mm Remover weight
07936-3710300 07936-37 10600 07741-0010201
or 07936-371020A (U.S.A.only)
Bearing remover handle Driver Attachment, 72 x 75 rnm

07936-3710100 07749-0010000 07746-0010600
Attachment, 62 x 68 mm Attachment, 52 x 55 mm Attachment, 37 x 40 mm

07746-0010500 07746-0010400 07746-0010200
13-5
Attachment, 32 x 35 mrn Pilot, 20 mm Pilot, 30 mm

07746-0010100 07746-0040500 07746·0040700
Pilot, 17 mm Pi lot, 25 mm Gear holder, M1.5

07746-0040400 07746·0040600 07724.Q010200
or 07724-001A200 (U.S.A. only)
l ock nut wrench, 20 x 24 mm Extension bar

07716-0020100 07716·0020500
or equivalent commercially avail-

able in U.S.A.
13-6
TROUBLESHOOTING
Excessive noise
• Worn crankshaft bearings
• Worn or damaged connecting rod big end
• Worn or damaged connecting rod small end
• Worn balancer shaft bearings
• Improper balancer installation
• Worn, seized or chipped transmission gear
• Worn or damaged transmission bearing
Transmission jumps out of gear
• Worn gear dogs
• Worn gear shifter groove
• Bent shift fork shaft
• Broken shift drum stopper arm
• Broken shift drum stopper arm spring
• Worn or bent shift forks
• Broken gearshift spindle return spring
Hard to shift
• Improper clutch operation
• Incorrect transmission oil weight
• Bent shift fork
• Bent fork shaft
• Bent fork claw
• Oamaged shift drum guide grooves
• Bent shift spindle
Engine vibration
• Excessive crankshaft runout
• Improper balancer timing
,(
13-7
BALANCER GEAR/BALANCER
REMOVAL
- Right crankcase cover (page 11-51
- l eft crankcase cover (page 12-4)
- Clutch (page ' ' -7)
- Starter clutch (page 11 -'9)
Insert the gear holder between the balance r dri ve
and driven gears.
TOOL:
Gsar holder, Ml .5 07724·0010200 or
07724·001A200
(U.S.A . only)
Remove the balancer shaft nut and washer using

the special tools.
TOOLS:
lock nut wrench, 20 x 24 mm 07716·0020100
Extension bar 07716·0020500 or
commerciallyavail-
able equiva lent
(U.S.A. only)
Remove the balancer drive and dri ven gea rs.
Tu rn the balancer shaft as shown and remo ve it.
INSPECTION
Check the balancer shah for wear, damage or exces-
sive scratches.
Check the balancer shah gear for wear or damage.
Check the balancer drive/dr iven gear for wear or
damage.
INSTALLATION
Enf1lJge the Install the balancer shaft into the crankcase as
balancer shBft gear shown.
port/Otl WIth the oil
pump driven gear.
Install the balancer drive gear whi le aligning its

wide cut-out in the splines with the punch mark on
the crankshaft.
13-8
Install the balancer driven gear to the balancer shaft
while aligning its wide cut-out with the clinched
tooth of the balancer shaft.
Align the punch mark of the driven gear with the

punch mark of the drive gear by turning the bal-
ancer shaft.
Insert the gear holder between the balancer drive

and driven gears.
~:~~~~~~~~~~~~~~~~~
TOOL:
Gea r holder, M1.5 07724-0010200 or
07724-001A200
(U.S.A. o nly)
Apply transmiSSion oi l to the balancer shaft nut

threads.
Install the washer and balancer shaft nut.
Tighten the balancer shaft nut to the specified
torque using the special tools.
TORQUE: 44 N' m (4.5 kgf·m. 32 Ibf-tt)
TOOLS:
Lock nut wrench, 20 x 24 mm 07716·0020100
Extension bar 07116-0020500
- Sta rter clutch (page 11-23)
- Clutch (page 11 -12)
13-9
- - - - - - - -- - - - - - -
CRANKCASE SEPARATION
Refarte service information (page 13-3) for removal
of necessary parts before separating the crankcase.
Remove the collar and a-r ing.
Remove the bolt, coliar, washer and cam chain

tensioner. ,
~~~~~~~i~S~E~E~~~~l
Remove the cam chain from the crankshaft.
Remove the transmission oil drain bolt and sealing

washer.
Loosen the crankcase bolts and tightening bolt in a
crisscross pattern in two or three steps.
Remove the crankcase botts, washers and stay.
Place the left crankcase facing down and separate

RIGHT CRANKCASE
the left and right crankcase halves.
13-10
CRANKCASE/ CRANKSHAFT/ TRANSMISSION/ BALANCER
Remove the oil pump inner/outer rotors and shaft.
Remove the one-way valve. DOWEL PINS
Remove the dowel pins and gasket.
TRANSMISSION OISASSEMBL Y
Separate the crankcase halves (page 13-10),
Temporarily install the right crankcase.
Place the right crankcase facing down and separate
the right and left crankcase halves.
Remove the shift fork shafts.

Remove the shift fork guide pins from the shift
drum grooves and remove the shift drum.
Remove the shift forks.
Remove the mains haft and countershaft as an

( MAINSHAFTJ
assembly from the r ight crankcase.
\. COUNTERS HAFT
Disass emble the tra ns mission: ASSEMBLY
• Keep track of the disassembled parts (gears,
bushings, washer s, and rings) by sliding them
onto a tool or a piece of wire .
• Do not remove the snap rings over the shafts.
Expand the snap ring ends and slide the snap
ring off the Shaft, along with the gear behind it.
13-11
INSPECTION
GEAR
Check the gear dogs, dog holders and teeth for
damage or excessive wear.
Measure the I.D. of each gear.
SERVICE LIMITS :
M4: 28.05 mm 11,104 in)
M5: '05 - '07: 25.07 mm (0.987 in)
After '07: 28.07 mm (1 .105 in)
C1 : 22.04 mm (0.868 in)
C2: 30.07 mm (1.184 in)
C3: '05 - '07: 25.07 mm (0.981 in)
After '07:28.07 mm (1.105 in)
BUSHING
Check the bushings for damage or excessive wear.
Measure the O.D. of each bushing.
SERVICE LIMITS:
M4: 27.94 mm (1.100 in)
C2: 29.95 mm (1 .179 in)
After '07 :
M5: 27.94 mm (1 .100 in)
C3: 27.95 mm (1 .100 in)
Measure the I.D. of each bushing.
SERVICE LIMITS:
C2: 27.04 mm (1 .065 in)
After '07:
MS/C3: 25.04 mm (0.9858 in)
Measure the gear to bushing clearance.
SERVICE LIMITS:
M4: 0.11 mm (0.004 in)
C2: 0.12 mm (0.005 in)
After '07:
M5/C3: 0.12 mm (0.005 in)
NEEDLE BEARING
Check the C1 gear needle bearing for damage.
Replace it if necessary.
o
•
13-12
MAINSHAFT/ COUNTERSHAFT
Check the spli ne grooves and sl iding surfaces for
damage or abnormal wear. M5
Measure the 0.0. of the mainshaft and countershaft
at the gear an d bushing sliding areas.
SERVICE LIMITS;
Mainshaft: MS; 24.94 mm (0.982 in)
Countershaft; Cl bearing : 18.94 mm (0.746 in)
C2 bushing : 26.94 mm (1 .061 in)
C3: 24.96 mm (0.983 in)
'05 - '07: M easu re the gear to shaft clearance.

SERVICE lIMITS:M5: 0.13 mm (0.005 in) C2 BUSHING C3 C1 BEARING
C3 : 0.082 mm (0.0032 in)
Measure the bushing to shaft clea rance.
SERVICE LIMITS:
C2: 0.12 mm (0.005 in)
After '01:
MS/ C3: 0.12 mm (0.005 in)
SHIFT FORK
Check the shift f ork for abnor mal wear or deforma-
tion.
Measure the shift fork 1.0. and claw thickness.
SERVICE LIMITS :
1.0.: Center: 11.011 mm (0.4335 in)
Right and left: 12.070 mm (0.4752 in)
Claw thickness: 4.8 mm (0.19 in)
SHIFT FORK SHAFT

Check the sh ift f or k shaft for ab normal wear or
defor mation.
Measu re the shift fork shaft 0.0 .
SERVICE LIMITS:
Center: 10.969 mm (0.4318 in)
Right and left: 11.950 mm (0.4705 in)
13-13
SHIFT DRUM
Inspect the shift drum for scoring, scratches or evi-
dence of insufficient lubrication. SHIFT DRUM
Check the shift drum gro oves for abnormal wear or
damage.
•
TRANSMISSION BEARING
Turn the inner race of each bearing with your finger. r - -- -- - -- - - - - - - - - - - - - ,
The bearings should turn smoothly and quietty.
the crankcase.
Replace any bearing if the inner race does not turn
smoothly and quietly, or if the outer race fits loosely
in the crankcase (page 13-18).
CRANKSHAFT REMOVAL
REMOVAL
Separate the crankcase (page 13-'0).
Remove the transmission (page 13· 11). RIGHT CRANKCASE CRANKS HAFT
The crankshaft can Remove the crankshaft from the right crankcase.
be removed wirh
the transmission
installed.
13-14
INSPECTION
Turn the inner race of the crankshaft bearing with , - -- - - - - - - - - - - - - - - - - ,
your finger.
Also check that the beari ng outer race fits tightly in
the crankcase.
Replace any bearing if the race dose not turn
smoothly, quietly, or if the outer race fits loosely in
the crankcase (page 13-16),
Place the crankshaft on a stand or V-blocks.

Set the dial indicator on the main journal as shown.
Rotate the c rankshaft two revolutions (720°) and
read the funout.
SERVICE LIMITS: l : 0.05 mm (0.002 in )
R: 0.03 mm (0.001 in )
4 .0 mm (0. 16 in)
Measure the connecting rod big end radial clear-

ance in both X and Y di rections.
Measure the connecti ng rod big end side clearance.

FEELER GAUGE
l SERVICE LIMIT: 0.75 mm (0.030 in )
13-15
CRANKCASE BEARING REPLACEMENT
CRANKCASE BEARING/OIL SEAL LOCATION
RIGHT BALANCER RIGHT CRANKSHAFT RIGHTCOUNTEASHAFT

SHAFT BEARING (6003) BE,'RIII'( (30 x 76 x 19) (5203U)
RIGHT CRANKCASE:
RIGHT MAINSHAFT
BEA RING (5205A)
LEFT CRANKCASE:
~~------------~------------~~~
LEFTCRANKSHAFT
RDl.LER BEARING
COUNTERSHAFT
BEARING (24 x 56 x 14)
LEFTB"LANCE'" SHAFT SEAL MAINS HAFT
BEARING (20 x 32 x 14) (38)( 52 X 7) BEARING (6203U) OIL (31 x 40 x 7)
CRANKSHAFT BEARING
Remove the torx screws and right crankshaft bear-
ing set plates.
Remove the crankshaft oi l seals and bearings from

both crankcase halves.
•
•
13-16 •
Drive in new Drive new crankshaft bearings into both crankcase
bearings squarely halves using the special tools.
with the marking
side facing toward TOOLS :
the inside of the left crankshaft bearing:
crankcase. Driver 07749-0010000
Attachme nt, 62 x 68 mm 07746-0010500
Right crankshaft bearing :
Driver 07749-0010000
,- Attachment, 72 x 75 mm 07746·0010600
Pilot, 30mm 07746-0040700
Clean and apply locking agent to the set plate larx

screws.
NOTE:
Use Pro Honda Hondalock 3 or equivalent high
strength locking agent.
Install the torx screws with the set plates and
tighten to the specified torque.
TORQUE: 'OS - '01: 10 N' m (1 .0 kgf·m. 1Ibf·ft)
After '01: 20 N'm (2.0 kgf·m. 15 Ibf·ftl
Apply transmission oil to a new right crankshaft oil

seal outer surface.
,i~~~~~~~iF~~~~~~~l
Install a new right crankshaft oil seal to the crank-
case until it is flush with the crankcase surface.
Apply transmission oil to a new left crankshaft oil

seal outer surface. in )
( Install a new left crankshaft oil seal to the specified

depth below the crankcase surface as shown.
13-17
TRANSMISSION/BALANCER
BEARINGS
LEFT CRANKCASE
Remove the countershaft and balancer shaft oil
seals.
Remove the screws and countershaft bearing set

plates.
Remove the snap ring from left crankcase.
13-18
Remove the mains haft bearing, and balancer shaft
bearing using the special tools as shown.
TOOLS:
Mainshaft bearing :
Bearing remover set 17 mm 07936·3710300
Re mover handle 07936·3710100
Remover weight 07741-0010201 or
07936·37102OA
(U.S.A. only)
Balancer shaft bearing:
Bearing remover set 20 mm 07936-3710600
Remover handle 07936-3710100
Remover weight 07741·0010201 or
07936·371020A
(U.S.A . only)
Remove the coun tershaft bearing and shift drum

bearing.
Drive in new Drive new bearings into the left crankcase using the """"""::;:-;;:'"
bearings squarely special tools.
with the markmg
side facing TOward TOOLS:
the inside of the Countershaft bearing :
crankcase. Driver 01749-0010000
Attachment, 52 )( 55 mm 01746-0010400
Mains haft bearing :
Driver 01149-0010000
Attachment, 31 )( 40 mm 01746-0010200
Pilot, 11 mm 01746-0040400
Balancer shaft bearing:
Driver 07749-0010000
Attachment, 32 )( 35 mm 01746-0010100
Pilot, 20 mm 01746-0040500
Shift drum bearing:
Driver 07749-0010000
Attachment, 31 )( 40 mm 01746-0010200
Ahar installing 8 Install the snap ring into the left crankcase securely.
snap ring. always
rotate it in its
groove ro be sure it
is fully seared.
13-19
Clean and apply locking agent to the countershaft
bearing set plate screws.
Install the screws with the set plates and tighten the
screws to the specified torque.
TOROUE: 10 N'm (1.0 kgf·m , 7 Ibf·tt)
Apply grease to new countershaft and balancer .. .....

lit OIL SEALS
shaft oil seal lips.
Install a new balancer shaft oil seal to the crankcase
until it is flush with the crankcase surface.
Install a new countershaft oil seal to the specified
depth below the crankcase surface as shown .
BALANCER SHAFT OIL SEAL:

0 - 1.0 mm (0 - 0.04 in)
COUNTERS HAFT OIL SEAL:
RIGHT CRANKCASE
Remove the socket bolts and set plates. on' T< ' <OT PLATES
Remove the countershaft bearing, mainshaft bear·
ing and shift drum bearing .
Remove the bolts and set plates.

Remove the balancer shaft bearing.
13-20
Drive in new Dr ive in new bearings into the right crankcase using
bearings squarely the special tools.
with the marked
side fBcmg toward TOOLS:
the inside of the Shift drum bearing:
cran kcase. Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 25 mm 01746-0040600
Mainshatt bearing :
Driver 07749-0010000
Attachment. 52 x 55 mm 07746-0010400
Pilot, 25 mm 07746-0040600
Countershaft bearing :
Driver 07749-0010000
Attachment, 31 x 40 mm 07746-0010200
Pilot, 17 mm 07746-0040400
Balancer s haft bearing :
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 17 mm 07146-0040400
Clean and apply locking agent to the set plate bolts.
Install the bolts with the set plates and tighten the
bolts to the specified torque.
TORQUE:
Gearshift drum bearing set plate bolts:
10 N'm (1.0 kgf·m, 7 lbf.ftj
Mainshaft bearing set plate bolts:
10 N 'm (1.0 kgf·m , 7 Ibf.ftj
Balancer s haft bearing set plate bolts:
10 N 'm (1.0 kgf·m , 7 Ibf·ftj
CRANKSHAFT INSTALLATION
Clean both crankcase mating surfaces before
assembling and check for wear or damage. RIGHT CRANKCASE CRANKSHAFT
If there is minor roughness or irregularities on the
crankcase mati ng surfaces, dress them with an oil
stone.
After deaning, lubricate the bearings and connect-
ing rod big end with dean engine oil.
Install the crankshaft into the right crankcase.
13-21
TRANSMISSION ASSEMBLY
Apply molybdenum oil solution to the mainshaft , - - - - - - - - - - - - -- - - - -
and countershaft spline area and transmission gear
sliding surface. CORRECT INCORRECT
Assemble all parts into their original positions.
• Check the gears for freedom of movement or
rotation on the shaft.
• Install the washers and snap rings with the
chamfered edge facing the thrust load side. Con-
firm the inner side of snap rings and washer
when you detect the chamfered side.
• Do not reuse a worn snap ring which could easily
spin in the groove.
• Check that the snap rings are seated in the shaft
grooves, and alig n their end gaps with the L_ _ _ _ _ _--=:.::."--R~I~N~G=___ _ _ _ _ _~
grooves of the spline.
MAINS HAFT 1'05 - '07) :
M1 (13T) MAINSHAFT
SNAP RINGS
M5123T)
SPl .INEWASHER
M307T)
M2 (16T)
13-22
MAINSHAFT (After '07):
M1 (13T ) MAINS HAFT
M5(23T)
M5 BU~; H "' G
SPLI NE WASHER
M3 7T)
THRUST WA.sHI'RS
SPl.lNE WASHE R
M2 (16T)
COUNTERSHAFT ('05 - '07) :

THRUST
C5 (19T) WASHER
SNAP RING \
C3 T) NEEDLE BE,'R" m
C4 (19T)
CO U NTE RSHAFT
C2BUSHING~
THRUST
~C21
WASHER
13-23
COUNTERSHAFT (Aft er '07):
NEEDLE BEARING
THRUST WASHE,R
C3121T)
THRUST WASHER
(19T)
COUNTERS HAFT
THRUST
WASHER
INSTALLATION
Apply transmission oil to all transmission gear
teeth. - , :AII gear teeth
Engage the mainshaft and countershaft gears. MAINS HAFT ASSEMBLY
CQIUN"rERSftAFTASSEMBLY
Install the mainshaft and countershaft assembly
into the right crankcase.
Make sure the three thrust washers are installed
(mainshaft; left only/countershaft; both ends).
13-24
Each shift fork has an identifi cation mark, "EVR" is
for the rig ht shift fork, "EYL· is the left shift fork and
"Eye· is for the center shift fork.
"EVA "
Apply transmission oil to the shift drum gu ide

grooves.
, Apply molybdenum oil solution to the following
parts:
- Shift fork claws and guide pins
- Shift fork sl idi ng surfaces
- Sh ift fork shaft
Install the shift forks to the grooves in the sl iding
gears .
• Face all shift fork marks to the left crankcase.
Install the shift drum by al igning the guide pins on
the shift forks with the guide grooves in the shift
drum.
Slide the shift fork shafts through the shift forks, and
into the crankcase.
CRANKCASE ASSEMBLY
Temporarily install the left crankcase.
Place the left crankcase facing down and sepa rate
the left and right crankcase halves.
l
Install the oi l pump inner/outer rotor and shaft in
the left crankcase.
Install the one-way valve, dowel pins and a new
gasket.
13-25
Before 8ssembly, Place the right crankcase onto the left crankcase.
lubricate the
transmissIOn
bearings with clean
transmission oil.
Apply locking agent to the crankcase tigh t eni ng bolt

threads.
Insta ll the crankcase tightening bolt and washer.
Install the crankcase bolts and washers.
Tighten the crankcase bolts in a crisscross pattern in
two or three progressive st eps.
Apply transmission oil to the transm ission oil drain
bolt threads and seating surface.
Insta l l a new washer and tig hten the drain bolt to
TORQUE: 16 N·m 11.6 kgf·m , 12 Ibf.ft)
Carefully trim the protru di ng gasket material from
the cyli nder base gasket surface.
NO TE :
• Do not let gasket material fall into the crankcase.
• Do not damage the base gasket su rface.
Check that the crankshaft turns smoothly.
Install the cam chain to the cranksha ft.
Clean and apply locking agent to the cam ch ain
tensioner bolt th reads
Install the ca m chain tensioner, collar, washer and
bolt.
Tight en the cam chain tensioner bolt to the speci-
fied torque.
TORQUE: 12 N'm 11.2 kgf·m , 9 Ibf.ft)
Coat a new O-ri ng and the inside of the cou ntershaft

collar with g rease.
Install the D·ring and collar o nto the cou ntershaft.
Inst all the removed parts in the reverse o rder of
removal.
• Refer to service information (page 13-3) f or
•
i nstallation of the removed parts afte r assem-
bling the crankcase.
13-26
14. FRONT WHEEL/SUSPENSION/STEERING
'.
COMPONENT LOCATION ························ 14-2 HANDLEBAR················ ··························· 14-33
SERVICE INFORMATION ......................... 14-4 HPSO (Honda Progressive Steering Damper):

After '07 ........................................... ....... 14-38
TROUBLESHOOTING ··· ·· ·· ········ ················ 14-7
STEERING STEM ······· ·· ··························· 14-47
FRONT WHEEL ············ .. ····················· ······ 14-8
CLUTCH LEVER ...................................... 14-52
FORK······ ···························· ····· ················· 14-13
14-1
FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION
'05- '07:
16Ibf.ft)
16Ibf·h)
kgf·m, 32 Ibf·tt)
30 N·m (3.1 22Ibf·ft)
20 N·m (2.0 kgf.m,

15Ibf·ft)
34 N' m (3.5 kgf·m,

25 rbf·ft)
7 N'm (0.7 kgf·m, 5.2 Ibf.ftl
kgf.m. 22 IbHt)
•
20 N'm (2.0 kgf·m , 15
88 N·m (9.0 kgf·m , IbHtl
13 N'm (1 .3 kgf·m, 10 Ibf·h)
14·2 •
FRONT WHEEl/SUSPENSION/STEERING
After '07:
22 N·m (2.2 kgf·m, 16 Ibf·ft)
16lbf·ft j
- :.
44 N·m (4.5 kgf·m , 32 Ibf.ft)
30 N 'm (3.1 , 22 Ibf.ft)
20N-m
15Ibf.ft)
34 . (3.S kgf·m ,
25 Ibf·ft)
20 N'm (2.0 kgf-m , 151bHt)
,
(
20 N·m (2.0 kgf·m, 15 Ibf.ft)
88 N'm (9.0 kgf-m , 65 IbUt)

13 N·m (1.3 kgf·m, 10 Ibf.ft)
14-3
SERVICE INFORMATION
GENERAL
• Keep grease off the brake pads and disc.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a con taminated disc
with a high quality brake d egreasing agent.
• When servicing the front wheel, fork or steering stem, support the motorcycle using a work stand or equivalent under
the engine.
• After front wheel installation, check the brake operation by applying the brake lever.
• Refer to the brake system information (page 16-3),
• When using the lock nut wrench, use a 20-inch long deflecting beam type torque wrench. The lock nut wrench increases
the torque wrench's leverage, so the torque wrench reading wil l be less than the torque actually applied to the fork
damper. The specification given on this page is actual torque applied to the fork damper, not the reading on the torque
wrench when used with the lock nut wrench. The procedure later in the text gives the actual and indicated torque.
SPECIFICATIONS
Unit: mm (in
EUMr
I 9B kPa I
Axl' ,unout
Wheel ,im ,unout ,~ - 2:0-
- 2.0
Wheel , I See
*"
Fo,k Sp,;ng " . . I
i -
lImk orr Pw Honda HP Fo, k orr 5W 0'
, I
orr l,v,l 42 - 4711.65 - 1.B51 -
filll0U~
Fluid
'05'- '071
1~~, '071
-
o,k 192 om' 16.5 US 0', 6.B Imp 0,1 -
,
I ~
Aft"
~
Ii
'dlok,_ ,fu
,full In
I I
-
-
, orr Pw Honda HP Fo,k orr 5W 0'
,. "0_
",:C,' "" I
F'ee piston deplh 16B' FI 213-
, I fo",. 9 clicks out from fu l l in -
14-4
TORQUE VALUES
Front axle holder bolt 20 N'm (2.0 kgf·m, 15 Ibf.ft)
Front axle nut 88 N'm (S.O kgf·m, 65 Ibf·ft)
Front brake disc nut 16 N'm (1.6 kgf·m, 12 Ibf·ft) U-nut
Front spoke 3.68 N'm (0.4 kgf.m, 2.7 Ibf·ft)
Front rim lock 12 N ·m (1.2 kgf·m, Slbf·ft)
Handlebar upper holder bolt 22 N ·m (2.2 kgf.m, 16Ibf.h)
Handlebar lower holder nut 44 N·m (4.5 kgf.m, 32 Ibf.ft ) U-nut
Front master cylinder holder bolt 9.9 N'm (1.0 kgf·m, 7.3 Ibf·ft)
Clutch lever pivot bolt See page 14·52
Clutch lever pivot nut 10 N·m (1.0 kgfm, 7Ibf·ft) U-nut
Engine starter switch housing screw 1.1 5 N·m (0.1 kgf·m, 0.8Ibf·ft)
Engine stop button screw 1.5 N'm (0.2 kgf·m, 1.1 Ibf·ft)
Front brake caliper mounting bolt 30 N·m (3.1 kgf·m, 22 Ibf·ft) Apply locking agent to the threads
Fork cap 30 N·m (3.1 kgf·m , 22 Ibf·ft)
Fork center bolt 69 N'm (7.0 kgf·m, 51 Ibf·ft)
Fork center bolt lock nut 22 N'm (2.2 kgf·m, 16Ibf·ft)
Pressure release screw 1.2 N'm (0.1 kgf·m, 0.9 Ibf·ft)
Fork damper 34 N'm (3.5 kgf·m, 25 Ibf·ft) -'.
Fork protector mounting bolt 7 N'm (0.7 kgf·m, 5.2 Ibf·ft) Apply locking agent to the threads
Front brake disc cover bolt 13 N 'm (1.3 kgf·m, 10 Ibf.ft)
Front brake hose guide bolt 5.2 N'm (0.5 kgf·m, 3.8 Ibf·ft)
Fork top bridge pinch bolt 22 N'm (2.2 kgf·m, 161bf·ft)
Fork bottom br idge pinch bolt 20 N'm (2.0 kgf·m, 15Ibf·ft)
Steering stem nut 108 N'm (11.0 kgf·m, 80 Ibf·ft)
Steering stem adjusting nut See page 14-5 1
Tripmetar cable clamp screw 0.7 N'm (0. 1 kgf·m, 0.5Ibf·ft)
Steering damper mounting bolt 20 N'm (2.0 kgf·m, 15lbf·ftj Apply lockin g agent to the threads
(After '07)
Throttle bolt (throttle side) 4 N'm (004 kgf·m, 3.0 Ibfft)
TOOLS
Spoke wrench, 6.1 mm Steering stem socket Ball race remover
07JMA-MA60100 07916-3710101 07946-3710500
or 0770 1-0020300 (6.1 mm) or or 07702-0020001 (U.S.A. only)

equivalent commercially available
in U .S.A.
Fork seal driver, 47 mm Driver Attach ment, 30 mm 1.0.

07VMD-KZ30100 07749-0010000 07746-0030300
or 07VMD-KZ3010A (U.S.A. only)
14-5
Anachmem, 37 )( 40 mm Pilot, 20 mm Bearing remover head, 20 mm

07746-0010200 07746-0040500 07746-0050600
Bearing remover shaft Piston base Bearing race installer (2 required)

07GGD-0010100 07958-2500001 07VMF·KZ30100
Installer shaft lock nut wrench, 50 mm Fork rod stopper

07VMF·KZ30200 07WMA-KZ30100 07AMB-KZ3Al00 (U.S.A. on ly)
Collar (After '07) Depth gauge (After '07)

07KPF-VD60100 Q7AMJ-MENA100
14-6
TROUBLESHOOTING
Hard steering
• Steering stem adjusting nut too tight
• Faulty or damaged steering head bearings
• Insufficient tire pressure
• Faulty steering damper (After '07)
Steers to one s ide or does not track straight
• Bent fork tube
,, • Bent axle
• Wheel installed incorrectly
• Unequal oit quantity in each for k tube
• Faulty steering head bearings
• Bent frame
• Worn wheel bearings
• Worn swing arm pivot components
• Unevenly adjusted right and leh fork legs
Front wheel wobbling
• Bent rim
• Worn front wheel bearings
• Bent spokes
• Faulty tire
• Axle not tightened properly
• Unbalanced tire and wheel
Wheel hard to turn
• Faulty wheel bear ing
• Bent front axle
• Brake drag
Soft suspension
• Weak springs
• Low fork fluid level
• low tire pressure
• Incorrect fork fluid weight
Stiff suspension
• Fork oil quantity too much
• Incorrect fo rk fluid weight
• Bent or damaged fork tubes
• Clogged fork fluid passage
Front suspension noisy
• Insufficient fluid in fork
• loose fork fastener
L'
14-7
FRONT WHEEL/SUSPENSION / STEERING
FRONT WHEEL
REMOVAL
Remove the bolts and brake disc cover.
Raise the fr ont w heel off the ground by placing a

workstand or equivalent under the engi ne.
Remove the axle nut and loosen the left axle holder
bolts.
Loosen the lock nut and discon nect the tripmeter

cable.
loosen the right axle holder bolts.
Be careful no! 10 Remove the axle and front wheel.
damage Ih6 brake •
Do not operate the brake lever after removing
pads WIth rfIB disc.
the front wheel. To do so will cause d ifficu lty in
fittin g the brake disc between the pads.
INSPECTION
A XLE
Set the axle on V-blocks and measure the runout.
Turn the axle and measure the runout using a dial
indicator.
Actual run out is 112 of the total indicator re ading.
SERVICE LIMIT: 0.20 mm (0.008 i n )
•
14-8
FRONT WHEEL/SUSPENSION/ STEERING
WHEEl BEARING
Turn t he inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check th at the bearing outer race fits tightly in
the hub. '-'-
Replace the Replace the bearings if the inner race does not tu rn
beanngs mpairs. smoothly, quietly, or if outer race fits loosely in the
hub.
WHEEL BEARING
WHEEL RIM
Check the rim runout by placing the wheel in a
truing stand.
Spin the wheel by hand, and read t he runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS:
Radial : 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 inl
Check the spokes and tighten any that are loose.
DISASSEMBLY
Remove the tripmeter gear box.
Remove the left side collar and dust seal.

Remove the brake disc bolts and nuts.
Remove the brake disc.
,
'-
14-9
Rep/ac8rhe wheel Install the rem over head into the bearing .
beanngsmpairs. From the opposite side of the wheel, install the
Do notreuse oJd remover shaft and drive the bearing out of the
bearmgs. wheel hub.
Remove the distance coliar and d rive out the other
bearing.
TOOLS:
Bearing remover head. 20 mm 07746·0050600
Bearing remover shaft 07GGD-0010100
ASSEMBLY
16 N'm (1.6 12Ibf.ft)

After '07:
TAIPMETER GEAR BOX
.~ .
.--.
RIGHT WHEEL BEARING
"
DISTANCE COLLAR
9 Ibf.ft)
BRAKE DISC
Place the hub in the center of the rim, and begin the , -- - -- - - - - - - -- - -- - - ,
lacing with new spokes. n-~-- RIM
Adjust the hub position so the distance from the 28.0 ± 1.0 mm
hub left end surface to the side of the rim is 28.0 ± (1.10±O.04in)
1,0 mm (1. 10 ± 0.04 in) as shown.
--4-
WHEEL HUB
14-10
Torque the front spokes in two or three progressive
steps
TOOL:
Spoke wrench. 6.1 mm 07JMA·MR60100
or 07701·0020300
(6.1 mml or equiv-
alent commer·
dally available in
U,S.A.
TORQUE: 3.68 N 'm (0.4 kgf-m , 2.7 Ibf.ft)
Install the front rim lock, sening rubber. tube and

tire.
Tighten the front rim lock to the specified torque.
TORQUE: 12 N 'm (1 .2 kgf·m , 9lbf.ftj
Pack all bearing cavities with grease.

Drive the left wheet bearing in the wheel hub until it
is fully seated using special tools .
Rep/Bee the wheel • Install the wheel bearings with the sealed sides
bean"ngs in pairs. toward the outside.
Do not reuse old
bearings. TOOLS:
Driller 07749·0010000
Attachment, 37 x 40 mm 07746·0010200
Pilot. 20 mm 07746--0040500
Install the distance col la r i nto place, then drive the
right w heel bear ing using the same speCial tools.
Install the brake disc onto the wheel hub with the
drive mark facing out.
Install the brake disc bolts and nuts.
Tighten the nuts 10 the speCified torque.
TORQUE: 16 N 'm 11 .6 kgf·m , 12 IbUtl
Pack a new left dust seal lip with grease and install it
into the hub.
14-11
Check the left side collar and tripmeter gear box for
wea r or damage.
Pack the tripmeter gea r box and dust seal li p with
greaSB.
Install the left side collar to the w heel.
Install the gea r box w h ile aligning the trip met er
gear tabs of the gea r box with the grooves on
wheel.
INSTALLATION
Clean the clamping su rface of the axle and axle
hol ders.
Be careful nor to Install the front wheel between the for k legs while
damage rhe brake inserting the disc between the pads, and align the
pads with the disc. tab of the tripmeter gear as shown.
Check that the tripmeter gea r box O-ring is in good
condition, replace it if necessary.
Apply thin layer of grease to the axle and insert the
axle from the rig ht side.
Insta ll and tighten the front axle nut to the speCified

torque.
TORQUE : 88 N'm (9.0 kgf·m , 65 Ibf.ft)

Tighten the left axle holder bolts to the specified
torque.
TORQUE: 20 N'm (2.0 kgf-m, 15 Ibf.ft)
With the f ront brake applied, pump the front su s-

pension up and down severa l times to seat the axle
and check t he front brake operation.
14-12
Be sure the fork legs are parallel . then tighten the
right axle holder bolls to the specified torque.
TORQUE: 20 N'm (2 .0 kgf·m , 15 Ibf·ft)
Connect the tripmeter cable and tighten the lock nut
secu rel y.
Install the brake disc cove r and bo lts.

Tighten the bolts to th e specified torque.
TORQUE: 13 N'm 11 .3 kgf·m , 10 Ibf.ft)
FORK
REMOVAL
NOTE:
Ahar '07: When removing the both fork legs, remove the
steering damper to prevent damaging it (page 14-
3BI.
- Fro nt visor 1'05 - '07: page 3-5, After '07: page 3-
61
- Front wheel (page 14-8) FORK PROTECTOR
Do nor suspend the Remove the mounting bolts and front bra ke calip er.
brake caliper from
Do not operate the brake lever aft er removing the
the brake hose.
cal iper and front wheel. To do so will cause diffi·
Do no! twist the culty in fining the brake disc between the brake pad.
brake hose.
Remove the bolts and brake hose clamp.
Remove the screws and tripmeter cable clamp.
Remove the bolts and fork protector.
BOLTS CALIPER
14-13
loosen the fork top bridge pinch bolts.
When the fork is ready to be disassembled, remove
the handlebar and holders (page 14-32) and loosen
the fork damper using the following procedure.
When disassembling the fork leg, turn the rebound

and compression adjust ers countercl ockwise t o the
softest position to prevent damaging the adjust-
ment needle (be su re to record the number of turns
from the starting position).
REBOUND AU.JU'
Dono / use8 loosen the fork damper using the special tool, but
crescent or do not remove it yet. FORK DAMPER
do_
adjuSfable wrench
10 loosen rhe fork TOOL:
damper;/r couldbe Lock nut w rench, 50 mm 07WMA·KZ30100
l oosen the fork bonom bridge pinch bolts and pull

the fork leg down and out.
14-14
DISASSEMBLY
813 careful no! to Clean the fork assembly, the sliding surface of the
scratch the slider fork slider and the bottom of the slider afound the
end nor to damage center bolt before disassembl ing the fork.
the dust S6al.
Measure the length between the axle holder and
outer tube, and record it before disassembling the
fork.
Hold the oute r tube and remove the fork damper

using the special tool. '05 - '07 shown:
FORK DAMPER
TOOL:
Lock nut wrench, 50 mm 07WMA·KZ30100
Slide the outer tube down onto the axle holder.
OUTER TUBE
Drain the fork oil from the fork leg .

Drain the fork oil from the oil hole (After '07: oi l '05 - '07 shown: OIL HOLE
holes) in the fork damper.
Temporarily install the fork damper assembly into

, the outer tube. FORK DAMPER ASSEMBLY
OUTER TUBE - - '
14-15
Do not over-ughfen Set Ihe axle holder of the slider in a vise with a piece
the VIse on the axle of wood or soft jaws to avoid damage. CENTER BOLT
holder.
Loosen the center bolt.
If a PIston base is Push the fork damper out from the slider until the
nol available, refer lock nut is fully exposed and install the piston base
to the next step fO or mechanic's stopper tool between the axle holder
make an alterna tive and lock nut.
tool.
TOOL:
Piston base 07958-2500001 or
Forti: rod stopper 07 AMB-KZ3A 100
(U.S.A. only)
Make the mechanic's stopper 1001from a thin piece ~~~~~~~~~~~~~~~~~~~

of steel (1.0 mm thick) as shown if you do not have a
special tool. 55mm
25mm
33mm
~m ~ -
R7.55 - 7.6mm )
r
Hold the lock nut and remove the fork center bolt
from the fork damper.
14-16
FRONT WHEEL/SUSPENSION / STEERING
Remove the push rod from the piston rod.
Be careful not to Remove the piston base or mechanic's stopper tool

damage the lock: while pushing the fork cap.
nut and fork: center
bolt hole.
Remove the fork damper assembly from the fork

assembly. '05 - '07 shown: FORK DAMPER ASSEMBLY
Remove the fork assembly from the vise.
Remove the fork spring from the fork assembly.
SPR ING
FORK AS!:EMBLY
OUTER TUBE AND SLIDER DISASSEMBLY

Be caref ul not to Remove the dust sea l and stopper ring.
scra tch the slider. STOPPER RING
Check that the slider moves smoothly in the oute r
tube.
If it does not, check the slider for bends o r damage,
and the bushings for wear or damage (page 14-19).
DUST SEAL
14-17
Using quick successive motions, pull the slider out
of the outer tube.
Do nor damage the Carefully remove the slider bushing by prying the
DUST SEAL
slider bushing, slot with a screwdriver until the bushing can be
especially the pulled off by hand.
sliding surface. To
preven t loss of
tenSIOn, do not - Guide bushing
open the bushing - Back-up ring
more than - Oil seal
necessary. - Stopper ring
- Dust seal
SLIDER
BUSHING
FORK DAMPER DISASSEMBLY

Set the fork damper in a vise with a piece of wood
or soft jaws to avoid damage.
Hold the fork damper assembly using the special
tool.
TOOL:
l ock nut wrench, 50 mm 07WMA·KZ30100
Remove the fork cap assembly from the fork

damper. FORK CAP ASSEMBLY
NOTE :
• Be careful not to damage the fork cap bushing.
• Do not disassemble the fork cap assembly.
• Replace the fork cap as an assembly if it is dam-
aged.
FORK DAI~P"R
14-18
Empty the fork oil from the fork damper by pumping
the damper rod several times. FOR K DAMPER
r-
INSPECTION
FORK CAP
Check the fork cap assembly for damage.
SPRING BUSHI NG
Check the bushing for excessive wear or scratches.
Check the spring for fatigue or damage.
Check the compression adjuster for clicks.
Replace the fo rk cap as an assembly if necessary.
Apply fork oil to new O-rings and install them.
etoCll O. RINGS
FORK CENTER BOLT

Check the fork center bolt for damage.
AD.JUSTE R ROD
Check the adjuster rod for stepped wear or damage.
Check the rebound adju ster for clicks.
Replace the fork center bolt as an assembly if neces-
sary.
Apply fork oi l to a new D-ring and install it.
etoCll O. RI NG
SLIDER/ OUTER TUBE

Check the outer tube and slider for score marks,
scratches and excessive or abnormal wear. '05 - '07 shown:
Check the outer tube for damage or bend.
SLIDER
14-19
Set the slider on V-blocks and measure the runout.
Turn the slider and measure the runout using a dial '05 - '07 shown:
indicator.
Actual runout is 112 of the total indicator reading.
Do not reuse the Replace if the service limit is exceeded, or there are
slider if it is bent. scratches or nicks that will allow fork oil to leak past
the seals.
SLIDER
FORK SPRING
Measure the fork spring free length by placing it on
a flat surface.
SERVICE LIMIT: 493 mm (19.4 in)
BUSHING/BACK-UP RING
Check the bushing for excessive wear or scratches.
If copper appears on the surface, replace the bush- G
ing . BUSHC
Replace the back-up ring if there is distortion at the
points shown.
Remove any metal powder from the slide r and
guide bushings with a nylon brush and fork oil.
rK\
", .
)~
I \
-J 0
BACK-U\P RING
FORK DAMPER
Check the f ork damper for bends or damage.
Check the fork damper piston rod for bends, wear or
damage.
Check the fork damper operation by pumpi ng the
-
'05 - '07 shown: DAMPER
piston rod.
If the operation is not smooth, fill the fork damper
with fork oil and check the fork damper operation
again (page 14-25).
14-20
ASSEMBLY
'OS - '07 show n:
SLIDER BUSHING
SLIDER
FORK CAP
fI
. . O-RINGS """~~~~ n
FORK DAI'P"R
,
PUSH ROO " ".
~ . . fI O-RING
I
DUST SEAL LJ BACK-UP RING
CENTER BOLT
FORK SPRING
fI" STOPPER RING
WEAR
Before assembly, wash all parts with a high flash -
point or non-flammable solvent and wipe them dry.
OUTER TUBE AND SLIDER ASSEMBl V
W rap the end of the slider with tape.
Coat new oil seal and dUst seal lips with fork oil. . . OUST SEAL TAPE
Install the dust seal and stopper ring onto the slider .
Install the oil seal onto the slider with its marked
side facing the dust seal.
....
!$.~
Remove the tape from the end of the slider.
, OIL SEAL
. . !-'l!~
.....
STOPPER RING
Be careful nor to Install the back-up ring, guide bushing and slider
damage the slider bushing.
bushing coating. Do
NOTE:
nor open the slider
bushing more than Remove the burrs from the bushing mating surface,
necessary. being carefu l not to peel off the coating.
14-21
FRONT WHEEL/ SUSPENSION/STEERING
Coal the slider and guide bushings with fork oil and
install the slider into the outer tube.
Drive in the guide bushing together with the back-

up ring into the outer tube using the special tool.
Dr ive the oil seal into the outer tube using the spe-
cial tool.
TOOL;
Fork seal driver, 47 mm 07VMD-KZ30100 Dr
07VMD·KZ3010A
(U.S.A. only)
GUIDE
Install the stopper ring into the g roove in the outer

tube. STOPPER RING
Install the dust sea l.
DUST
FORK DAMPER REFILLING/ ASSEMBLY
Clean the fork cap assemblv and fork damper D'A'1PE'R
threads. FORK FORK CAP AS~;EMBLY
14-22
Extend the fork damper piston rod to its maximum
length. FORK DAMPER
Pour the recommended fork oil into the fork
damper.
RECOMMENDED FORK Oil:
Pro Honda HP Fork Oit 5W or equillalent
STANDARD CAPACITY:
- 192 cm J (6.5 US OZ, 6.8 Imp ozl
Pump the fork damper piston rod slowly several

times and bleed any air from the fork damper. FORK DAMPER
Extend the fork damper piston rod to its maxim um

PISTON ROD
,, t
~F=O=R=K=D=A=M=P=E=R============~
length.
Adjust the oil level of the fork damper as shown.
Oil lEVEL: 42 - 47 mm (1.65 - 1.85 in)
.-lOlL LEVEL
Be careful not to Apply fork oil to the bushing and new O-rings on the
damage the forlt: fork cap assembly. . . ,,;;:-_ _ _ _ __ '"'
cap bushing. Extend the fork damper piston rod to maximum.
Hold the rod end, install the for k cap assembly into
the fork damper.
If it is difficu lt to install the fork cap assembly, the
fork damper oil level might be higher than standard .
Inspect the fork damper oil level again.
FORK DAMPER
14-23
Do nor over-tighten Set the fork damper in a vise with a piece of wood
FORK DAMPER FORK CAP
IhB vise. or soft jaws to avoid damage.
ASSEMB LY
Tighten the fork cap assembly to the specified
torque by holding the fork damper using the special
tool.
TOOL:
l ock nut w re nch, 50 mm 07WMA·KZ301 00
TORQUE: 30 N'm (3 .1 kg f·m, 22 Ibf.tt)
Hold the fork damper in an upright position and

pump the fork piston rod 100 mm (3.9 i n) slowly.
several times .
i.
Ii 100 mm (3.9 in )
PISTON ROD
V
Turn the lock nut clockwise until it is lightly seated.
LOCK N UT
PISTON ROD
NOTE:
• Set the rebound adjuster and compression
adjuster counterclockwise to the softest position . FORK DAMPER
• Check the fork damper piston rod sliding surface
for damage.
• Apply fork oil to the fork damper piston rod slid·
ing surface.
Be careful not to Cover the piston rod end with a clean shop towel to
benci or wmagft prevent damage.
the fork damper
l
Blowout any extra oil in the fork damper spri ng
PIston rod wflen
cham ber by fu lly stroki ng the fork damper piston
~TONROO
the piston rod 1$
rod.
stroked.
14-24
8y doing this Drain the extra oil from the oil hole (After '07: oi l
procedure, about holes) of the fork damper. '05 - '07 shown: FORK DAMPER
17 em' of fork fluid
will be drained from
the damper sprmg
chamber through
the oil hole (After
'07: oil holes). This
will cause 175 cm J
of fork fluid to be
le ft in the chamber.
Blowout any oil from the oil hole (Afte r '07: oil
holes) of the fork damper using compressed air.
Wipe off the oil completely from the fork damper.
If you cannot use compressed air, remove the pres·

sure release screw on the fork cap. PRESSURE REI_EP,SE. SCREW
Hold the fork damper upside down for 10 minutes
and drain the oil from the fork damper spring cham-
ber.
Tighten the pressure release screw to the specified
torque.
TORQUE: 1.2 N 'm (0.1 kgf·m, O.9Ibf.tt)
SPR:!NG CHAMBER
FORK DAMPER OPERATION INSPECTION

• Turn the compression adjuster counterclockwise
FORK DAMPER
to the softest position.
l • Check the fork damper piston rod sliding surface
for damage.
• Apply fork oil to the fork damper piston rod slid-
ing surface.
Be careful not to Inspect the fork damper operation after air bleeding
bend or damage (page 14-23).
the fork damper
Cover the piston rod end to prevent damage.
piston rod when
the piston rod IS Fully stroke the fork damper piston rod by pushing
srroked. down the fork damper.
Check the fork damper piston rod for smooth opera-
tion. PISTON ROD
If the fork damper piston rod operation is not L _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _~
smooth, check the piston rod for bends or d amage.
14-25
Hold the fork damper level while the fork damper
piston rod is fully extended and compressed by
FORK DAMPER
hand.
Release the fork damper piston rod then check that
it extends to its maxi mum length.
H
If the fork damper piston rod does not extend to
maximum, bleed the fork damper again.
,
--'-- " ----_ ...
PISTON ROD
Wipe the oil completely off from the fork damper.

Compress the fork piston rod 200 - 250 mm (7.9- F ORKDAM~
9.8 in) from fully extended and hold the fork damper
.~
in an upright position for 10 minutes.
There shou ld be no oil leaking from the fork damper
spring chamber and piston rod.
If oil leaks from the spring chamber or piston rod,
replace the fork damper assembly.
Hold the fork damper on level ground and release
the fork damper piston rod, then check that the pis-
ton rod extends to its maximum length.
PISTON ROD
:=r
;;
\i'
200-250 mm
(7.9-9.Bin)
FORK DAMPER INSTALLATION/ PREPARATION

If the outer tube and slider (fork) have not been dis-
assembled, turn the fork upside down for 20 min- OUTER TUBE/SUDER
utes and drain the oil from the inside of the outer
tube and slider completely (7 cc at 20"C/ 68" F). , ~,
/-
~~
/'
Ii
k.
/
] ,
W <
/
«
all//:(_/////////// //~;
Amount of fork oil left in the fork

(without damper and spring) O"C (32<>F)
JJ';E1~:
unit: cc ~
minute "
5 10 20 35 55 85 145 "
30/86 7.1 5.9 4.7 4.2 3.5 3.5 3.5 , "
"
~
20/68 10.6 8.2 11 5.9 5.6 4.7 4.7 • •
b
0
10/50
0132
11.8
12.9
8.3
10.6
12
9A
6.2
8.2
5.8
19
4.9
11
4.8
5.9
••, ,•·
! •• • •
l..... rto<I II....
• • •• ••
-
•• ••
14-26
If the fork damper has not been disassembled from
the outer tube/slider, turn it upside down for 20 min- FORK DAMPER/OUTER TUBE/SUDER
utes and drain the oil from the inside of the outer
tube and slider completely (12 cc at 20°C/ 6B O F).
Amount of fork oil left in the fork

(within damper and spring)
unit: cc
minute ,
5 10 20 35 55 85 145
30/86 27 15.3 10.6 9.4 8.3 7.9 7.9
~
20/68 29.4 16.5 11.8 10.6 9.4 8.2 8.2
1:3
• 10150 28.2 21.4 16.5 15.3 12.9 11.8 11.8
0/32 30.6 22.4 18.8 16.5 16.5 15.3 14.1
(minutes)
Inverted time
Tighten the lock nut fully and measure the length as

shown. NUT
STANDARD: 11 - 13 mm (0.43 - 0.5 1 in)

Wipe the oil completely off the fork damper.
FORK DAMPER IN STALLATION

Wipe the oil completely off the fork spring .
Install the fork spring into the fork assembly. '05 - '07 shown: FORK DAMPER ASSEMBLY
Temporarily install the fork damper assembly into
the for k assembly.
SPRING
FORK ASSEMBLY
14-27
Do not over- lIghten Set the axle holder of the slider in a vise with a piece
the vISe on the 8Jt/eof weod or soh jaws to avoid damage.
holder,
Push the fork damper out of the lock nut from slider,
while install the piston base or mechanic's stopper
tool between the axle holder and lock nut.
TOOL:
Piston base 07958·2500001 or
Fork rod stopper 07AMB·KZ3A100
(U.S.A . only)
Measure the combined length of the lock nut and

piston rod end again.
~~~~~~~~~::
STANDARD: 11 - 13 mm (0.43 - 0.51 in)
Check /he push rod Install the push rod into the p iston rod until it stops.
Ins t /JllallOn by
Apply fork oil to new O'ring and install it.
turning rhe push
Install the fork center bolt to the fork damper piston
rod fight and I6fr
rod bV aligning the flat-side of the center bolt
adjusting rod with the flat-side of the push rod.
Tighten the center bolt full y by hand.
Measure the length of the lock nut and cente r bolt ~~~~~~~~~~~~~~~~~~~
clea rance. LOCK NUT
STANDARD: 1.5 - 2.0 mm (0.06 - 0.08 in)

If the clearance is out of specification, check the lock
nut and center bolt installation .
1.5 - 2.0 mm
(0.06 - 0.08 in)
CENTER BOLT
Tighten the lock nut to the center bolt by hand until
they touch.
Tighten the lock nut to the specified torque.
TOROUE: 22 N ·m (2.2 kgf·m , 16Ibf.ft)
14-28
FRONT WHEEl/SUSPENSION/ STEERING
8e careful 00110 Remove the piston base or mechanic's stopper tool
damage the lock between the axle holder and lock nut while pushing ~-:~X Lt HOLDER
nut end fork cemer the fork damper.
bolt hole.
Install the fork center bolt into the axle holder and
tighten it to the specified torque.
TORQUE: 69 N'm (7.0 kg f·m , 51 Ibf.ft)
Measu re the length between the axle holder and

outer tube.
Compare the length at assembly and disassembly;
they should be same length .
STANDARD: 317 ± 2 mm (12.5 ± 0.08 in)
If the length at assembly is longer than at disassem-
bly, check the center bolt and lock nut installation.
o
317 ± 2 mm 112.5 ± 0.08 in)
14-29
Oil CAPACITY ADJUSTMENT
Remove the fork damper assembly from the outer ' O-U
-T- e- R
- T-U-S-e- - - - - - -F-O
-R- K-D-A-M
-p-e
-R--,
tube.
ASSEMBLY
Be sure the oil Pour the recommended fork oil into the fork leg.
capacity is the
RECOMMENDED OIL:
same If! both fork
leg,. Pro Honda HP Fork Oil SW or equivalent
STANDARD Oil CAPACITY:

'05 - '07: 332 ems (11 .2 OZ, 11 .7 Imp 01)
After '07: 324 em' (11 .0 US OZ, 11 .4 Imp oz)
Maximum oil 402 em' Slightly stiffer near

capacity (13.6 US oz, full compression.
14.2 Imp oz) RECOMMENDED OIL
M inimum oil 306cm 3 (10.3 Slightly softer near
capacity US oz, 10.8 full compression.
Imp oz)
Pull up the outer tube slowly and install the fork

damper assembly into the outer tube.
FOR K DAMPER ASSEMBLY
"..
I - - _ - D-RING
OUTER TUBE -~
INSTALLATION
Inslall the fork leg and tighten the fork bottom
bridge pinch bolts to the specified torque,
Re fer to torque Tighten the fork damper to the specifi ed torque

wrench resding using the special tool.
mformation. 011
(page 14-5) selVice TOOL:
information. Lock nut wrench, 50 mm 07WMA-KZ30100
TORQUE: Actual: 34 N'm (3.5 kgf·m , 25 Ibf.ftl

Indicated: 31 N'm (3.2 kgf·m , 23 Ibf.ftl
LOCK. __ .~==
14-30
STANDARD POSITION
Loosen the bottom bridge pinch bolts.
PRESSURE RelEASE SCREW
For ease when releasing the air pressure after the
forks are installed, position the fork outer tubes so
the pressu re release screws are in front of the com-
pression adjusters.
Align the top surface of the top bridge with the
outer tube upper su rface as shown.
Tighten the fork bottom bridge pinch bolts to the (IiliS:9r~

specified torque.
TOROUE: 20 N'm (2.0 kgf·m , 15 Ibf.ftJ

Tighten the fork top bridge pinch bolts to the speci·
fied torque.
TORQUE: 22 N'm (2.2 kgf·m , 1Slbf.ft)
I NOTICE I
Over-tightening the pinch bolts can deform the
outer tube. A deformed outer tube must be
replaced.
Inspect the wear rings for wear or damage.

OUTER TUBE
Replace the wear ring, if it is 1.5 mm (0.06 in) or flat
with the outer tube.
1.5 mm (0.06 in)
WEAR RING
Make sure the wear rings with their end gaps facing
rearward.
l
14-31
- - - - - -- - - - -
Clean and apply locking agent to the fork protector
mounting bolt threads.
Install the fork protector and tighten the mounting
FORK PR()TECT()R
TORQUE: 7 N'm (0.7 kgf·m , 5.2 Ibf·tt)
Clean and apply locking agent to the front brake cal-
iper mounting bolt threads.
Insta ll the front brake caliper and tighten the mount-
ing bolts to the specified torque.
TORQUE: 30 N-m (3. 1 kgf·m , 22 IbUt) 10
CALIPER
Install the tripmeter cable clamp and screws. MOUNTING
Tighten the tripmeter cable clamp screws to the
specified torque.
BOLTS BOLTS J
TORQUE: 0.7 N'm (0.1 kgf·m . 0.5 Ibf·tt)
Install the brake hose clamp and bolts.

Return the rebound adjuster and compression ,
COI~PI1ESS I CINADJUSTER
adjuster to the original positions as noted during
removal.
Ahar '07: Install the steering damper (page 14-38) if it was
removed,
- Front visor 1'05 - '07: page 3-5, After '07: page 3-
6)
- Front wheel (page 14-12)
REBOUND AUJU' Ito"
HANDLEBAR
REMOVAL
Remove the handlebar pad from the handlebar.
HANDLEBAR PAD
Remove the wi re bands.

SCREW CLUTCH HOLDER
Remove the screw and engine stop button. ,,
Remove the bolts and clutch lever holder. ,
14-32
Do not disconnect Remove the bolts and front brake master cyl inder
the hydraulic line. holder. MASTER CYI-'NIlER
Keep the brake
master cylinder
upright to prevent
air from entering
the hydraulic
system.
BOLTS
Remove the wire bands.

Remove the screws and engine starter switch hous- STARTER SWITCH HOUSING
ing.
If you will not disassemble the throttle housing,

remove the throttle housing as an assembly as fol- '05 - '06 shown: THI'O-rTLEHOUSING
lows.
loosen the throttle housing bolts, turn the handle-
bar to the right fully, then remove the throttle hous-
ing.
.-
TS
If you will disassemble the throttle housing , remove

the dust cover and bolts. '05 - '06 shown: THRonLE HOUSING
DUST COVER
BOLTS
(
I.
14-33
FRONT WHEEUSUSPENSION/STEERING
Remo .... e the throttle housing from handlebar.
Disconnect the throttle cables from the thronle pipe.
d THROTTLE CABLES
loosen Ihe handlebar lower holder nuts.
Remove the bolts, upper holders and handlebar.

Remove the nuts, washers, bushings and lower
holders.
INSTALLATION
Install the bushings. lower holders, washers and
handlebar holder nuts as shown (standard position).
The lower holder standard position as shown.
FORWARD
LOWER HOLDER
14-34
• By turning the lower holder 180 degrees, you can
180DEGREES STANDARD
install it 6 mm (0.24 in) rearward of the standard
position. By installing the optional lower holder, TURN HOLDER
you can set it 3 mm !O.12 in) rearwa rd of the STANDARD ,. POSITION
standard position. HOLDER
- Standard: 3 mm (0.12 in) offset to forward
- Standard 180 degrees turn: 3 mm (0.12 in) off-
set to rearward
- Optiona l: No offset
OPTIONAL LOWER HOLDER POSITION

Loosely install the handleba r and upper holders.
Align t he paint mark on the handlebar with the top

of the lower holder.
Place the upper holder on the handlebar with the
punch marks facing forward.
Install and tighten the front handlebar upper holder
bolts first, then tigh t en the rear bolts to the specified
torque.
TORQUE: 22 N·m (2.2 kgf·m , 16 Ibf·ft J
Tighten the handlebar lower holder nuts to the
specified torque.
TORQUE: 44 N 'm (4.5 kgf·m , 32 Ibf·ft)
If you did not disassemb le the throttle housing,

apply grease to the sliding surface of the throttle
( pipe.
Inst all the throttle housing, aligning the end of the
\....... housing with the paint mark on the handlebar.
Tighten the throttle housing upper bolt fi rst, then
the lower bolt.
Adjust the throttle grip freep lay (page 4-9).
14-35
If you disassemble the throttle housing, install it 85
follows:
Apply oil to the throttle pipe sliding surface.
Apply grease to the throttle cable end and sliding
area.
Con nect the throttle cables to the throttle pi pe.
Install the throttle housing, aligning the end of the
housing with the paint mark on the ha ndl ebar.
Tighten the throttle housing upper bolt fir st, then
the lower bolt.
Tighten the throttle bolt to the specified torque.
TORQUE: 4 N'm (0.4 kgf·m , 3.0 Ibf.ft)
Install the throttle housing dust cover.
Adjust the throttle grip freeplay (page 4-9).
If the handlebar grips are removed, apply Honda , - - - - - - - - - - - - - - - - - - - ,
Bond A or Pro Honda Handgrip Cement (U.S.A.
only) to the inside of the grip and to the clean sur-
fa ces of the throttle pipe and the left end of the han-
dlebar.
Allow the adhesive Wait 3 - 5 minutes and install the gri p.
to dry for Rotate the grips for even application of the adhe-
approx/rNte/y' sive.
hoor before us/fIf).
Align the ·6~ mark on the left grip with the pai nt ~=================~
mark on the handlebar. PAINT MARK
Align the mark on the right grip with the edge of the
throttle grip end.
"6" MARK INDEX LINE
Align the engine start switch housing as shown.

Install and tighten the screws to the specified
torque.
TORQUE: 1.15 N'm (0.1 kgf·m, 0.8Ibf.ft)
Install the wire bands.
14-36
Position the brake master cylinder on the handlebar.
PAINT MARK
Install the master cyl inder holder with its "UP" mark
facing up and align the end of the holder with th e
paint mark on the handleba r.
Tighten the upper master cylinder holder bolt first,
then tig hten the lower bolt.
TORQUE: 9.9 N'm 11 .0 kgf·m , 7.3 IbHt)
Install the clutch lever bracket and holder w ith the

punch mark on the holder facing up.
Al ign t he end of the holder w ith the paint mark on
the handleba r.
Tighten the upper bolt fi rst, then the lower bolt
securely.
Installihe engine stop button on the handlebar.

Align the end of the holder with th e paint mark on ENGINE STOP BUleTON MARK
the handlebar.
Install the engine stop button screw wi th the washer
and engine stop button wire terminal.
Tighten the engine stop button screw to the speci-
fied to rque.
TORQUE: 1.5 N ·m (0.2 kgf·m , 1.1Ibf.ft)
s~~~
Route the wire Clamp the engine stop button/clutch switch wi re
properly {'OS - '07: with wi re bands . WIRE BANOS
page 1-25. After
'07: page 1-32!.
14-37
Insta ll th e handlebar pad.
HAI"Dl.EB"R PAD
HPSD (Honda Progressive Steering

Damper): After '07
Remove the front visor (page 3-5),
Remove the steering damper bolts, collars and
st eering damper.
Clean and apply a locking agent to the steeri ng

damper mounting botts.
Install the s teering Install the steering damper, collars and bolts.
damper onto the •
The upper side collar is shorter than the lower
steering head pipe
side colla r.
with its 'UP'marlc •
Check that the stop per ri ng sid e of the damper
facing up and facing
rod is facing toward the front.
toward the front.
Tighten the steering dampe r bolts to the specified
,
torque. STE ERING
DAMPER
TORQUE: 20 N 'm 12.0 kgf-m , 15 IbUt)
Raise the fron t wheel off the ground by placing a

Check that the steering moves smoothly from side-
t o-side.
Inst all the front visor (page 3-5). •
14-38 •
INSPECTION
Remove the steering damper (page 14-38),
Visuallv inspect the steering damper for wear or
damage.
Check the following :
- Damper case for deformation or oil leakage
- Damper rod for bending or damage
r Replace the damper case or damper rod if neces-
J sary.
MeaslJre rh e Fully extend and compress the damper rod by hand.

SPHERICAL BEARING
damper rod length Release the damper rod then check that it extends
with the 'inside'to its maximum length.
jaws of 8 vermor
STANDARD (maximum length):
caliper.
117.55 - 118.35 mm (4.628 - 4.659 in )
Check the damper rod for smooth operation.
If the damper rod operation is not smooth, check
the damper rod for bends or damage.
If the damper rod does not extend to maximum, dis-
assemble the steer ing damper (page 14-40).
Check the spherical bearings for wear or damage .
Move the spherical bearing with your finger. The
spherical bearing should move smoothly and qui- L=D~A~M~P~E~R.:.:.R=O=D,--_ _ _ __ _ _ _ _ _ _---"
etly.
Replace the spherical bearing if it does not move
smoothly or quietly.
Install the steering damper (page 14-38).
SPHERICAL BEARING REPLACEMENT

Remove the steering damper (page 14-38 ).
SPHERICAL BEARING
Press the spherical bearing out of the damper
mou nts.
14-39
Dnve the bearing IfI Press a new spherical bearing into the damper
Bvenly: do not Bilow mounts using the special tool.
It to tilt.
TOOL:
COLLAR
....
~ STOPPER RING
Collar 07KPF·VD60100
Install a new stopper ring into the groove of the
damper mounts securely.
qI
Set a 7 mm bolt and nut to the spherical bearing as
I~~SP~H~E~R~IC~A~L~~~~==============~
7 BOLT
shown.
Measu re the stabled rotation torque of the spherical
bearing inner by rot ating the bolt.
STANDARD: 0.04 N'm (0.004 kgf·m , 0.03 Ibf.ft) max.
7mm
DISASSEMBLY
RBCOfd rhe Remove the steering damper (page 14-38) .
d6mpmg force
Clean the damper assembly thoroughly.
adJuster posItion .
Install a 4 mm screw to the end cap.
Remove the snap ring while pushing the end cap,
and then remove the end cap and O-ring.
Remove the washers and return spring from the
damper case.
Install 8 8 mm screw to the free piston, then remove ~8~m~m~S~C~R;E~W::=~::~~~::=~=-==""

the free piston and O·ring .
O-RING
FREE
14-40
Drain the damper oil from the damper case.
'.-
Remove the plug bolt and O-ring.
PLUG BOLT
Remove the adjuster piece from the damper case.
AD,JUSTER PIECE
Always replace rhe Remove the dust seal.
damper rod
, assembly WIth B
nswons.
Remove the snap ring from the damper case
groove.
'-
SEAL
14-41
Remove the damper rod assembly out of the
damper case. DAMPER CASE
Check the damper case inner surface for abnorm al

scratches.
Replace the damper case if necessary.
,
\
DAMPER ROD ASSEM BLY
HPSD ASSEMBLY
NOTE:
• When assembling the steering damper, follow
the procedures below.
• Clean the inner surface of the damper case thor·
oughly.
• Bleed the air completely in oil.
• Always replace the damper rod as an assembly with 8 new one.
A DJ USTER PIECE
~~r-____-------- PlUGBOLT
..
SNAP RING
FREE PISTON - -_ _ I
. -__----DUSTSEAl
. . f l O-RING
RETURN SPRING
DAMPER ROD ASSEMBLY

eI
. . f l O-RING RING fI
14-42
Check: thaI/he Pour recommended damper oil into a suitable con-
damper oil tainer until the steering damper is fully submerged. DAMPER CASE
~
temperature is
20'C (68"F). RECOMMENDED DAMPER OIL:
Pro-Honda HP Fork Oil 5W or eq uivalent
• Check the damper oil for contamination.
• Do not allow foreign materials to enter the
damper oil.
Submerge the damper case into the oil.
1
Submerge the damper rod into the oil.

In oil:
Bleed any trapped Shake a new damper rod assembly until there are
air af rhe O.f'ing no air bubbles.
searing surface by •
Be careful not to damage the damper rod and
fUming /he ().n'ng.
damper piston, especially around the damper
rod sl iding surface.
\I C·RING
Bleed any air out from the damper case and damper ~ln=O=il:=====D=A=M=P=E=R=P='=S=T=O=N====~
piston following the procedure below:
,. Install the damper piston into the damper case,
pump the damper rod quickly.
NOTE :
• To open t he piston valve, pump the piston rod
quickly.
2. Remove the damper piston from the damper
case.
3. Bring any air out from the damper case by using
your finger as shown.
4. Repeat steps 1 to 3 unti l there are no air bubbles
in the damper case and damper piston 3 times
\I DAMPER ROD
fo r complete air bleeding .

AIR BUBBLES
Install the damper rod into the damper case care-
fully.
14-43
Keep rhe damper Install the snap ring to the damper case groove.
In oi l:
•
case submerged in DUST SEAL
• Be careful not to damage or deform the snap
oil.
ring.
• Be certain the snap ri ng is firmly seated in the
groove.
Install the dust seal to the damper case until it is
flush with the damper case surface.
•
Fully extend the damper rod.

In oil:
Bleed any rrapped Install a new O-ring to the free piston.
eir at the O-rmg
Install and push the free piston fully into the damper
seating surface by
case wh ile holding the damper rod at maximum
turning the O-ring.
length.
O-RING
• Check that the free piston is fully seated to the
damper case.
~
FREE PISTON
Keep the damper Install the adjuster piece into the threads of the
assembly damper case and thread it one turn.
In oi l:
submerged in oil. 1 turn
•
•
PIECE
Check that the damper rod is fully extended to its
maximum length. In oil: PLUG BOLT
Bleed any trapped Install a new O-ring to the plug bolt.

air at the CHing
seating surface by
turning the O-ring. O-RING
Make sure the Install and tighten the plug bolt securely.
adjuster knob
moves freely before
tightening the plug
NOTE:
Oil is displaced as the adjuster piece and plug bolt
bel,. are installed into the damper case. The displaced oil
•
causes the free piston to move slightly as shown in
the illustration.
__ : OIL FLOW
14-44 •
FRONT WHEEL/ SUSPENSION/ STEERING
Remove the steering damper from the oil.
Drain the damper oil from the sub tank.
Out of oil: DEPTH GAUGE
Gauge th e depth between the spring seati ng surface

of the fre e piston and su rface o f the damper case SCREW
using the special tool as shown.
TOOL:
Depth gauge 07AM J -MENA100
Before using the 1001, make su re th at the shoul-

d ered end of the probe is extending from the coliar
side of the depth gauge. COLLAR
Insert the co llar o f the depth gauge into the sub
tank. Loosen the thumb screw and lower th e shoul-
SUB TANK
dered end of the probe unti l it stop s.
Tighten the thumb screw and remove the t ool.
Measure the depth of the free piston with a ca liper ' - - - - - -C
CO
c :-L-LcA-::R- -- - - - - - - '
by measuring the distance between the end of th e
probe and the collar.
STANDARD:
27.3 - 27.9 mm (1.07 - 1.10 in )
at o il t em perature 2 0~ C (68°FJ
Measu re the oil temperature.
If measured temperature is other than 20" e (68' f).
SHOU LDERE D
refer to the oil chart (page 14-45).
END
If the measured depth is other than th e sta ndard
length, disassemble the steering damper and start
over. PROBE
Th e depth of the fr ee piston will change acco rding

to the oil t emperatu re as shown. (inl (mml
1.14 29
28.5
'"
1.10
,.'""
215
,." "
26.5
1.02
" Oc-----~,.;----~"';------;;:60I.C)
'" 25.5
,c,---~.:.;-----c,;;"';----,;'40(.F\
Insta ll the return spring and washers into the

damper case.
Apply damper oil to a new a-ring and inst all it to the
end cap groove_
Install the end cap.
14-45
Be cerrain the snap Thread a 4 mm screw to the end cap and install a
ring is firmly seared new snap ring to the damper case white pushing the
Out of oil: 4mmSCREW
in the groove. end cap until the snap ring groove appears.
Check the operation of the damper rod, pump it C-O-,-,-o-'-o-"-,- - - - - - -- - - - - --,

slowly, extend or compressed by hand.
Check the following:
- Dilleakage
- Abnormal noise by trapped air
If you hear abnormal noise by trapped air, reassem -
ble the steering damper.
DAMPER ROD
MeasurB the Measure the length between the spherical bearings ~O=,=,=O='=O=II='=============~
damper rod length as shown:
wirh rhe "mside"
jaws of a vernier STANDARD:
caliPer. Fully compressed damper rod length:
93.55 - 94.35 mm (3.683 - 3.715 in)
Fully extended damper rod length:
117.55 - 118.35 mm (4.628 - 4.659 in)
If the measured lengths are outside the standard
length, disassemble the steering damper and start
over.
NOTE :
The normal operation of the HPSD can not be
secu red when the fully comp ressed damper rod L _ _ _ _ _ _ _ _ _ _ __ _ __ _ _...J
length is more than standard.
Return the damping force adjuster to its original
position.
STANDARD POSITION:
9 clicks out from full in
14-46 •
STEERING STEM
REMOVAL
Remove the fol lowing:
- Front viso r ('05 - '07; page 3-5, After '07: page 3-
6)
- Handlebar (page 14-32)
- Front wheel (page 14-8)
After '07: Remove the steering damper (page 14-38).
Remove the bolts, collars and front fender.
Remove the bolts and brake hose guides.

'05 - '07 Shown ~
Remove the bolt and tripmeter cable guide. BOL TfTRIPMETER CABLE GUIDE
'05 - '07: Remove the nuts, washers, tripmet er and connecto r

st ay.
'05 - '07: TRIPMETEA
Afrer '07: Remove the nuts, cable guide and t ripmeter.

After '07:
Remove the bolt and connector stay.
BOLT
14-47
Remove the steering stem nut and washer.
NUTIWASHEA
,
Remove the forks !page 14-13). ,,
Remove the fork top bridge.
TOP
Remove the steering stem adjusting nut using the
special tool. STEM SO(:KET
TOOL:
Steering stem socke t 0791 6-3710101 or
07702·0020001
(U .S.A. only)
Remove the upper dust seal, upper tapered roller

bear ing and steering stem. '05 - '07 shown:
OUST SEAL - - - - - . ,
Check the bearings and outer races for wear or
damage.
UPPER BEARING
BEARING REPLACEMENT
Always replace the Remove the upper and lower bearing outer races
bearingundraces from the head pipe using the special tools.
as a set.
TOOL:
Ball race ramover 07946-3710500
14-48
Install a new lower outer race, bearing race install-
ers and installer shah as shown. 1N5:TALLI'RSHAFT
Hold the shaft with a wrench and turn the installer
to install the lower outer race.
TOOLS:
Bearing race installer
12 required) 07VMF·KZ30100
Installer shaft 07VMF· KZ30200
BEARING RACE
INSTALLERS
LOWER OUTE R RACE
Install a new upper outer race, bearing race install-

ers and insta ller shaft as shown. INSTALLER SHAFT UPI'ER OUTER RACE
Hold the shaft with a wrench and turn the installer
to install the upper outer race.
TOOLS:
Bearing race installer
(2 required) 07VMF·KZ30100
Insta ller shaft 07VMF· KZ30200
( BEARING RACE INSTALLERS
14-49
FRONT WH EEL/SUSPENSION/STEERING
Temporarily install the stem nut to avoid damaging
the steering stem threads. '05 - '07 shown: ST"ERII NG STEM
Remove the lower tapered roller bearing and dust

LOWER BEARING
seal from the steering stem.
Apply urea based mUlti-purpose grease with

extreme pressure to the dust seal lips.
Install a new dust seal.
Install the lower bearing using a hydraulic press and
the special tool as shown.
TOOL:
Attachment, 30 mm 1.0. 07746-0030300
INSTALLATION
NOTE:
• Use water resistant grease #2 (urea based multi-
purpose grease) for the steering bearings and '05 - '07 shown:
dust seals: DUST SEAL - - - - - - :
- Excelite EP2 (Kyodo Yushi)
- Stamina EP2 (Shell) or equivalent
UPPER BEARING
Pack the upper and lower tapered roller bearings
with grease.
Apply grease to all of the bearing surfaces.
Install the upper tapered roller bearing in the steer-
ing head.
Sl ide the steering stem into the steering head from
the bottom. *~
Install the upper dust seal. LOWER BEARIN;[~i:::
14-50
Install the steering stem adjusting nut.
STEERING SOCKET
Tighten the steering stem adjusti ng nut to the speci-
fied torque using the special tool.
TOOL:
Steering stem socket 07916-3710101 or
07702·0020001
(U.S.A. only)
Move the steer ing stem lock-ta-Iock several times to
seat the bearings.
Loosen the adjusting nut to t orque of 0 N'm (0
kgf·m, 0 Ibf·ft), and retighten to the specified torque.
TORQUE: 7.0 N 'm (0.7 kgf·m , 5.2Ibf.ft)
Recheck tha t the steering stem moves smoothly
without play or binding.
Install the top bridge and washer.
l oosely install the stem nut. '05 - '07 shown: TOP BRIDGE
Insert the fo rks (page 14-30).
Tig hten the stem nut t o the specified torque.
TORQUE: 108 N'm (11 .0 kgf·m. 80 IbUt)
Recheck the st eering stem adjustment by turning
the top bridge lock-to-Iock and checking for smooth-
ness.
There should be no binding.
'05 - '07: Install the connector stay, tripmeter, washers and

'05- '07:
t ig hten the nuts secu rely.
(
i....
After '07: Inst all the tripmeter, cable guide. nuts and tighten
the nuts securely. After '07:
Install the connector stay, bolt and tigh t en the bolt

securely.
,
(
14-51
FRONT WHEEUSUSPENSION/STEERING
Install the tripmeter cable guide and tighten the bolt
securelv.
Install the front brake hose guides and tighten the
TORQUE: 5.2 N ·m (0.5 kgf·m, 3.8 IbHtj
Install the front fender. coliars and tighten the bolts

secu rely.
After '07: Install the steering damper (page 14-38).
Install the f ollowing :
- Front wheel (page 14. 12)
- Handlebar (page 14-34)
- Front visor 1'05 - '07: page 3-5, After '07: page 3-
6)
CLUTCH LEVER
....
REMOVAlliNSTAlLATION
Remove the clutch lever pivot nut, bolt, coilar, "''''',..,.".
CLUTCH LEVER PIVOT BOLT
clutch lever and hot start lever.
Apply grease to the sliding surface of the clutch
lever pivot bolt.
.
Install the clutch lever. hot start lever, collar, clutch
lever pivot bolt and nut.
Tighten the pivot bolt to the specified torque.
Loosen the pivot bolt to 45° - 90°, and tig hten the
pivot nut to the specified torque.
TOROUE:
Clutch lever pivot bolt:
2.0 N 'm (0.2 kgf·m, 1.5 Ibf.ftl - 45° to 90°
Clutch lever pivot nut: CLUTCH LE VER NUT
10 N·m (1.0 kgf·m, 7 rbf·ftl
14-52
15. REAR WHEEL/SUSPENSION
COMPONENT LOCATION ························15-2 SHOCK ABSORBER .... ···························· 15-14
SERVICE INFORMATION ························· 15-3 SHOCK LINKAGE ........................... ........ 15-30
TROUBLESHOOTING ············ ·········· ·········1 5-7 SWINGARM·· ·········································· 15-36
REAR WHEEL ··········· .. ······························· 15-8
15-1
REAR WHEEL/SUSPENSION
COMPONENT LOCATION
30 N·m (3.1 ,22lbHtl
54 N'm (5.6 kgf·m, 41Ibf.ft )
321bUt)
53 N'm (5.4 39Ibf·tt)
1.2 N ·m (0.1 kgf·m, 0.9 Ibf.ft)
27 N·m (2.B kgf·m, 20 Ibf·tt)
12 N'm (1.2 kgf·m, 9lbHt)
After '07:
,
._---------------------_.
15-2
SERVICE INFORMATION
GENERAL
AWARNING
• Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a fire or explosion result-
i ng in serious injury.
,. The shode absorber contains nitrogen under high pressure. Do not al low fire or heat nea r the shode absorber.
• Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then rem ove the valve from
the shock absorber.
• Keep grease off of the brake pads and disc.

• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasi ng agent.
• When servici ng the rear wheel or suspension support the motorcycle using a workstand or equivalent under the engine.
• For optimum suspension performance and linkage componen t service life, the swingarm and shock linkage pivot bear-
ing (along with related seals and bushings) should be disassembled, cleaned, inspected for wear and lubricated with
mUlti-purpose grease NlGI No.2 (molybdenum disulfide additive) every 7.5 hours of operation (competition use only).
• Optional rear wheel sprocket s, drive chain, shock springs and spring preload pin spanners are available. For optional
parts (page '-37). ' .
• For brake system information (page 16-3).
• Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting points.
SPECIFICATIONS
absorber
mm 20.0 - 24.0 kgf (44.1 - 52.9 Ibf)
l
10 clicks out from full in
j i I i
15-3
TORQUE VALUES
Rear axle nut 128 N·m (13.1 kgf·m, 94Ibf.ft) U-nut
Rear spoke 3.7 N·m (0.4 kgf·m, 2.7IbHt)
Rear rim lock 12 N·m ( 1.2 kgf·m, 9lbHt)
Oriven sprocket nut 32 N·m (3.3 kgf·m, 24 Ibf.ft) U-nut
Rear bake disc nut 16 N·m (1.6 kgf·m, 12 Ibf·ft) U-nut
Rear wheel bearing retainer 44 N·m (4.5 kgf·m, 32 Ibf·ft)
Shock absorber upper mounting nut 44 N·m (4.5 kgf·m, 32 Ibf·ft) U-nut
Shock absorber lower mounti ng nut 44 N'm (4.5 kgf·m, 32 Ibf·ft) U-nut
Shock absorber damper rod end nut 37 N·m (3.8 kgf·m, 27 Ibf·ft) Stake
Shock absorber compression damping adjuster
Shock absorber spring lock nut
Drive chain roller bolt
Drive chain roller nut
29 N·m (3.0 kgf·m, 21 Ibf·ft)
44 N ·m (4.5 kgf·m, 32 Ibf·ft)
12 N·m (1.2 kgf·m, 9Ibf.ft)
12 N·m (1.2 kgf·m, 9Ibf·ft)
Stake
U-nut
•
Shock arm nut (swingarm side) 53 N·m (5.4 kgf·m, 39 Ibf·ft) Apply oil to the threads
and flange surface, U-nut
(shock l ink side) 53 N·m (5.4 kgf·m, 39 Ibf·ft) Apply oil to the threads
Shock link nut (frame side) 53 N'm (5.4 kgf.m, 39 Ibf·ft) App ly oil to the threads
Swingarm pivot nut B8 N'm (9.0 kgf·m, 65 Ibf.ft) U-nut
Drive chain guide mounting bolt/nut 12 N'm (1.2 kg f·m, 9Ibf·ft) U-nut
Drive chain slider screw 4.2 N' m (0.4 kgf·m, 3. 1 Ibf·ft) Apply locking agent to the
threads
Rear brake hose guide screw 1.2 N'm (0. 1 kgf·m, 0.9 Ibf·ft)
Drive chain adjuster lock nut 27 N'm (2.8 kgf·m, 20 Ibf·ft)
Sub·frame upper mounting bolt 1'05- '07) 30 N·m (3.1 kgf·m, 22 Ibf·ft)
Sub-frame lower mounting bolt r05 - '07) 49 N·m (5.0 kgf·m, 36 Ibf·ft)
Sub-frame upper/lower mounting
bolt (After '07) 49 N·m (5.0 kgf·m, 36 Ibf·ft)
left step bracket mounting bolt (upper) 55 N'm (5.6 kgf·m, 41 Ibf·ft)
(lower) 30 N·m (3.1 kgf'm , 22 Ibf·ft)
15-4
REAR WHEEl/SUSPENSION
TOOLS
Spoke wrench, 6.6 mm Slider guida. 16 mm Driver
070MA-KZ30100 07PMG-KZ40100 07949-3710001
r.
or equivalent commercially avail- not available i n U.S.A.

able in U.S.A.
Driver Attachment, 28 x 30 mm Anachment, 40 x 42 mm

07749-0010000 07946-1870100 07746-0010900
Anamment, 24 )( 26 mm Pilot, 19 mm Pilot, 20 mm

07746-0010700 07746-0041400 07746-0040500
@
~. . .
--
'-:'~
Pilot, 22 mm Pilot, 25 mm Bearing remover head, 25 mm

07746-0041000 07746-0040600 07746-0050800
r@,
8
15-5
Bearing remover shah Retainer wrench. 48 mm Retainer wrench body
07GGD-0010100 07YMA·KZ40100 07710·0010401
or 07HMA-KS70100 (U.S.A. ani

Pin spanner (2 required ) Piston ring guide Collar, 23 x 17 mm
07702-0020001 070MG-KZ30100 07GMD-KT8A 110
or Pin spanner A not available in U.S.A.

8920, -KS6-S10 (2 required )
Attachment, 30 mm I.D.
07746-0030300
15-6
TROUBLESHOOTING
Soft suspension
• Weak shock absorber spring
• Incorrect suspension adjustment
• Oil leakage from damper unit
• Tire pressure too low
• Nitrogen gas leakage from the reservoir
Stiff suspension
• Damaged shock absorber spherical bearing
• Bent damper rod
• Damaged swingarm pivot bearings
• Damaged suspension linkage bearings
• Bent swingarm pivot
• Incorrect suspension adjustment
• Tire pressure too high
Steers to one side or does not track straight
• Bent rear axle
• Axle alignment/chain adjustment not equal on both sides
Rear wheel wobbles
• Bent rim
• Worn rear wheel bearings
• Faulty tire
• Tire pressure too low
• Faulty swingarm pivot bearings
Rear wheel turns hard
• Faulty reaf wheel bearings
• Bent rear axle
• Rear brake drag
• Drive chain too tight
Rear suspension noise
• Faulty rear shock absorber
• loose rear suspension fasteners
15-7
REAR WHEEL
REMOVAL
Raise the rear wheel off the ground by placing a "''7~7
workstand or equivalent under th e engine.
loosen the axle nut.
l oosen the d rive chain adjuster lock nuts and turn
the adjusters clockwise fully.
Remove the axle nut and washer.
•
Push from
chain the rear wheel sprocket.
the driven forward to derail the drive i~~~i~~~~~iii~~~;~
Be careflJl not to Remove the axle, adjusting blocks and rear wheel.
damage the brake • Do not operate the brake pedal after removing
pads with the disc.
the rear wheel. To do so wi l l cause difficulty in L!:~~~-'!
fitting the brake disc between the brake pads.
Remove the right and left sid e collars.
INSPECTION
A X LE
Set the axle on V-blocks and measure the runout.
Turn the axle and measure the runout using a dial
indicator.
Actual runout is 1/2 of the total indicator reading.
SERVICE LIMIT: 0.20 mm (o.ooa in)
15-8
WHEEl BEARING
Turn the inner race of each bearing with your finger.
The bearings shou ld turn smoothly and quietly.
the hub.
Replace the wheel Replace the bea rings if the inner ra ce does not t urn
bean"ngs in pairs . smooth ly, quietly, or if outer race fits loosely in the
h ub.
W HEEL BEARING
WHEEl RIM
Check the rim (unout by placing the wheel in a , - - - - -- - - - - - - - - - - - ,
truing stand.
Spi n the wheel by hand, and read t he runcut using a
dial indicator.
Actua l (unout is 1/2 the indicator reading.
SERVICE LIMITS:
Radial : 2.0 mm (0.08 in )
Axia l: 2.0 mm (0.08 in)
Check the spo kes and tighten any t hat are loose.
DISASSEMBLY
Remove the bolts, nuts and brake disc.
Remove the right dust seal.
l Remove the driven sprocket bolts, nuts and wash- iii~~~;~i~~S~~~~~~~

ers.
Remove the driven sprocket.
Remove the left dust seal.
15-9
Remove the bearing retainer using the special toots.
TOOLS:
Retainer wrench, 48 mm 07YMA· KZ40100 or
07HMA·KS70100
(U.S.A. on IV)
Retainer wrench body 07710·0010401
Replace the whBfti Install the remover head into the bearing.
bearings In pBlrs. From the opposite side of the wheel, install the
Do not reuse/he remover shaft and drive the bearing out of the
old be8rmgs. wheel hub.
Remove the distance coliar and drive out the bear-
ings.
TOOLS:
Bearing remover head, 25 mm 07746·0050800
Bearing remover shaft 07GGO·0010100
ASSEMBLY
~ BRAKE DI SC BOLT
.... • - - . . DlSTANCECOLLAR
RIGHT DUST SEAL ~ RIGHT W HEEL
~ .... BEARING BRAKE DISC NUT
RIGHTSI~R I
16 N'm (1.6 kgf·m , 121bf.ft)
___-1____ SPOKE 3.7 N'm (0.4 kgf·m. 2.7 Ibf.ft)

DRIVEN SPROCKET NUT
32 N'm (3.3 kgf·m. 24 Ibf.ft)
RETAINER
DRIVEN SPROCKET
44 N'm (4.5 kgf·m, 32 Ibf.tt)
,,: After '07:

,, (?£?o
D~~
,
LEFT SlOE COLLAR
",·LA
Gato GO (/J!i?iI
l ___________ _
e ..um., ~I
12 N'm (1.2 kgf·m, 9Ibf-ft)
111 •.um., LEFT DUST SEAL
15-10
Place the hub in the center of the rim, and begin lac·
ing with new spokes.
45.5 ± 1.00 mm
Adjust the hub position so the distance from the (1 .79±O.04 in)
hub left end surface to the side of the rim is 45.5 ±
1.00 mm (l.79±O.04 in ) as shown.
Torque the rear spoke in two or three progressive •

steps.
TOOL:
Spoke w ren ch, 6.6 mm 070MA·KZ30100 o r
equiva lent com mer·
cia lly ava il able in
U.S.A.
TORQUE: 3.7 N·m (0.4 kgf·m , 2.7 Ib f.ft)
Install the rear rim lock, setting rubb er, tube and P'!~~~~
tire.
Tighten the rear rim lock to the specified torque.
TORQUE: 12 N' m (1.2 kgf ·m , 9 Ibf.ft)
Pack all bearing cavi ties with grease.

LEFT: BEARINGS
NlNfJr mstall the old Drive in a new right bearing using the special 1001s.
l bearings; once the

bearings have been
TOOLS:
removed they Driver 01749·0010000
SEAL
must be replaced Attachment, 40 x 42 mm 01746·0010900

WIth new ones. Pilot, 25 mm 01746·0040600
• Drive the right bearing in the wheel hub until it is
fully seated with the marking side fa cing up.
Install the distance collar into place, then drive the SEAL
left inner and outer bearings using the same tools
as shown.
• Drive the left inner bearing in the wheel hub until -.J
I,;~;;;;~;;';;';';;;':;;;;"!<L_ _ _ _ __ _ _
it is fully seated wi th the sealed side facing
down.
• Drive the left outer bearing in the wheel hub until
it is fully seated with the sealed side facing up.
15-11
Apply grease to new bearing retainer threads.
Install and tighten the bearing retainer to the speci-
fied torque using the special tools.
TOOLS:
Retainer wrench, 48 mm 07YMA·KZ40100 or
07HMA·KS70100
(U.S.A . only)
Retainer wrench body 07710-0010401
Peen the edge of the retainer.
Install the driven sprocket.

Install the botts, washers and nuts, and tighten the
nuts to the specified torque.
TORQUE: 32 N·m (3.3 kgf·m , 24 Ibf·tt)
Apply grease to new left dust seal lips, then install
the dust seal.
Install the brake disc onto the wheel hub with the
minimum thickness mark (M IN TH 3.5 mm) facing
out.
Inst all the bolts/nuts.
Tighten the nuts to the specified torque.
TORQUE: 16 N'm {1 .6 kgf·m, 121bf.ftJ
Apply grease t o new right dust seal lips, then install
the dust seal.
15-12
INSTALLATION
Install the right and left side col lars.
Jf the rear brake caliper bracket is removed, install it

onto the slide rai l of the swingarm. CALIPER BR,'CI(ET
Be careful no r to Place the rear wheel into the swingarm.

damage the brake Apply thin coat of grease to the axle.
piJds wirl'l the disc. Install the drive chain over the driven sprocket.
Install the adjusting block and axle from the left
side.
Install the adjusting block, washer and axle nut.
l Adjust the drive chain slack (page 4-24).

Tighten the axle nut to the specified torque.
TORQ UE: 128 N 'm (13. 1 kgf ·m, 94 Ibf·ftj
Snug the adjusters against the adjusting blocks and
tigh t en the lock nuts to the specified torque .
TORQUE: 27 N'm (2.8 kgf ·m , 20 Ibf.ft)
15-13
SHOCK ABSORBER
REMOVAL
Remove the seat (page 3·3).
Loosen the ai r cleaner connecting boot band screw.
Remove the sub-frame lower mounting bolts and ,---------~-------_,

loosen the upper mounting bolt. SU B-FRAME
Do not IIh lift the sub-frame as shown.
past 90'!
Tighten the sub-frame upper mounting bolt to the
88 careful not to
specified torque. 90°
dafll8{16 rhe wires
andcab/es. TORQUE:
'05 - '07: 30 N'm (3.1 kgf·m. 22Ibf.ft)
After '07: 49 N-m (5.0 kgf·m, 36Ibf.tt)
If you plan to Remove the shock abso rb er upper mounting bolt

disassemble the and nut .
shock absorber.
loosen !he spring
lo(;l: nut and
adjusting nUl.
Remove the shock absorber lower mounting bolt,

nut and shock absorber.
15-14
DISASSEMBLY
Measure the spnng Set the shock absorber upper mount in a vise with a
length for piece of wood or soft jaws to avoid damage. ADJUSTING NUT
reinstallation later.
Loosen the lock nut and adjusting nut.
TOOLS:
Pin spanner 07102-0020001 (2 req u ired) o r
Pin sp anner A 89201 ·KS6·810 (2 required)
NUT
Remove the stopper ring, spring seat and spring.
STOPPER RING
BLADDER REPLACEMENT
• Set the rebou nd adjuster and comp ression
adjuster counterclockwise to the soft est position.
• Replace the bl adder when oil leaks around the
chamber cap or oil spills out w h en releasing the
nitrogen from the reservoir.
• Perform this procedure before draining the oil
from the damper.
Point the valve Depress the valve core to release the nitrogen from
away from you ro the reservoir.
prevent debris
getting in )o1:)tJr AWARNING
eye'.
• The chamber cap will be under significant
pressure and could ca u se serious injury.
• Release all nitrogen pressure before disas-
l sembly.
• Wear protective clothing and adequate eye
protection to prevent injury and debris
entering your eyes.
Remove the valve core.

CAP CORE
15-15
Depress the Put a suitable tool on the chambe r cap and push it
chamber cap jU51 i n by lightly tapping on the tool with a plastic ham- SUITABLE TOOL VALVE CAP
rhe minimum mer until you have good access to the stop ring.
amount for stopper
ring access. NOTICE
To avoid damaging the threads of the gas valve,
install the valve cap before depressing the chambe r
cap.
•
Two small screwdrivers and a shop towel are
required to remove the stopper ring. SCREWDRIVERS
To avoid d8fTJ8gmg
the inside surfaces
of the reservoir,
cover the
The stopper ring groove in the reservoir is ramped
toward the inside to give the stopper ring a square
shoulder on which to seat secu rely. t
To remove the stoppe r ring, first push one end of
screwdrivar with a
the stopper r ing out of its groove, then slip the sec-
shop towel.
ond screwdriver between the stopper ring and the
reservoir to act as a ramp.
Now, use the other screwdriver to pull the stopper
r ing completely out.
• Check the stopper ring groove for burrs. Remove
any bu rrs with a fine emery cloth before pulling STOPPER RING SHOP TOWEl
the damper rod out of the case.
Set the shock absorber in a vise with a piece of
wood o r soft jaws to avoid damage.
Using a suitable squeeze bottle, fi ll the reservoir
with t he recommen ded shock oil.
RECOMMENDED SHOCK OIL:
Pro Honda HP Fork Oil 5W or equivalent
Slowly pump the damper rod until no air bubbles
appear in the valve core hole, then pull the damper -~~
rod all the way out.
SHOCK OIL
Install the valve core securely.

Wea r protective clothing and a face gua rd 10 protect VALVE CORE
your eyes and face i n case the chamber cap pops
out Quickly and forcibly.
Remove the chamber cap and bladder following the
procedure below:
NOTE:
• The chamber cap will be removed with hydraulic
pressure so its force ca n be significant consider-
ing the air in the bladder.
•
1. Wrap the shop towel around the chamber cap.
Compress the damper rod slowly, to force the
chamber cap out.
15-16
2. Set the damper in a vise with soh jaws with the
damping adjuster facing up, being careful not to DAMPING AD'JUSTER
distort the damper body. Remove the damping
adjuster and O-rings.
NOTICE I
Do not over-tighten the vise. Damage to the damper
case will result.
3. Fill the damper w ith Pro Honda HP Fork Oil 5W or

equivalent through the damping adjuster hole, SHOCK OIL
while slowly pulling the damper rod out.
4. Reinstall the damping adjuster after 1illing the
damper .
• The damper must be kept upright to prevent oil
from leaking out.
5. Prace the damper with the reservoir chamber cap
facing up.
6. Repeat steps 1 to 5 unti l the chamber cap is

remo ved from the reservoir. CHAMBE R CAP NEW BLADDER
Do nor use any 50rt Remove the bladder from the chamber cap.
of tool to remove
the bladder.
because It may
damage the
c/'Iamber cap.
Attach a new bladder to the chamber cap.
, Do not reuse the

bladder.
If the bladder becomes distorted during installation,
depress the valve core to reform it.
x o
NO GOOD GOOD
'-
15-17
Clean the inside of the reservoir and fill it w ith rec-
ommended shock oil. 1.0 - 2.0 mm (0.04 - 0.08 in)
Pro Honda HP For1c: Oil 5W or equivalent
Apply light coat of shock oil to the lip of the bladder,
and press the chamber cap into the reservoir to
about 1.0 - 2.0 mm !O.04 - 0.08 in) below the stop-
per ring groove.
Be sure the stopper Install the stopper ring in the groove of the reservoir
ring is seated in the securely.
ring groove all the
Temporarily fill the reservoir with air slowly until
way around or the the chamber cap seats against the stop ring.
chamber cap can
come apart when
riding the
motorcycle.
Make sure the chamber cap face is level with the ' - -E-Q-U-A- L- H-E-
'G-H
--T -----------,
reservoir face. CHAMBER CAP
If the chamber cap does not seat fully, the chamber
cap may fly out when filling the reservoir with nitro-
gen.
Release the air from the reservoir by depressing the
valve core.
Bleed the air from the shock absorber bladder (page
15-26).
Fill the reservoir w ith nitrogen to the specified pres·
sure (page 15-27).
RESERVOIR
DAMPER DISASSEMBLY
Point the valve Depress the valve core to release the nitrogen from ~~:"::'':::'
away from you to the reservoir (page 15-15).
prevent debris
getting in your
eyes.
AWARNING
• The chamber cap will be under significant
pressure and could cause serious injury.
• Release all nitrogen pressure before disas-
sembly.
• Wear protective clothing and adequate eye
protection to prevent injury and debris
entering your eyes.
Before disposal of the shock absorber, release the

nitrogen by pressing the valve core. Then remove
the valve from the shock absorber.
Remove the damping adjuster.
Drain most of the shock oil from the damper and
reservoir, by pumping the damper rod in and out
several times.
15-18
wood or soft jaws to avoid damage.
Remove the end plate and tape or tie it to the rubber
stopper so it will not get in the way.
Push in the rod guide case until you have good

access to the stopper ring.
Two small screwdrivers are required to remove the
stopper ring. The stopper ring groove in the damper
case is ramped towards the inside to give the stop-
per ring a square shoul der on w hich to seat
securely.
To remove the stopper ring. first push one end of

the stopper ring out of its groove, then slip the sec-
ond screwdriver between the stopper ring and the
damper case to act as a ramp.
Now. use the other screwdriver to pull the stopper
ring completely out.
Check the stopper ring groove for burrs.
Burrs Will damsge Remove any burrs with fine emery cloth pulling the
tile damper rod damper rod out of the case.
Piston ring.
Carefully pull the damper rod assembly out of the

damper case.
DAMP'ERROO ASSEMBLY
15-19
PISTON RING REPLACEMENT
Inspect the piston ring.
If the piston ring is damaged, cut th e piston ring and
replace it along with new O-rings.
O-RINGS
PISTON RING
Apply fork oil to new a'rings and piston ring.

Place the piston ring guide attachment over the pis- 1
~~~;=;~~~=~~~~~;;;;~;=,;~~~
S!I ~ . . PISTON RING
ton and install new Q-rings and piston ring into IIIijjjIII
place by hand. ..
TOOL:
Piston ring guide 070MG·KZ30100
not available in
U.S.A .
Compress the piston ring against the ring groove
and seat the piston ring into the ring groove.
GUIDE
OAMPER ROD DISASSEMBLY
To keep lint or dirt from getting onto the damper , -0 - - - - - - - - - -- - - - - - - ,
rod parts, do not wear gloves while working on the 30 at first then
damper rod. gradua lly angle to 45 0
10 mm (O.4 i n)
Set the lower shock mount in a vise with a piece of
Unstake the damper rod end nut with a file as
45"
shown.
Be careful to file the end nut by hand so that the
0.0. of the rod end is about 10 mm (OA in) . Be care-
ful not to over-file.
FILE
Tu rn the end nut back-and-forth in 1/4 turn incre-
ments until it loosens, then rotate another 1/4 turn
and repeat turning back-and-forth until the nut loos-
ens completely.
If the damper rod is cracked or damaged when
removing the end nut, replace the damper rod
assembly with a new one.
•
15-20
Make sure thBl Remove the burrs from the damper rod end with a
filings are not stuck file and chase the thread s with a die.
in the damper rod.
DIE: 12 x 1.25 mm
Clean the damper rod with solvent aher chasi ng the
threads.
• Use a piece of mechanics wire to keep the
removed valves in the correct order,
• Keep dust and abrasive away from all damper
rod parts.
• Thorough ly clean the va lves in solvent and blow
them dry with compressed air if they have been
disassembled and separated. I
• Be careful not to get solvent on the D-ring and SHOP TOWEL
piston ring.
• The valve arrangement and number of valves
shown is typical and may not represe nt this
model exactly.
Remove the valve stopper, rebound valves and pis-
ton from the damper rod. PISTON VALVE STOPPER
REBOUND VALVES
Remove the compression valves and valve stopper.
, COMPRESSION VALVES
Chase the threads with a die and clean with oil.

Back out the damping adjuster.
Wrap the threads of the damper rod with tape.
Remove the rod guide case from the damper rod.
ROD GUIIDE C:~!:!!~~AMPER ROD
15-21
Remove the end plat e, rubber stopper and rubber
seat from the damper rod. RUBBER "u,,"," STOPPER
END PLATE
ROD GUIDE CASE INSPECTION

Inspect the rebound rubber and dust seal lips for
wear or damag e and replace the rod guide case
with a new one if necessary.
Visually inspect the rod guide case metal.
If the metal is worn so that the copper surface
appears, replace the rod guide case with a new one.
Remove the O-ring from the rod guide case and

replace it with a new one. ROD GUIDE CASE
DAMPER ROD INSPECTION

:tI C-RING
/J
Inspect the damper rod sliding surface fo r damage
or dist ortion. 8 mm (0.3 in) 8 mm (0.3 in)
- r-
"-=
• •
SLIDING SURFACE
•
15-22 •
DAMPER ASSEMBLY
Before assembly, wash all parts with solvent and
blow them dry with compressed air. COIMPf'ESSION VALVES
Make sure there is no dust or lint on any of the
parts.
I NOTICE I
• Set the rebound adjuster and compression
adjuster counrerclockwise to the softest position .
.. Never assemble valves which might have gotten
dusty or otherwise contaminated during the dis-
assembly process. Disassemble them, thor-
oughly clsan them with solvent and blow them
dry with compressed a;r before assembly.
.. Use care to avoid gerring solvent on the piston VALVE
ring and O-ring .
• The valve arrangement and numbsr of valves
may differ from those shown.
II! STOPPER II! O-R"'G

DAMPING ADJUSTER END NUT
<"'PP". RING
DAMPER ROD
~"'~~--END PLATE
RUBBER STOPPER
DAMPER RUBBER
SEAT
ADJUSTING NUT
'II BLADDER
VALVE
SEAT
STOPPER
CHAMBER CAP
STClPP"" RING
VALVE CORE
PISTON
STClPPI'" RING ".,'UUNUVALVES COMPRESSION VALVES
Install the rubber seat, rubber stopper and end

plate. RUBBER SEAT RUBBER STOPPER
~\-
l
END PLATE
15-23
Apply shock oil to a new O-ring, and install it to the
SLIDER GU IDE
rod guide case.
Install the special tool onto the damper rod.
TOOL:
Slider guide, 16 mm 07PMG-KZ40100
not available in
U.S.A. O-RING
Carefully install the rod guide case with the rebound
rubber facing up, over the damper rod.
114111
Remove the special tool.
ROD
The valve Install the valve stopper and compression valves

arrangement and onto the damper rod.
number of valves
may vary from
Those shown.
" ;.
COMPRESSION VALVES
Install the piston onto the damper rod.

VALVE STOPPER
Note the insTaliarion Install the rebound valves with their polished sur-
direction of the faces facing down.
piston valves.
I NOTICE I
Be careful not to bind the valves when installing the
piston onto the damper rod. Also, check that they
are concentric with the damper rod.
Install the valve stopper.
REBOUND VALVES
o
Set the lower shock mount in a vise with a piece of
Instal l and tighten a new damper rod end nut to the
specified torque.
TORQUE: 37 N'm (3.8 kgf·m, 27 Ibf·ftj
15-24
Stake the end of the damper rod in three places as
END NUT
shown, to the end nut.
Coat the damper rod with Pro Honda HP Fork Oi l 5W

or equivalent. Check the rod guide case by sliding it
up and down fully to be sure there is no restriction.
1
Coat the damper case inner surface, piston ring and
O-ring with Pro Honda HP Fork Oil 5W or equivalent,
and insert the damper rod assembly carefully.
Install the stopper ring into the groove in the
damper case.
After assembling, check that the stopper ring is
seated in the groove of the damper case completely.
You shou ld not be able to pull the damper rod out
of the damper case.

wood or soft jaws to avoid damage. END PLATE
l I NOTICE I
Do not over-tighten rhe vise and distort the damper
case.
Drive the end plate squarely and evenly into the
damper case with a plastic hammer.
15-25
Fill the damper case and reservoir with recom-
mended shock oil th rough the damping adjuster
hole.
Pro Honda HP Fork Oil 5W or equiva le nt
STANDARD OIL CAPACITY:
395 em' (13.4 US OZ, 13.9 Imp oz)
Make sure the rod Slowly pump the damper rod until there are no bub-
guide case IS bles in the oil that overflows from the damper case.
seaTed 8~;nS l the
Remove the damper unit from the vise.
stopper ring by
pullmg the damper
rod e// rhe way our.
Do not Ie! oil flow Position the damper unit so the damping adjuster ' - - - - - -
S-H-O-C-K- O
- 'L-- - - - - - - '
out of rhe reSefVOl( hole faces up. Turn the dampe r unit as shown to
bleed any air from the reservoir completely.
• When bleedi ng ai r from the reservoir, be ca reful
to hold the damper at the angles shown so the
filler hole points up.
Be sure the Temporari ly ch arge the reservoi r w ith 49 kPa (0.5
reS8fVCNf pressure kgf/cm2, 7. 1 psi) of air slowly to inflate the bladder.
IS COfTscr USing an Check for any oil that may leak out of the valve
accurare pressure
while pressurizing. Replenish oi l as necessary.
Qauge.
Fill the damper with reco mmended shock oi l to the

damping adjuster hole neck. ~ ~ O-RINGS
Apply oil to new O-rings and install them to the -- I
damping adjuster.
Dip the damping adjuster in clean shock oil.
Slowly instal l the damping adjuster.
TIghten the damping adjuster to the specified
torque.
TORQUE: 29 N·m (3.0 kgf·m, 21 Ibf·tt)
Wipe off all oil from the damper rod; oil left on the
damper rod can lead to premature failure of the oil
sea l.
Check the oil leaks.
Stake the dampi ng adjuster as shown.
•
Stake
15-26
Release the air that was in the reservoir at precom·
pression. Fill the reservoir with 980 kpa (10.0 kgf!
cm 2, 142 psi) of nitrogan gas.
ACAUTION
The shock absorber is fined with a gas-filled
reservoir. Use only nitrogen gas to pressurize
the shock absorber. The use of an unstable gas
can cause a fire or explosion resulting in seri-
ous injury.
Install the valve cap.
Install the spring with its tapered end facing down.

Install the spring seat and stopper ring.
Loosely tighten the adjusting nut and lock nut.
Turn the shock absorber lower mount so the

rebound adjuster screw is on the same side of the
shock reservoir.
SAME SIDE
One rum of the Turn the spring adjusting nut until the spring length
adjus ting nut measurement recorded at disassembly is reached LOCK NUT
changes the spring or until the spring length is as specified below.
length by 1. 5 mm
(0.06 in). STANDARD SPRING LENGTH :
'05 - '07: 258.5 mm (10.18 in) STANDARD
After '07: 258.0 mm 110.16 in) LE NGTH
Hold the adjusting nut and tighten the lock nut.
TORQUE: 44 N'm (4.5 kgf·m , 32 Ibf·ft)
Use this standard spring length as the baseline.
See the Owner's Manual for detailed instructions on
adjusting preload and damping for riding conditions
and rider skil l.
15-27
SPHERICAL BEARING REPLACEMENT
Remove the dust seals.
DUST SEALS
Check the spherical bearing for wear or damage.
If it is worn or damaged, it must be repla ced.
Press the spherical bearing to get the clearance nec-

essary to rem ove th e stopper ring using the special RING
tool.
TOOl:
Collar, 23 x 17 mm 07GMD· KTSA1'O
Remove the stop ring.
Press the spherical bearing out of the upper mount

using the special tools. COLLAR
TOOLS:
Collar, 23 II 17 mm 07GMD-KTBA110
Attachment, 30 mm I.D, 07746-00303 00
ATTACHMENT
Apply multi-purpose grease NLGI No.2 (motybde· ~~=~==============~

nurn disulfide MoS2 additive) to the new spherical COLLAR
bearing.
Dflve the bearing in Press a new spherical bearing into the upper mount.
evenly, do not Bilow
It to tilt
TOOL
Collar, 23 II 17 mm 07GMD·KTBA1'O
15-28
Install a new stopper ri ng into the groove of the
upper mount securely.
Press the spherical bearing into the upper mount
using the special tool, until it seats against the stop-
per ring.
TOOL:
Collar, 23 x 17 mm 01GMD·KTSA110
Be sure fa Install
rhe correct dust
seal In each Side.
Apply grease to new dust seal lips and install them.
III ~---. DUST SEALS
INSTALLATION
Set the shock absorber onto the shock arm with the
rebound adjuster facing right side.
Install the lower mounting bolt by aligning the flat
side of the bolt with the stopper on the shock
absorber.
Install and tighten the lower mounting nut to the
specified torque.
TORQUE: 44 N' m (4.5 kgf·m , 32 Ibf.ft)
Install the upper mounting bolt by aligning the flat

side of the bolt with the groove of the frame.
Install and tighten the shock absorber upper mount-
ing nut to the speCified torque.
TORQUE: 44 N·m 14.5 kgf·m , 32 Ibf.ft)
15-29
Loosen the sub-frame upper mounting bolt and
connect the air cleaner connecting boot secu rely.
Tighten the sub-frame mounting bolts to the speci-
fied torque. "-
TORQUE ('05 - '07):
Upper: 30 N 'm (3. 1 kgf·m , 22 lbf.ft)
Lower : 49 N 'm (5.0 kgf ·m . 36 Ibf.ft)
•
TORQUE IAfter '07) :
Upper/ low er: 49 N'm (5.0 kgf·m , 36 Ibf·It)
securely.
Install the fuel tank (page 3-8),
Install the seat (page 3-3).
SHOCK LINKAGE
REMOVAL
Remove the cotter pin, washer, joi nt pin, spring and .. '~"'~~,
left step.
Remove the step bracket mounting bolts and step W"""O"''''''-'''

bracket assembly.
Remove the nut and drive chain roller.
15-30
- Shock absorber lower mounting bolt/nut
Shock arm bolt/nut/washer (shock link side)
- Shock arm bolt/nut/washer (swingarm side)
- Shock arm
- Shock link bolt/nutlwasher (frame side)
- Shock link
'.
LOWER
BOLT/NUT
Remove the side collars, pivot collar and dust seals

I -
from the shock link. SIDE COLLAR SHOCKUNK
PIVOT COLLAR DUST SEAL
Remove the sida collars and pivot collars from the

shock arm (swingarm side, shock link side). SIDE COLLARS PIVOT COL.LAI"
15-31
Remove the dust seals and washers (swingarm
side, shock link side).
Remove the dust seals, side collars and pivot coliar
(shock absorber side).
INSPECTION
Check the dust seals and colla rs for wea r, damage
SHOCK ARM: PIVOT COLLARS
or fatigue.
Check the needle bearings for damage o r loose fit.
Check the shock arm and shock lin k for cracks or
damage.
If the needle bearings are damaged, replace them.
SIDE COLLARS
DUST SEAL
SHOCK LINK: SIDE COLLARS
PIVOT COLLAR DUST SEALS
BEARING REPLACEMENT
SHOCK ARM NEEDLE BEARING
Press the needle bearings (shock link side and swin-
germ side) out of the shock link using the special
tools and 8 hydraulic press.
TOOLS:
Driver
Attachme nt, 24 )( 26 mm
Pilot . 20 mm
01949·3710001
07746·0010700
07746-0040500
•
Attachme nt, 30 mm 1.0. 07746-0030300
15-32
Press the needle bearings (shock absorber side) out
of the shock link using special tools and a hydraulic DRIVER
press.
TOOLS:
Driver 07749·0010000
Attachment, 24 II 26 mm 07746·0010700
Pilot, 19 mm 07746· 0041400
Attachment, 30 mm 1.0 . 07746-0030300
Pack new needle bearings with grease.

~ NEEDLE BEARINGS
Press rhe needle Press new needle bearings into the shock li nk side • !fill
pivot with the special tools and a hydraulic press so
bearing in to Ihe
shock afm with the that the needle bearing surface is 6.0 - 6.5 mm !0.24 L .....
marked side facing - 0.26 in) below the end of the shock arm surface.
out.
TOOLS:
Driver 07749·0010000
Attachment. 24 x 26 mm 07746·0010700
Pilot,20mm 07746·0040500
!
6.0-6.5 mm
(0.24 - 0.26 in)

BEARINGS
Press the needle Press new needle bearings into the swingarm side
bearing into the pivot with the special tools and a hydraulic press so
shock arm WIth the that the needle bearing surface is 4.4 - 4.7 mm (0. 17
tI
marked SIde facmg - 0.19 in) below the end of the shock arm surface.
'''''. TOOLS:
Driver 07749-0010000
Attachm ent, 24 x 26 mm 07746-0010700
Pilot, 20 mm 07746· 0040500
4.4-4.7 mm
!0.17 - 0.19 in)
Pack a new needle beating with grease.

NEEDLE BEARINGS
Press the needle Press a new needle bearing into the shock absorber
g
l beBnflQ Into the
shod< arm WIth the
side pivot with the special tools and a hvdraulic
press so that the needle bearing surface is 3.0 - 3.2
mm (0.12 - 0. 13 in) below the end of the shock arm
mark&d side facing
out. surface. j
TOOLS:
Driver 07749-0010000
Attachment, 24)( 26 mm 07746-0010700 3.0 - 3.2 mm
Pilot, 19 mm 07746-0041400 (O. 12-0.13in )
15-33
SHOCK LINK NEEDLE BEARING
Remove the needle bearing from the shock l ink.
NEEDLE BEARING
,,
SHOCK LI NK

4.4- 4.7 mm
Press rhe needle Press new needle bearings into the pivot wi th th e ~ (O.17-0.19inl
bearmg mto the special tools and a hydraulic press so that the nee-
shock link with the die beari ng surface is 4.4 - 4.7 mm (0.17 - 0. 19 i n)
marked side facing below the end of the shock arm su rface. r- •
OU<.
TOOLS:
Driver 07749-0010000
Attachment, 24 x 26 mm 01746·0010700
Pilot, 20 mm 07746-0040500
....
<:!..
NEEDLE
_ !iijjjjj.. BEARINGS
INSTALLATION
Apply mUlti-pu rpose grease NLGI No.2 (molybde-
num disu lfide additive) to the shock arm, dust seal _..¥iii2t SIDE COLLARS
lips, side collar seating surface and needle beari ng
rol ling area .
• Make su re the needle bearing rollers are in posi-
tion before installing.
Number of needle roll ers:
Shock link side: 32
Sw i nga rm side: 32
Shock absorber side: 27
Install the dust seals and washers (shock link side),

Install the dust seals to the shock arm (swingarm
side).
Inst all the p ivot collar, side collars and dust seals
(shock absorber side), • ~ PIVOT CUl.LA'"
Install the pivot collars and side collars to the shock SIDE COLLARS
D
ar m (swi ngar m side, shock link sid e).
15-34
Apply mUlti-pu rpose grease NLGI No.2 (molybde-
num disulfide additive) to the dust sea l lips, side
coliar seating surface and needle bearing rolling
area.
Install the dust seals, pivot collar and side collars .
• Make sure the needle bearing rollers afe in posi-
tion before installing.
Number of needle rollers: 32
PIVOT COLLAR •
Apply oil
threads andtoflange
the shock
surface.arm and shock link nut ~;~~~~~~~~j
Loosely install the following;
- Shock link
Shock link bolt/nut/washer (frame side)
- Shock arm
- Shock arm bolt/nut/washer (swingarm side)
NOTE:
After '07; Align t he flat surfaces of the shock arm
bolt and swingarm.
- Shock arm bolt/nut/washer (shock l ink side)
Install the shock absorber lower mounting bolt
aligning the flat side of the bolt with the stopper on
the shock absorber.
Tighten all nuts to the specified torque.
TORQUE:
Shock link nut (frame side):
53 N·m (5.4 kgf·m , 39 Ibf.ft)
Shock ann nut (swingann side):
53 N,m (5.4 kgf·m , 39 Ibf.ft)
Shock arm nut (shock link side):
53 N·m (5.4 kgf·m , 39 Ibf.ftl
Shock absorber low er mounting nut:
44 N·m (4.5 kgf·m , 32 Ibf.ft)
( -
15-35
Install the drive chain roller with the . ..... mark facing
out.
Tighten the nut to the specified torque.
TORQUE: 12 N'm f1 ,2 kgf·m, 9 Ibf.ft)
Install the step bracket assembly and mounting

bolts.
Tighten the upper mounting bolt to the specified
torque.
TORQUE: 55 N'm (5.6 kgf·m . 41Ibf·ft)
Tighten the lower mounting bolt to the specified
torque.
Insta ll the left step. spring, joi nt pin, washer and

new cotter pin securely as shown.
SWINGARM
REMOVAL
-
WAS HER

BRI"E CALIPER
- Rear wheel (page 15-8)
Do nor disconnect Remove the rear brake cal iper from the sl ide rai l on
the hydraulic line. the swingarm. •
I NOTICE I
Do not suspend the brake caliper from the brake
hose. The brake hose may be damaged.
L.."'.....~
•
15-36
Remove 1he screws and brake hose guides.
~,
Check 1he chain guide slider for wear or damage.

- Bo lts
Nuts
Chain guide
Chain guide slider
Collars ('05 - '07)
Drive chain !page 4-25)
Raise the rear wheel off the ground by placi ng a

works1and or equivalent under the engine.
Remove the shock arm bolt, nut and washer !swi ng-
arm side).
(SWINGARM SIDE)
15-37
Remove the pivot nut and washer.
Remove the pivot bolt and swingarm.
'.
OISASSEMBL V
Check the chain slider for wear or damage .
Remove the screws and chain slider.

NEEDLE BEARING
- Side collars
- Dust seals
- Washers
- Thrust needle bearings
- Pivot collars
Check the dust seals and collars for wear, damage
or fatigue.
Check the needle bearings for damage or loose fit.
Check the thrust needle bearings for wear or dam-
•
age, replace it if necessary.
Check the swingarm for cracks or damage. PIVOT COLLAR
Replace any damaged parts, if necessary. WASHERS SIDE COLLAR
15-38
BEARING REPLACEMENT
Press the needle bearings out of the swingarm
using the special tools and a hydraulic press.
TOOLS:
Driver 07949-3710001
Attachme nt, 24 x 26 mm 07746·0010700
Pilot . 22 mm 0774&-0041000
Atta chment, 30 mm 1.0. 07746-0030300

Press a new needle bearing into the swinga rrn using
the specia l tools and 8 hydraul ic press as shown.
TOOLS:
Driver 07749·0010000
Attachment, 28 x 30 m m 07946-1870100
Pilot, 22 mm 07746-0041000
NEEDLE BEARINGS
ASSEMBLY
WASHERS
Itt
~.v;;.. DUST SEAL
,--------- -- -----,
Aher '07:
l _______________ , ,,
PIVOT COLlAR
SIDE COLLAR
~.v;;.. DUST SEAL

~
15-39
- - -- - - - _ .. -
Apply grease t o the th rust needle bearing rolling
THRUST NEEDLE BEARING
area and dust seal lips.
- Washers
f! ~~ -.~
- Th rust needle bearings
-
-
Pivot collars
Dust seals
• un;..
DUST WASHERS
- Side collars
SEALS
1.5 - 2.0 mm
(0.06 - 0.08 in)
Install the chain slider so its hole fits over the tab on
the swingarm.
CHAIN >LIL'tH
Clean and apply locking agent t o the screw threads.
Inst all and tighten the screws to the specified
torque.
" II!il3 SCREWS
INSTALLATION
Apply thin coat of grease to the swingarm pivot bolt
sliding surface.
Install the swingarm onto the frame.
Install the swingarm pivot bolt through the frame
and swingarm pivot.
15-40
Install the washer and swi ngarm pivot nut.
Tighten the swingarm pivot nut to the specified
torque.
TORQUE: 88 N'm !9.0 kgf·m , 65 Ibf.ft)
Apply oil to t he shock arm nut th reads and seati ng ~:':'"~~,..

surface.
'05 - '07: Install the shock arm bolt, nut and washer .
Aher '07: Install the shock arm bolt by aligning flat surfaces of
the shock arm bolt and swi ngarm.
Tighten the nut to the specified torque.
TORQUE: 53 N 'm !5.4 kgf·m , 39 Ibf.ft)

- Drive chain (page 4-25)
l -
-
-
Collars ('05 - '07)
Chain guide slider
Chain guide
Install and tighten the bolts and nuts to the specified
torque.
TORQUE: 12 N ' m (1 .2 kgf·m , 9 Ibf.ft)
15-41
Do nor FWlSf fhe Install the rear brake caliper to the slide rail on the
brake hose. swing ar m. BRAKE CALIPER
Install the brake hose guides and tighten the screws

to the specified torque.
TORQUE: 1.2 N'm 10.1 kgf·m, O.9Ibf·ft)
- Rear wheel (page 15-13)
15-42
16. HYDRAULIC BRAKE
COMPONENT LOCATION ···.. ··········· .. ··· .. · 16-2 FRONT MASTER CyLINDER·· ················ 16-12
SERVICE INFORMATION ························· 16-3 REAR MASTER CYLINDER .................... 16-15
TROUBLESHOOTING ············ ············· ·.... ·16-5 FRONT BRAKE CALIPER ························ 16-18
BRAKE FLUID REPLACEMENTI AIR REAR BRAKE CALIPER ........... ..... .......... 16-20
BLEEDING ················································· 16-6
BRAKE PEDAL ···································· .. ·· 16-24
BRAKE PAD/ DISC .. ·································16-10
,
\.
16-1
HYDRAULIC BRAKE
COMPONENT LOCATION
1.0 N'm (0. 1 kgf·m . O.7Ibf.ft)
5.9 N'm (0.6 kgf·m, 4.4 rbf·ft)
34 N'm !3.5 kgf·m,

5.4 N'm (0.6 kgf·m, 25Ibf.ft)
4.0 Jbf·h)
5.9 N'm (0.6 kgf·m, 4.4 IbUt)
AJ--- 34 N'm (3.5 kgf·m, 25 IbUt)
ft1 18 N·m (1.8 kgf·m, 13 rbf·ttl
Iij ~ \' 1.0 N' m (0.1 kgf·m, 0.7 Ibf.ftl
~ N'm 13.1 'g'·m, 22 Ib'·hl

2 N -m to.2 kgf·m. 1.5Ibf.ft ) b
/ 34 N'm 13.5 'g'.m.
25 Ibf.ft)
~ ~ /
5.4 N'm (0.6 kgf·m, 4.0 Ibf.ft)
34 N'm I . 'g'·m. 25 Ib'·hl f 11'!~ID::
18 N'm 0,8 kgf.m, 13 tbUt)
13 N·m (1.3 kgf·m, 10 Ibf·tt)

•
5.9 N-m (0.6 kgf·m, 4.4 Ibf·h)
36 N 'm (3.7 27Ibf.ft )
16-2
HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL
AWARNING
Frequent inhalation of brake pad dust, rega rdless of material composition could be hazardous to your health .
• Avoid breathing dust particles .
• Never use an air hose or brush to ctean brake assembl ies. Use an OSHA-approved vacuum cleaner.
; I NOTICE I
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
wi th high qual ity brake degreasing agent.
• Check the brake system by applying the brake lever or pedal after the air bleeding.
• Never allow contaminates (dirt, water, etc.) to get into an open reservoir.
• Once the hydrau l ic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing t he system. Do not mix different types of
fluid, they may not be compatible.
• Always check brake operation before riding the motorcycle.
SPECIFICATIONS
TEM
Fcoot I ;
ke IISC i
ke lise
R,,,
16-3
HYDRAULIC BRAKE
TORQUE VALUES
Brake hose oil bolt 34 N-m (3.5 kgf-m, 25 Ibf.fU
Brake lever pivot nut 5.9 N-m (0.6 kgf·m, 4.4 Ibf.ft)
Brake lever pivot bolt to N-m (0.1 kgf-m. 0.7 IbHt)
Brake lever adjuster lock nut 5.9 N'm (0.6 kgf-m, 4.4 Ibf.ftl
Front master cylinder reservoir cover screw to N-m (0.1 kgf-m, O.7I hf.ft)
Front master cylinder holder bolt 9.9 N-m (to kgf-m, 7.3 Ibf·h)
Front brake caliper mounting bolt 30 N-m (3.1 kgf·m, 22 Ibf.ft) Apply locking agent to the threads
Front/rear caliper bleed valve 5.4 N·m (0.6 kgf·m, 4.0 Ibf.ftj
Rear master cylinder reservoir cover bolt to N-m (0.1 kgf·m, 0.7Ibf·ft)
Rear master cylinder mounting bolt 13 N·m (1.3 kgf·m. 10 Ibf.ft)
Brake caliper pad pin 18 N·m (1.8 kgf·m, 13Ibf·ft)
front brake caliper pad pin plug 2 N·m (0.2 kgf·m, 1.5 fbf·ft)
Brake pedal pivot bolt 36 N'm (3.7 kgf·m, 27 Ibf·ft)
Brake pedal adjuster lock nut 5.9 N'm (0.6 kgf·m, 4.4 Ibf·ft)
Front brake disc cover bolt 13 N·m (1.3 kgf·m, 10 Ibf·ft)
TOOL
Snap ring pliers

07914-SA50001
16-4
HYDRAULIC BRAKE
TROUBLESHOOTING
Brake lever/pedal soft or spo ngy
• Air in hydrau l ic system
• Leaking hydraulic system
• Contaminated brake pads/disc
• Worn cal iper piston seal
• Worn master cylinder piston cups
• Worn brake pads/disc
• Contaminated caliper
• Caliper not sliding property
• l ow brake fluid level
• Clogged fl uid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Contaminated master cyl inder
• Bent brake lever/pedal
Bra ke lever/pedal ha rd
• Clogged/restricted brake system
• Sticking/worn caliper piston
• Caliper not sliding properly
• Clogged/restricted flui d passage
• Worn caliper piston seal
• Stickingfworn master cylinder piston
• Bent brake lever/pedal
Brake drags
• Contaminated brake pads/disc
• Misaligned w heel
• Clogged/restricted brake hose joint
• Wa r ped/deformed brake disc
• Caliper not sliding properly
• Cloggedfrestricted brake hydraulic syst em
• Stickinglworn caliper piston
• Clogged master cylinder port
16-5
HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
• A contaminated brake disc or pad reduces stop-
ping power. Discard contaminated pad s and
clean a contaminated disc with a high quality
brake degreasing agent.
• Once the hydraulic system has been opened, or if
the brake feels spongy the system must be bled.
• When using a commercially available brake
bleeder. follow the manufacturer's operating
instruction.
BRAKE FLUID DRAINING
Donor allow Check the master cylinder parallel to the ground,
fOfe,gn mallma/ to before removi ng the reservoir cover. SCREWS
enter tile system.
For the front brake, remo ve the screws, re servoir
A void spil/ifI{J fluid
cover and diaphragm.
on plastIC Of rubber
parts. Piece 8 rag
over these parts
whenever the
system is serviced.
For the rBaf brake, remove the bolts, reservoir

cover, set plate and diaphragm.
For the rear brake, remove the bolts and rear brake
caliper guard.
16-6
HYDRAULIC BRAKE
Connect a bleed hose to the bleed valve.
loosen the bleed valve and pump the brake lever
(pedal).
Stop operating the brake when no more fluid flows
out of the bleed valve.
BRAKE FLUID FILLING/AIR BLEEDING

Do not mix different Fill the master cylinder with DOT 4 brake fluid to the
types of fluid since upper level. UPPER LEVEL
they are not
compatible.
Dono/aI/ow
foreign matena! to
enter the system.
Connect a commercially available brake bleeder to ~IIIIIIIIIIII~~~~__~~~~~-.:""'~-~

the bleed valve.
FRONT MASTER CYLINDER
REAR MASTER CYLINDER
16-7
HYDRAULIC BRAKE
Operate the brake bleeder and loosen the bleed
valve. If an automatic refill system is not used, add
fluid when the fluid level in the reservoir is low.
If air enters the Perform the bleeding procedure until the system is
bleeder from completely flushed/bled.
around rhe bi8ed Close the bleed valve and operate the brake lever or
valve threads, seal
pedal.
The threads wI Th
If it still feels spongy, bleed the system again.
reflon tape.
REAR CALIPER
If a brake bleeder is not available, perform the fol -

lowing procedure.
Connect a clear bleed hose to the bleed valve.
Pressurize the system with the lever or pedal until
there are no air bubbles in the fluid flowing out of
the small hole in the reservoir and lever or pedal
resistance is felt.
Do not release rhe ,. Pump the brake lever or pedal severa l times,
lever Of pedal until then squeeze the brake lever or pedal all the way
the bleed valve has and loosen the bleed valve 112 of a turn.
been closed. Wait several seconds and dose the bleed valve.
2. Release the brake lever or peda l slowly and wait
several seconds after it reaches the end of its
travel.
3. Repeat steps 1-2 until there are no air bubbles in
the bleed hose.
After bleeding air completely, tighten the bleed
valves to the specified torque.
TORQUE: 5.4 N 'm (0.6 kgf·m, 4.0 Ibf.ft)
16-8
HYDRAULIC BRAKE
For the rear brake, install the brake caliper guard
and tig hten the bolts securely.
Fill the reservoir with DOT 4 brake fluid to the top of

the upper level.
,..
FRONT:
Install the diaphragm and reservoir cover.
Tighten the reservoir cover screws to the specified RESERVOIR CO',"'''DLAPlm',GM
torque.
TORQUE: 1.0 N'm (0.1 kgf·m , 0.7Ibf.ft)
REAR:
l, Straighten the diaphragm and install it to the rear

master cylinder.
Check the diaphragm installation as shown.
Install the set plate and reservoi r cover.
Tighten the reservoir cover bolts to the specified
torque.
TORQUE: 1.0 N·m (0.1 kgf·m , 0.7 Ibf.ft)
16-9
HYDRAULIC BRAKE
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
For front brake, remove the bolts and brake disc
cover.
Push the caliper pistons all the way in to allow

installation of new brake pads.
NOTE:
• Check the brake fluid level in the brake master
cylinder reservoir 85 this operation causes the
level to rise.
For the front brake. remove the pad pin plug and
pad pin.
For the rear brake, remove the pad pin.
Remove the brake pads.

Install new brake pads to the pad retainer securely.
NOTE:
• Always replace the brake pads in pairs to assure
even disc pressure.
• A contaminated brake disc or pad reduces stop-
ping power.
• Discard contaminated pads and clean a contami·
nated disc with 8 high quality brake decreasing
agent.
16-10
HYDRAULIC BRAKE
For the front brake, push the brake pads against the
pad spring, then install the pad pin.
Tighten the pad pin to the specified torque.
TORQUE: 18 N'm 11.8 kgf·m, 13 Ibf.ft)
Install and tighten the pad pin plug to the specified
torque.
TORQUE: 2 N'm (0.2 kgf·m , 1.5 Ibf.ft)
Install the front brake disc cover and tighten the

bolts specified torque.
liiiSCO()VIE.
TORQUE: 13 N'm (1 .3 kgf·m , 10 Ibf.ft)
For the rear brake, install a new C-ring into the pad • ."n-
pin groove.
Install and tighten the pad pin to the specified
torque.
TORQUE: 18 N·m (1 .8 kgf·m . 13 IbUt)
Operate the brake lever or pedal to seat the caliper
piston against the pads.
BRAKE DISC INSPECTION

Remove the front brake disc cover (page 16-10). ...'05 - 07-!!::;::'
c. Visuallv inspect the brake disc for damage or cracks.
Measure the brake disc thickness with a microme-
ter.
SERVICE LIMITS:
FRONT: 2.5 mm (0.10 in)
REAR: 3.5 mm (0.14 in)
Replace the brake disc if th e sma l lest measu rement
is less than the service limit.
16-11
HYDRAULIC BRAKE
Measure the brake disc warpage with a dial i ndica- J;5 _ '07 ....
tor.
SERVICE LIMIT: 0.15 m m (0.006 in)
Check the wheel bearings for excessive play. if the

warpage exceeds the service lim it. _ _--:;t'
Replace the brake disc if the wheel bearings are no(-
mal. _....,~l
FRONT MASTER CYLINDER

REMOVAL
Drai n the front brake hydraulic system (page 16-6).
When removing the Remove the brake hose oil bolt, seal i ng washers
brake hose oil 0011, and brake hose eyelet.
cover the end of the
hose fO prBvenf
contamination.
Secure the hose to
prevent flud from
leakif19 oor.
SEALING WASHERS I BOLT
Remove the bolts, holder and master cylinder

assembly. MASTE R CYLI NDER
HOLDER
DISASSEMBLY
Remove the pivot bolt/nut and brake lever assem- OUST CO'VER
bly.
BRAKE
16-12
HYDRAULIC BRAKE
Remove the boot.
Remove the snap ring from the master cylinder
body using the special tool as shown.
TOOL:
Snap ring pliers 07914-SA50001
Remove the washer, master piston and spring.
r,
,
WASHER
INSPECTION
Clean the inside of the cylinder and reservoir with
brake fl uid. SPRING
Check the piston boot, primary cup and secondary PISTON
cup for fa tigue or damage.
Check the master cylinder and piston for abnormal
scratches.
°0
Measure the master cyl inder I.D.
SERVICE LIMIT: 11.050 mm 10.4350 in )
Measure the master piston 0.0.

16-13
HYDRAULIC BRAKE
ASSEMBLY
Replace the PIston, Dip the piston and master cylinder 1. 0 . in brake
cups, sprmg, snap fluid.
nng and boor as a Install the spring to the piston. PISTON
set, do not
$ubsutute indMdw/
pans.
When installing the Install the piston assembly into the master cylinder.
cups, do not alJaw
the lIps to rum
mSldeour
Be certain the snap Install the snap ring using the specia l tool.
ring is firmly seared
In the groove. TOOL:
Snap ring pliers 07914· SA50001 ,"
Apply si licone grease to the inside of the boot.
Install the boot to the master cyl inder.
Install the brake lever.

Apply silicone grease to the pivot bolt sliding sur- PIVOT BOlTf NUT
face .
Install and tighten the pivot bolt to the specified
torque.
TORQUE: 1.0 N 'm (0.' kgf·m, 0.7 Ibf·ft)
Tighten the pivot nut to the specified torque.
TORQUE: 5.9 N'm (0 .6 kgf·m, 4.4Ibf·ft)
Insta ll the dust cover.
BRAKE
INSTALLATION
Place the master cylinder assembly on the handle-
bar. MASTER CYLINDER PAINT MARK
Align the end of the master cylinder with the paint
mark on the handlebar.
Install the master cylinder holder with the · UP·
mark facing up.
Tighten the upper bolt first, then the lower bolt to
TORQUE: 9.9 N·m (1 .0 kgf·m. 7.3 Ibf·tt)
16-14
HYDRAULIC BRAKE
Align the brake hose eyelet between the stoppers.
Insta ll the brake hose eyelet with the oil bolt and
new sealing washers.
Tighten the brake hose oil bolt to the specified
torque.
TORQUE: 34 N·m 13.5 kg f·m , 25 Ibf·ft )
Fill and bleed the front brake hydraulic system
(page 16-7).
REAR MASTER CYLINDER

REMOVAL
Drain the rear brake hydra ulic system (page 16-6).
Remove the brake pedal (page 16-24).
Vv1Ien removing the Remove the brake hose oil bolt, sealing washers
brake hose 011 bolt. and brake hose eyelet.
CCMlf the end o( the
hose to prevent
contamina tIOn.
Secure the hose to
prevent fluid (rom
leakIng out.
Remove the master cylinder mounting bolts and

rear master cylinder.
L DISASSEMBLY
Remove the boot.
Remove the snap ring from the master cylinder
body using the special tool as shown.
TOOL:
Snap ring pliers 079 1 ~SA5000 1
Remove the push rod, master piston and spring .
16-15
HYDRAULIC BRAKE
INSPECTION
Clean the inside of the cylinder with brake fluid.
Check the piston boot, primary cup and secondary
cup for fatigue or damage.
Check the master cylinder and piston for abnormal PUSH ROD
scratches.
MASTER .,SlrON
Measure the master cylinder I.D.
SERVICE LIMIT: 9.575 mrn !0.3770 in)
Measure the master piston 0 .0 .

SERVICE LIMIT: 9.465 rnm (0.3726 in)
ASSEMBLY
Rep/see the piston, Dip the piston and master cylinder I.D. in brake
cups. sprmg, snap fluid .
rlfl{} and boot as 8 Install the sp ring to the piston.
S8t; do not
substitute mdividual
pans. PUSH ROO
~en Installmg the Install the piston assembly into the master cylinder.
cups, do not allow Apply silicone grease to the round ed surface of the
the lips to turn push rod.
inside our
16· 16
HYDRAULIC BRAKE
Install the push rod into the master cylinder.
SNAP RING
BB ceffllin the snap Install the snap ring using the special tool.
rinr; IS firmly seared
TOOL:
in the groove.
Snap ring pller 07914·SA50001
Apply silicone grease to the boot fining area.
Install the boot.
Adjust the brake pedal to the desired height by 100s- , - - - - - - - - - -- - - - - ----,

ening the lock nut and turning the adjuster. ADJUSTER
STANDARD LENGTH : 79.6 mm (3 ,13 In)
Tighten the lock nul to the specified torque.

79.6 mm (3.13 in)
LOCK NUT
INSTALLATION
Install the master cyli nder and tighten the mount ing
TORQUE: 13 N' m (1.3 kgf·m, 10 Ibf.ftl
Install the brake hose with the oil bolt and new seal-
ing washers.
~:.:~~.....~
Push the eyelet joint against the stopper, then
tighten the brake h ose oil bolt to the specified
torque.
TORQUE: 34 N ·m !3.5 kgf·m, 25 Ibf·ftJ
Insta ll the brake pedal (page 16·24).

Fill and bleed the rear brake hydraulic system (page
16-7).
16-17
HYDRAULIC BRAKE
FRONT BRAKE CALIPER
REMOVAL
Drain the front brake hydraul ic system (page 16-6),
Remove the brake pads (page 16-10), iiRiIKEHOSE
Remove the brake hose oil bolt, sealing washers

and brake hose eyelet.
Remove the caliper m ounting bolts and then

remove the caliper and bracket as an assembly.
; BRACI(ET ASSEMBLY
DISASSEMBLY
Remove the caliper bracket from the cali per body.
CALIPER RETAINER BOOTS
Remove the brake pad spring from the caliper body. BRACKET
Remove the brake pad retai ner from the calipe r
bracket.
Remove the caliper pin boot end bracket pin boot .
PAD SPRIN G
If necessary, lig htly apply compressed air to the cal-
iper fluid inlet to get the piston o ut.
Place a shop rag under the caliper to cushion the
piston when it is expe1led.
Do nor bring rhe 81f Use the air in short spurts.
nozzle roo close fO
•
fhe mist or the
PIStOflS may be
tOtcad au! with
excesslVl! forcs thar
collid Cdllse millry
•
16-18
HYDRAULIC BRAKE
Be careful not to Pu sh the dust seals and piston seals in and l ift them
damage the piston out. PISTON SEALS
sliding surface.
Clean the seal groov es, caliper pistons and caliper
piston sliding surfaces with clean brake fl uid.
r'.
, I
INSPECTION
Check the cal iper cylinder and pistons f or scor ing,
-
, scratches or damage.
Measure the caliper cyl inder I.D.
Measure the caliper piston 0.0.
ASSEMBLY
L' Coat new piston seals with clean b rake fluid.
Coat new dust seals with si licon grease. PISTON SEALS
Install each pis/on

seal, dust sea/and
Install the piston and dust seals into the grooves in
the ca l iper body. ~.
caliper piston in
Coat the caliper pistons with clean brake fluid and
their proper
install them i nto the caliper cylinder with thei r open
locations. ends facing t he pad.
tI CALIPER
. . PISTONS
16-19
HYDRAULIC BRAKE
Install the brake pad retainer onto t he ca l iper
RETAINER
bracket.
Note the installation Install the pad spring into the caliper body. CALIPER
direction of the pad BRACKET
Replace the caliper and bracket pin boots jf there is
spring.
wear, deterioration or damage.
Apply silicone grease to the inside of the boots then
insta l l them.
Apply si licone grease to the cal iper pin bolt sliding
area.
When assembling Assemble the caliper and bracket .
the ca/(oer and
bracket. set the
boot into rh9 slide PAD SPRING CALI PER
pin groove.
INSTALLATION
Install the cal iper/bracket assembly to the fo rk leg. 1]~:~~~g~
Clean and apply locking agent to the caliper mount·
ing bolt th reads.
Install and tig hten the mounting bolts to t he speci-
fied torque.
Insta ll the brake hose eyelet to the cali per body with ....- - --
new sealing washers and oil bo lt.
Push the brake hose eyelet to the stopper on the cal-
i per, then tighten the oi l bolt to the specified torque.
TORQUE: 34 N·m (3 .5 kgf·m, 25 Ibf.ft)
Instal l the brake pads (page 16-10).
Fi ll and bleed the front brake hydrau l ic system
(page 16-7).
REAR BRAKE CALIPER

REMOVAL
Drain the rear brake hydra ul ic system (page 16·6).
Remove the brake pads (page 16-10).
Remove the bolts and brake caliper gua rd.
l oosen th e oil bolt . •
•
16-20
HYDRAULIC BRAKE
Remove the rear wheel (page 15-8).
BRAKE CAI.lPE:RlE'RACK"TASSEMBLY
Sl ide the brake cal iper and bracket assembly back-
ward and pull it off o f the slide rail on the 5wingarm.
Remove the brake hose oil bolt, seal ing washers

and brake hose eyelet.
DISASSEMBLY
Remove the bolts and brake disc cover.
Remove the caliper bracket from the ca liper body.

Remove the brake pad spring from the caliper body.
Remove the brake pad retainer from the caliper
bracket.
CALIPER BRACKET
'"DISC COVER
PAD SPRING
Remove the caliper pin boot and bracket pin boot.
16-21
HYDRAULIC BRAKE
If necessary. lightly apply compressed air to the cal-
iper ftuid inlet to get piston Qut.
Place a shop rag under the caliper to cushion the
piston when it is expelled.
Do nor bring the aif Use the air in short spurts.
nozzle too close to
the inlet or the
pistons may be
forced out with
excessive force that
could cause InIUry.
~ careful not fa Push the dust seal and piston seal in and l ift them
dBmsge the piston out. PISTON SEAL
sliding surface.
Clean the seal grooves, caliper piston and caliper
piston sliding surface wi th clean brake fluid.
INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.
Measure the caliper cvlinder 1.0.
Measure the caliper piston 0 .0 .

16-22
HYDRAULIC BRAKE
ASSEMBLY
Install the piston

s8al, dust seal and
caliper piston in
their proper
Coat new piston seal with clean brake fluid.
Coat new dust seal with silicone grease.
Install the piston and dust seals into the grooves in
the caliper body.
Coat the caliper piston with clean brake fluid and
install it into the caliper cylinder with its open end
st.
PISTON SEAL
~st
DUST SEAL
loca/ions.
facing the pad.
. . CALIPER
• PISTON
Install the brake pad retainer onto the caliper

bracket.
Install the pad spring into the caliper body.
Replace the caliper and bracket pin boots if there is
wea r, deterioration or damage.
Apply silicone grease to the inside of the boots then
install them.
Apply silicone grease to the caliper pin bolt sliding
area.
When assembling Assemble the caliper and bracket.
the caliper and
bradet. set the
boot Into the slide CALIPER
pin groove.
Install the brake disc cover and tighten the bolts

securely.
l
INSTALLATION
Install the brake hose eyelets to the caliper body
with new sealing washers and oil bolt.
"
DISC COVER
\ " SEALING WASHERS

""
16-23
HYDRAULIC BRAKE
Install the brake caliper/bracket assembly onto the
swingarm by aligning the bracket tab with the slide BRAKE CAILlPI'RlI'RA.CKIET ASSEMBLY
rail on the swingarm .
Install the rear wheel (page 15-13).
Install the brake pad (page 16-10),
Push the brake hose eyelet to the stopper on the cal·

iper. then tighten the oi l bolt to the specified torque.
TORQUE; 34 N'm (3.5 kgf·m , 25 Ibf.ft)

Install the caliper guard and tighten th e bolts
securely.
Fill and bleed the rear brake hydrauliC system (page
16-7).
BRAKE PEDAL
REMOVAL
Remove the clip, brake pedal pivot bolt, washer and
dust seals. T
Remove the return spring.
WASHER DUST SEALS

Remove and discard the cotter pin.
Remove the joint pin and brake pedal.
INSTALLATION
Connect the brake pedal to the push rod.
Install the joint pin and a new cotter pin.
-
16-24 •
HYDRAULIC BRAKE
Install the dust seals with their tip side facing out to
the brake pedal.
Apply grease to the sliding surface of the brake
pedal and pivot bolt.
Install the washer and pivot bolt.
Tighten the brake pedal pivot bolt to the specified
torque.
, ",) TORQUE: 36 N·m (3.7 kgf·m , 27 Ibf·ft )

Install the brake pedal clip securely.
Install the return spring.
16-25
MEMO
•
•
17. BATTERY/CHARGING SYSTEM
COMPONENT LOCATION ·.. ·.. · ...... ·.. ·.. · .... 17-2 BA TTERY .................................................. 17-6
SYSTEM DIAGRAM .. ································ 17-2 CHARGING SYSTEM INSPECTION········· 17-7
SERVICE INfORMATION ························· 17-3 REGULATOR/ RECTifiER ·········· ··············· 17-8
TROUBLESHOOTING ········· ······················ 17-5 ALTERNATOR CHARGING COIL············· 17·8
-
l
17-1
BATIERY/CHARGING SYSTEM
COMPONENT LOCATION
REGULATORIRECTIFIER
FUSE 15 A
A LTERNATOR
SYSTEM DIAGRAM
FUSE 15A
GYwrl. I eI
ALTERNATOR
C REGULATOR!
RECTIFIER
®
BATTERY
12V6AH •
G ; Green
A : Red
W: White
Y : Yellow
17-2
SERVICE INFORMATION
GENERAL
AWARNING
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequat e ventilation when
charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective
,"
, ,
clothing and a fa ce shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and cal l a physician immediately.
• Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician
immediately.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space.
• For a battery remaini ng in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• The battery sealing caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.
• The maintenance free battery must be replaced when it rea ches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if leh to discharge for a long period. These same con-
ditions 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 eventu·
ally die out, For this reason, the charging system is often suspected as the problem. Battery overcharge often results
from problems in the battery itself, which may appear to be an overchargi ng symptom. If one of the battery cells is
shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Unde r 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.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to
prevent sulfation from occurr ing.
• 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 initially charged.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-5).
• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or
extending the charging time may damage the battery.
BATTERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester. The recommended battery tester
puts a "load" on the battery so the actual battery condition of the load can be measured.
Recommended Battery Test er : Micro 404Xl (U .S.A. only), BM-210 o r equivalent
SPECIFICATIONS
~
TEM
f-TuS, I FuliV
0.1 mA max.
13.0 - 13.2 V
,« Need~
, Below 12.4 V
cur·
m"t
; 7. ) 'pm
17-3
TOOLS
Motorcycle battery analyzer Christie battery charger
Micro 404XL (U.S.A. only) MC101212T (U.S.A. only)
17-4
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. SA TTERY TEST
Remove the battery (page 17-6),
Check the battery cond ition usi ng the recommen ded battery teste r.
RECOMMENDED BATTERY TESTER:
Micro 404XL (U.S.A. only), BM·210 or equivalent
Is the battBry in good condition ?
NO - Faulty battery.
YES - GO TO STEP 2.
2. CURRENT LEAKAGE TEST
Insta ll the battery (page 17-6).
Check the battery cu rrent leakage test (l eak test; page 17-71,
Is the current leakage below 0. 1 rnA?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/ RECTIFIER CONNECTED
Disconnect the regula tor/rectifier connector and recheck the battery current leakage.
Is the current leakage below O. 1 rnA ?
YES - Faulty regulator/rectifier.
NO - Shorted wi re harness.
4. ALTERNATOR CHARGING COil INSPECTION
Check the alternator cha rging coi l !page 17-8).
Check for continuity between Yellow terminal and Ground, White term inal and Ground.
Is there continuity?
NO - Faulty charging coil.
YES - GO TO STE P 5.
5. CHARGING VOLTAGE INSPECTION
Measure and record the banery voltage u sing a digital mult imeter !page 17-6).
Start the engine.
Measu re the charging voltage (page 17-7).
Compare the measurements to the results of the following calculation.
STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage
=
• CV Charging Voltage
Is the measured charging voltage within th8 standard voltag87
YES - Faulty battery.
NO - GO TO STEP 6.
6. REGULATOR/ RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier connector (page 17-8).
Are the result of checked voltagB and resistance correct?
YES - Faulty regulator/rectifier.
NO _ . Open ci rcuit in rela ted wire
• Loose or poor contacts of related terminal
• Short ed wire harness
17-5
BATTERY
NEGATIVE
Remove the battery holder.
Disconnect the negative H cable and then the posi-
tive t+) cable, and remove the battery.
Connect the Installation is in the reverse order of removal.
positive termmal
After i nstalling the battery, coat the terminals with
first Bnd then the
clean dielectric grease.
negatwe cable.
VOLTAGE INSPECTION
Measure the battery voltage using a digital
multimeter.
VOLTAGE:
Fully cha rge d: 13.0 - 13.2 V
Under charged : Below 12.4 V
TOOL:
Digita l multimet er Commercially available in
U.S.A .
BATTERY TESTING
Remove the battery (page 17·6).
Refer to the instructions that are appropriate to the
battery testing equipment available to you .
TOOL:
Battery tester Micro 404Xl (U.S .A. only),
BM-2 10 or equ iva lent
BATTERY CHARGING (U.S.A. only)
Remove the battery (page 17-6).
Refer to the instructions that are appropriate to the
battery charging equipment available to you .
TOOL:
Christie battery charger M C101 2/2T (U.S.A. only)
17-6
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Disconnect the negative (-) cable from the battery.
Connect the ammeter (+) probe to th e negative H
cable and ammeter H probe to the battery H termi-
nal.
Check for cu rrent leakage.
NOTE : (-)CAB lE~_
When measuring current using a tester, set it to a
high range, and then bring the range d own to an
appropriate level. Current flow higher than the
range selected may blow the fuse in the tester.
SPECIFIED CURREN T LEAKAGE: 0.1 rnA m ax.
If cu rrent leakage exceeds the specified value, a
short ed circu it is likely.
locate the short by disconnecting connections one
by one and measuri ng the current.
CHARGING VOLTAGE INSPECTION

Be sur e the battery is in good condition before per-
forming this test.
Warm up the engine to normal operating tempera-
tu re.
Connect the multi meter between the battery posi-
tive (+1 and negative (-) terminals.
NOTE:
To prevent a short, make absolutely certain which
are the positive (+1 and negative (-) terminals or
cables.
Measure the voltage on the multi meter w hen the
engine runs at 5,000 rpm.
Sta ndard:
M easured BV < Measured CV < 15.5 V
=
• BV Battery Voltage
• CV = Charging Voltage
17-7
REGULATOR/RECTIFIER
SYSTEM INSPECTION
Remove the left side cover (page 3-3),
Disconnect the regulator/rectifier 4P (Natural) con-
necto r.
If the charging voltage reading (page 17-7) is out of
th e specification. check the following at the wire
harness side connector:
Item Tanninal Specification
Banerycnarging Redlwhite !+l Banery voltage
line and round H shou ld ra ister
Yellow and Continuity
Charging coil ground should exist
line White and
ground
Continuity
should exist 4PCO~~Tta
Grou nd line Green and Continu ity
ground should exist
If all lines are normal and there are no loose connec-
tions at the regulator/rectifier connector, replace the
regulator/rectifier unit.
Remove the left side cover (page 3-3) ,
Remove the wire band.
Disconnect the regulator/rectifier 4P (Natural) con-
nector.
Remove the nut and regulator/rectifier.
Align the regulator/ Insta llation is in the reverse orde r of removal.
rectifier Iocs ting pin
with the hole on the
brecket.
4P CONNECTOR
ALTERNATOR CHARGING COIL

INSPECTION
Remove the left radiator shroud (page 3-4J.
Disconnect the alternator 4P (Black) connector.
Check for continuity between the terminal of the
alternator side connector and ground.
CONNECTION: Yellow tenninal - Body ground
White termina l - Body ground
If any wire has no continuity to ground. repla ce the
alternator stator.
For stator removal (page 12-5).
17-8
18. IGNITION SYSTEM
COMPONENT LOCATION ........................ 18-2 IGNITION CONTROL MODULE (lCM) ····· 18-7
SYSTEM DIAGRAM .. ·· ··············· ······· ········ 18-2 IGNITION COIL ......................................... 18-7
SERVICE INFORMATION ......................... 18-3 IGNITION TIMING ................................ .... 18-8
TROUBLESHOOTING .............. ................. 18-4 THROTILE POSITION SENSOR

INSPECTION ············································· 18-9
IGNITION SYSTEM INSPECTION ............ 18-5
18-1
IGNITION SYSTEM
COMPONENT LOCATION
'05 - '07 shown:
ENGINE STOP Rlrrrn,N THROTILE pn'SITION SENSOR
ImmlnN COll
IGNIiTlClN CONTROL
MODULE oeM)
SPARK PLUG ALT..,NOTOR IGNITION PULSE GENERATOR
SYSTEM DIAGRAM
.... ,,' Ilu'GvLGIN 1 OM "'"

'"
@ ctj) ,• ....
.. , .
Yellow
IGNITION
PULSE GENERATOR . ""
W
G
White
G.",,"
81 ...
s~,u
R
IGNITlON ENGINE STOP
"''' ~Nm ON CONTROl MOOOLE

loeMl r~N
it PlUG THROTTlE
""moN
seNSOR
18-2
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
NOTICE
• The leM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive vo/t-
age may damage the module.
• Use a spark plug of rhe correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
• When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 18-4.
• The ignition timing cannot be adjusted since the Ignition Control Module UCM) is factory preset.
• A faulty ignition system is often related to poor connections. Check connections before proceeding.
SPECIFICATIONS
resistance
4-SIill
TORQUE VALUE
Timing hole cap 10 N·m (1.0 kgf.m, 7 Ibf.ft) Apply grease to the threads
TOOLS
Peak voltage adaptor Ignition Mate peak voltage tester

07HGJ·0020100 MTP07-0286 (U.S.A. only)
with commerCially available digital

'" multimeter (impedance 10 MOJDCV
minimum)
18-3
IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water got into the spark plug cap (affecting the ignition coil secondary voltage)
• If there is no spark at cylinder, temporarily exchange the ignition coil with a known good one and perform the spark
test. If there is spark, the original ignition coil is faulty.
No spark at plug
,
primary
"
voltage
6. i (measure the resistance).

7. ;gn;t;o, coil the resistance).
normal i voltage
with reverse connection).
2. Short ci rcuit in engine stop button wire.
3. Faulty engine stop bunon.
4. Loose or poo rl y connected leM connectors.
5. An open circuit or loose ignition coil wire.
6. Faulty exciter coil (measure the resistance).
7. Faulty ignition pulse generator (measure the peak volt-
cu r-
generator DCV.
2. Cranking speed is too low.
- Kickstarter is weak
- Battery is undercharged
3. The sampling timing of the tester and measured pulse
were not synchronized (System is normal if measured
vodtage;i,s over the standard at least once).
•
•
18-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spa rk at the plug, check all cennec- , - -- - - - - - - : - - : -- - - - - - - - - ,
tions for loose or poor contact before measuring DIGITAL MULTIMETER
• ~~~h ~~a~:C~~~~nded digital multi meter or a

commercially available digital multi meter with
,.~.~_-,._---
..... ' \ \..~
.
.. ;. ~~;:,dua~,~
I=
e 10 MOJDCV
an impedance of 10 M!lIDCV minimum.
• The display value differs depending upon the : '. .
internal impedance of the multi meter. <. . 00
Connect the peak voltage tester (lgnitionMate,
U.S.A. only) or peak voltage adapter to the digital
multi meter.
TOOLS:
IgnitionMate peak vottage tester MTP07-0286
(U .S.A . only) or PEAK VOLTAGE ADAPTOR
\
Peak voltage adaptor 07HGJ· 0020100
(not available in
U.S.A.)
w ith commercially available digital multi met er
(impedance 10 M fl/ DCV minimum)
IGNITION COIL PRIMARY PEAK

VOLTAGE
Check all system connect ions before inspection.
If the system is disconnected, incorrect peak vol tage
might be measured.
Check cylinder compression and check that the
spa rk plug is inst alled correctly.
Remove the fu el tank (page 3-8).
Shift the transmission into neutral.
Connect a known'good spark plug to the spark plug
cap and ground the spark plug to the cyli nder as
done in a spark test.
With the ign ition coi l primary wire connected, con-

nect the peak voltage adaptor to the ignition coi l .
re;;~~~~~i=====~
TOOLS :
IgnitionMate peak voltage tester MTP07·0286
(U .S.A. only) or
Peak voltage adaptor 07HGJ-0020100
(not available in
U .S.A .)
w ith commercially available digital multi meter
(impedance 10 M fl/ DCV minimum)
CONNECTION: Body ground 1+) - Black/ yellow H

Shift the transmission into neutra l.
Crank the engine and read the ignition coi l primary
peak voltage.
STANDARD: 100 V minimum
If there is no voltage, check the continuity in Black!

yellow and Green/black wires between the ignition
coil and ICM.
If the wires are good, follow the checks described in
the troubleshooting chart on page 18·4.
18-5
IGNITION SYSTEM
EXCITER COIL RESISTANCE
Remove the radiator shroud (page 3-4),
Disconnect the alternator 4P (Black) connector.
Measure the exciter coil resistance between the
connector terminals.
CONNECTION : Black/red - Blue
STANDARD: 9 - 28 (} (20"C/ 68°F)

If resistance is out of specification, replace the alter-
nator.
IGNITION PULSE GENERATOR PEAK

VOLTAGE
Remove the left side cover (page 3-3), ICM 6P (NATURAL) CONNECTOR
Disconnect the leM 6P (Natu ral) connector.
Connect the peak voltage adaptor probes to the con-
nector termi nals of the wire harness side.
TOOLS:
IgnitionMate peak voltag8 tester MTP07·0286
(U.S.A. only) o r
Peak \/oltage adaptor 07HGJ·0020100
(not available in
U.S.A.'
with commerci ally available digital multimeter
(impedance 10 M O/DCV minimum)
CONNECTION: Blue/ yellow f+) - Green/ white (- )

Crank the engine and read the peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured is abnormal, recheck
the following:
Remove the left side radiator shroud (page 3-4).
Disconnect the ignition pulse generator 2P (Black)
connector.
Connect the peak voltage adapter to t he connector
terminals of the ignition pulse generator side and
recheck the peak voltage.
If the peak voltage at the ICM connector is abnormal
and peak voltage at the ignition pulse generator
connector is normal, check for poorly connected
connectors or a broken wire harness.
If the peak voltage is abnormal at both connectors,
follow the checks described in the troubleshooting
chan on (page 18-4).
18-6
IGNITION SYSTEM
IGNITION CONTROL MODULE (lCM)
Remove the leh side cover (page 3-3),
Disconnect the reM connectors.
Remove the reM from the rBar fender.
Installation is i n the reverse order of removal.
IGNITION COIL
INSPECTION
Remove the fu el tank (page 3-8l.
GROUND
Remove the spark plug cap.
Disconnect the ignition coil primary wire.
Measure the ignition coil resistance between the
primary terminal and body ground.
STANDARD: 0.1 - 0.3 0 (20°C/ 68°F)
If the resistance is out of specification, replace the
ignition coil.
Measure the ignition secondary coil resistance ~::::::;;::"';:;::;::;;::;;;;";;i:-=;;r-:::-~::::;:~

between the primary terminal and plug cap.
STANDARD: 9 - 16 kn (20°C/68°F)
If resistance is out of range, remove the spark plug

cap and measure the ignition secondary coil resis-
tance between the primary t ermi nal and spark plug
wire.
STANDARD: 4 - 8 kO: (20 c C/68°F)

If the resistance is out of specification, replace the
ignition coil.
18-7
IGNITION SYSTEM
AemO\fB the following:
- Left radiator grill (page 7-8)
- Spa rk plug cap (page 4--12 )
Remove the left radiator lower mounting bolt,
washer and slide the left radiator forward .
Disconnect the ignition coil primary wire.
Remove the botts, nut, hose clamp and ignition coil.
REMOVALIINSTALLATlON (After '07)

- left radiator grill (page 7-8)
- Spark plug cap (page 4-12 )
Remove the left radiator lower mounting bolt and
slide the left radiator forward .
Release the siphon hose from the ignition coil stay

clamp. I!-~~~Ot:;:-~~~~~~~~~III!!:~~l
Disconnect the ignition coil primary wife connector.
Remove the bolt and ground wire.
Remove the ignition coil/stav by unhooking the igni· BOSS
tion coil stay boss from the left radiator lower
mount
IGNIITIC;N COIL
HOSE
IGNITION TIMING
NOTE:
• The ignition timing is factory preset and onlv
needs to be checked when an electrical system
component is replaced.
Warm up the engine to normal operating tempera-
ture.
Stop the engine and remove the timing hole cap.
Connect the timing light to the spark plug wire.
18-8
IGNITION SYSTEM
Attach a tachometer according to its manufacture's
instructions.
Read the instruction for timing light operation.
Start the engine and hold it at 1,800 ± 100 rpm while
pointing the timing light towards the index notch .
The ignition timing is correct if the "F" mark on the
flywheel aligns with the index notch in the left
crankcase cover.
Check that the O-ring is in good condition, replace it

if necessary.
Apply oil to the O-ring and install it onto the timing
hole cap.
Apply grease to the timing hole cap threads. ,.-
Install the timing hole cap and tighten it to the spec-
ified torque.
TORQUE: 10 N'm 11.0 kg f·m . 7 Ibf ·ftl
THROTTLE POSITION SENSOR

INSPECTION
3P (BLACK) CONNECTOR
Disconnect the throttle pOSition sensor 3P (Black)
connector.
Measure the resistance between the Blue and Black
wire terminals of the sensor side connector.
••
(
Check that t he resistance between the Yellow and
Black wire terminals varies with the throttle position BLUE YELLOW
while operating the throttle grip.
Fully closed-Fully open position:

Resist ance increases BLUE
Fully open-Fully closed position:
Resist ance decreases
If both measurements are abnormal, repla ce the
th rottle position sensor (page 6-26).
BLACK
BLACK
18-9
MEMO
19. ELECTRIC STARTER
,r
COMPONENT LOCATION ··· ······· ··············19-2 TROUBLESHOOTING ······· ··········· ············· 19-4
SYSTEM DIAGRAM ·································· 19-2 STARTER MOTOR ···································· 19·6
SERVICE INFORMATION ........................ · 19-3 STARTER RELAY SWiTCH .. ................ ·.. 19-13
19-1
ELECTRIC STARTER
COMPONENT LOCATION
'05 - '07 shown:
STARTER SWITCH
eLlJTe:H SWITCH
BATIERY
STARTER RELAY SWITCH/FUSE 15 A
<n•• TO'. MOTOR
SYSTEM DIAGRAM
STARTER
MOTOR
STARTER n~:g):;=l-l e
RELAY FUSE
SWITCH 15A
BATTERY
12V6AH
VIR G BI RIW
-rn--- -----o~
l'-o-
CLUTCH
SWITCH
BIIB<
' - - - - - - - - BVA
BI
STARTER
.-l
SWITCH
- - - --1>1::1-- - - '
l TO REGULATOR!
RECTIFIER BI : Black
Y : Yellow
G : Green
•
A : Red
Br : Brown
W : White
19-2 •
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
[ NOTICE
If the current is kept flowing through the s tarter motor to turn it while the engine is not cranking over, the starter motor
m8y be damaged.
• The starter motor can be serviced with the engine i n the frame.
• When checking the electric starter system, always fol low the steps in the troubleshooting (page 19·4).
• Always disconnect the negative cable at the banery before servicing the starter motor. The motor could suddenly start,
causing serious injury.
• A weak battery may be unable to turn the starter motor quickly enough. or supply adequate ignition current.
Refer to the following components information.
- Engine stop button (page 20-7)
- Starter switch (page 20-9)
- Clutch switch (page 20-8)
- Starter clut ch (page 11 -19)
SPECIFICATION
ITEM STANDARD SERVICE LIMIT
Starter motor brush length 10.25 (0.404) 6.75 (0.266)
TORQUE VALUE
Starter motor case bolt 3.4 N·m (0.3 kgf·m, 2.5 Ibf·ft )
19-3
ELECTRIC STARTER
TROUBLESHOOTING
Starter motor does not turn
1. Fu se Inspection
Check for blown fuse (15 Al.
Is th e fuse blown?
YES - Replace the fuse.
NO - GO TO STEP 2.
2. Batte ry Inspection
Make sure the battery is fully charged and in good condition.
Is the baHery in good condition?
YES - GO TO STEP 3.
NO - Charge or replace the battery (page 17-6),
3. Starter Relay Switch Operation
Check the starter relay switch operation.
You shou ld hear the relay " CLlCK~ when the starter switch is depressed and pull the clutch lever.
Is th ere 8 "CUCK"l
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. Starter Motor In spection
Apply battery voltage directly to the starter motor and check the operation.
Does the starter motor tum?
YES - . Poorly connected starter motor cable
• Faulty starter relay switch
NO - Faulty starter motor.
5, Relay Coil Ground Line Inspection
Disconnect the starter relay switch connector, then check for continuity between the green w ire ter-
minal of the wire harness side and body ground.
NO _ . Open circuit in wire harness
• Loose or poor contact connector
YES - GO TO STEP 6,
6, Starter Relay Switch Input Line In spection
Connect the starter relay switch connector,
Pull the clutch lever and engine starter switch is pushed, measure the voltage at the starter relay
switch connector (between Yellow/red (+1 and body ground HI.
Is the input line normal?
YES - GO TO STEP 7.
NO _ . Faulty clutch switch (page 20·8)
• Faulty engine starter switch (page 20·9)
•
•
Loose or poor contact of the related connector terminal
Open circuit in the wire harness •
19-4 •
ELECTRIC STARTER
7. Starter Relay Switch Continuity In spection
Connect the staner relay switch connector.
Pull the clutch lever and engine staner switch is pushed, check for continuity at the starter relay
switch.
YES - Loose or poor contact of the starter relay switch connector.
NO - Faulty starter relay switch.
r,
,, Starte r motor turns engine slowly
• l ow battery voltage
• Poorly connected battery cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected ground cable terminal
Starter motor turns, but engine does not t urn
• Sta rter motor is running backwards
- Case assembled improperly
• Faulty starter clutch
• Damaged st arter gear train
Starter relay swit ch clicks, but engine does not turn over
• Crankshaft does not turn due to engine problems
19-5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
• Remove the negative cable at the banery before
servicing the starter motor.
Remove the cylinder (page 10-5),
Remove the rubber cap from the starter motor ter-
minal.
Remove the nut and disconnect the starter motor
cable.
Remove the mounting bolts, and starter motor from
the crankcase.
OISASSEMBLY/INSPECTION
Remove the D-ring.
O-RING
Remove the motor case bolts.
Record InelocallOfl Remove the following:

and number of
shims.
-
-
-
Front cover
Insulated washer
Shims
FRONTCDVER
•
- Seal rings
- Washer
- Motor case
- Armature
MO'TORCASE ARMATURE
INSULATED WI'S,IER
19-6 •
ELECTRIC STARTER
Record the location Remove the shims.
and number of
shlms_ SHIMS
'.
Remove the brush spri ngs.
BRUSH SPRINGS
Check for continuity between the cable terminal and

insulated brush. Continuity:
There should be continuity.
Check for continuity between the cable terminal and

rear cover. No Continuity:
There should be no continuity.
19-7
ELECTRIC STARTER
Remove the followi ng:
- Screws
- Brush
- Washers
- Brush holder
- Insulator p lates
BR USH HOLDER INS ULATOR PLATES
- Nut
NUT
Record the location - Washer

Bndnumberol - Insulators TERMINAL BOlTIlNSULATOR
insulators. - D-ring
- Termi nal bolt/insulator INSU LATORS
WASHER
D-RING
Measure the bru sh length.
19-8 •
ELECTRIC STARTER
Do not use emery Inspect the commutator bars of the ar mature for
or sand PBper on discoloration. COMMUTATOR
the commutator.
ARMATURE
Check for continuity between pai rs of commutator

bars. Continuity: COMMUTATOR BARS
There should be continuity.
Check for continuity between each commutator bar

and armature shaft. No Continuity: COMMUTATOR BAR
There should be no continuity.
ARMATURE SHAFT
19-9
ELECTRIC STARTER
ASSEMBLY
DUST SEAL
WASHER
FRONT COVER
BRUSH SPRING SHIMS

WASHER
MOTOR CASE
REAR COVER
~~-----" 3.4 N·m lO.3 kgf.m, 2.5 Ibf·ft)

INSULATOR
- Insulator
- Terminal bolt
TERM INAL BOLT
- New O-ring
- Insulators INSULATORS
- Washer
- Nut
D-RING 111
19-10 •
ELECTRIC STARTER
Insulator plates
- Brush holder
- Washers
- Brush
- Screws
r.
- Brush springs
BRUSH SPRINGS
Apply grease to the armature shaft end.

Inslal/ the shims Install the shims onto the armature shaft.
properly as noted Install the armature onto the rear cover while push-
during removal. ing the brushes into the brush holder.
Align the mo tor Install a new seal ring and motor case to the rear
case groove to the cover while holding the armature tightly to keep the REAR COVER
(
insula/or tab. magnet of the casa from pulling the armature
against it.
RING Ii!!
I NOTICE I
The coil may be damaged if the magnet pulls the
armature against the case.
Align
19-11
ELECTRIC STARTER
Apply grease to the oil seal lip and needle bearing in
the front cover. WASHER
Install the washer by aligning its tabs to the front

cover grooves.
Install the shims and insulated washer onto the

....
Ins/till the shims
properly8S nOled armature shah. RING ~ FRONT COli ER
dvrmQ remoV8l. Install a new seal ring onto the motor case.
Install the front cover being ca reful not to damage
the oi l seal l ip.
WASHER
Tighten the motor case bolts to the specified torque.
TORQUE: 3.4 N'm 10.3 kgf·m, 2.5 Ibf.ft)
SOL
Coat a new O' ring with oil and install it into the
starter motor groove, O-RING " ,
19-12 •
ELECTRIC STARTER
INSTALLATION
Install the starter motor onto the crankcase.
Install and tighten the starter motor mounting bolt.
Install the starter motor cable and terminal nut onto
the motor terminal.
Tighten the nut securely.
Insta l l the rubber cap over the motor terminal prop-
erly.
Install the cylinder (page 10-10).
'-
STARTER RELAY SWITCH

INSPECTION
Remove the left side cover (page 3-3),
Pull the clutch lever fully, and push the engine
starter switch .
If the starter relay switch "CLICK", the coil is normal.
If you don 't hear the switch "CLICK", inspect the
starter relay switch using the procedure below.
GROUND LINE
Disconnect the starter relay switch 4P connector. I]~~:~~~
Check for continuity between the Green wire termi-
nal of the wire harness side connector and ground.
Ifthere is continuity, the ground circuit is normal.
19-13
ELECTRIC STARTER
POWER INPUT liNE
Connect the starter relay switch 4P connector.
Pull the clutch lever fully, and push the starter
switch.
Measure the voltage between the Yellow/red wire
terminal (+) and ground H.
If the battery voltage appears only when the clutch
lever is pu lled fully and starter switch is pushed, the
circuit is normal.
OPERATION CHECK
Remove the starter relay switch (page 19-14),
Connect a fully charged 12 V battery positive wire to
the relay switch Yellow/red wire terminal and the
negative wire to the Green wire terminal.
There should be continuity between the cable termi-
nals when the battery is connected, and not con t inu-
ity when the battery is disconnected.
Remove the left side cover (page 3-3).
Disconnect the starter relay switch 4P connector .
Pull out the starter relay switch from the rear fender.
Remove the bolts and disconnect the starter motor

and battery positive (+) cables.
19-14 •
20. LIGHTS/METER/SWITCHES
COMPONENT LOCA nON ........................ 20-2 ENGINE STOP BunON .......................... 20·7
SERVICE INFORMATION ·········· ·········· ·····20-3 CLUTCH SWITCH .................... ................. 20·8
HEADLIGHT··············································· 20-4 STARTER SWITCH ........... ........................ 20-9
TAIL LIGHT ................................................ 20-6 TRIPMETER ············································· 20·10
20-1
COMPONENT LOCATION
'05 - '07 show n:
STARTER SWITCH
CLUTCH SWITCH
ENGINE STOP BUnON
TAIL UNIT
•
20-2
SERVICE INFORMATION
GENERAL
I NOTICE
• A halogen headlight bulb becomes very hot while the headlight is ON, and remain hot for 8 while after it is turned OFF.
8e sure to let it cool down before servicing.
• Note the following when rep/acing the halogen headlight bulb.
,.-. - Wear clean gloves while replacing the bulb. Do not pur finger prints on the headlight bulb, as they may create hot
spots on the bulb and cause is to fail.
,. I - If you touch the bulb with your bare hands, clean it with a cloth moistened with denatured alcohol to prevent its early
failure.
- Be SUfe to install the dust cover afrer rep/acing the bulb.
• Check the battery condit ion before performing any inspection that requires proper battery voltage.
• A continuity test can be made with the switches installed on the motorcycle.
SPECIFICATIONS
ITEM SPECIFICATIONS
Headright 12 V 35W
Taillight LED
Fuse 15 A
TORQUE VALUES
Headlight mounting screw 0.7 N·m (0.1 kgf·m, 0.5 Ibf.ft)
Taillight mounti ng screw 4.2 N'm (0.4 kgf·m. 3. 1 Ibf.ft)
Taillight wire clamp screw 0.7 N·m (0.1 kgf·m, 0.5 Ibf.ft)
20-3
HEADLIGHT
BULB REPLACEMENT
Remove the front visor.
'05 - '07:
- '05 - '07: (page 3-5) /.
- Afte r '07: (p age 3-6)
I~
W hile pushing the bulb secket, turn it counterclock-

wise and remove the bulb socket.
Remove the bulb.
I NOTICE I
Avoid touching the halogen headlight bulb. Finger
prints can create hot spots that cause a bulb to
break.
Install a new bu lb into the headlig ht unit w hile

al igning the tab with the groove of the headlight
unit.
If you touch the bulb with you r bare ha nds, clean it
w it h a cloth moistened with denatu red alcohol to
prevent early bulb fail u re.
20-4 •
While pushing the bulb socket, tu rn it clockwise and
install the bulb socket.
Install the dust cover tightly against the head light

unit w ith its ~TOP" mark facing up.
Instal l the front visor.
- '05 - '07: (page 3-5)
- After '07: (page 3-6)

Remove the front visor (page 3-5). 'ADJUSTI NG SCREWi' CLAMP
l Remove the vertical beam adjusting screw, spring, '~~~'~.~-:

mounting screws, clamp and headlight unit. !:
Inst allat ion is in the reverse order of removal.
TORQUE:
Headlight mounting screw:
0.7 N'm (0.1 kgf-m. 0.5 Ibl·tt)
Adjust the headlight aim (page 4-3 1),
20-5
REMOVAL/INSTALLATION (After '07)
Remove the front visor (page 3-6).
Remove the vertical beam adjusti ng sc rew, spring,
mounting screws and headlight unit.
TORQUE :
Headlight mounting screw:
0.7 N'm (0.1 kgf-m, O.5Ibf.ft)
Adjust the headl ight aim (page 4-31)'
HEADLIGHT UNIT
TAIL LIGHT
INSPECTION
Start the engine and check the t aillight il lumination.
TAIL LIGHT UNIT
If any LED does not tu rn on, replace the tail light
unit.
REMOVALIINSTALLA TION
Remove the fol lowing:
CONNECTORS
- Seat (page 3-3)
Disconnect the tai llight wi re connectors.
Remove the screws and wire clamps.
Remove the screws, stay and taillight unit.
TORQUE:
Taillight mounting s crew:
4.2 N·m (0.4 kgf·m , 3.1 Ibf.ft)
Ta illight wire clamp screw:
0.7 N·m (0.1 kgf·m , 0.5Ibf.ft)
20-6 •
ENGINE STOP BUTTON
INSPECTION
'05 - '07:
- '05 - '07: (page 3-5)
- After '07: (page 3-6)
Disconnect the engine stop button 3P (Black) con-
necto r.
Check for continuity between the Blacklwh ite termi-

nal and Black/green terminal.
There should be continuity with the engine stop but-
ton depressed. and no continuity with the button
released.
20-7
LIGHTS/ METER/SWITCHES
CLUTCH SWITCH
INSPECTION
'05 - '07:
- '05 - '07: (page 3-5)
- Aher '07: (page 3-6)
Disconnect the engine stop button 3P (Black) con-
nector and clutch switch wire (Black/red) connector.
Check fDr continuity between the Black/brown ter-

minal and Black/red wire connector.
There should be continuity with the clutch lever
squeezed, and no continuity with th e cl utch lever
released.
If the continuity is abnormal. remove the clutch
switch (page 20-8).
REMOVAUINSTALLA TION
Remove the boot.
Remove the screw, stay, clutch switch and discon-
nect the connectors.
20-8
LIGHTS / METER/SWITCHES
Check for continuity between the clutch switch ter-
minals. CLUTCH SWITCH
/
There should be no continuity with the switch
pushed, and there shou ld be continuity with the
switch is released.
If the continuity at the connectors is abnormal and
the continuity at the clutch switch terminal is no(-
mal, check the connectors for loose connection and
the wire harness for an open circuit o r loose con-
nection.
STARTER SWITCH
INSPECTION
'05 -'07:
- '05 - '07: (page 3-5)
- Aher '07: (page 3-6)
Disconnect the starter switch 2P (Black) connector.
Check for continuity between the starter switch con-

nector terminals (Yellow/red and Black).
There should be continuity with the starter switch
pushed and no continuity with the switch released.
SHIRTI'R SWITCH
20-9
TRIPMETER
- '05 - '07: (page 3-5)
- After '07: (page 3-6)
Loosen the lock nut and disconnect the tripmeter
cable.
'05 - '07: Remove the nuts, washers and tripmeter.
Afrer '07: Remove the nuts, cable guide and tri pmeter.
Install ation is in the reverse order of removal. •
TRIPMETER
CABLE
20-10 •
21. WIRING DIAGRAM
WIRING DIAGRAM .................... ............... 21 -2
21-1
N :E
,
~ § 22
N
-Z
::0 z
Cl
STARTER SWITCH ENGINE STOP eU1TON I <" I C'l 0
ClUlCtl SWITCH
IIIIII IIIII •I c i>

<-
," - .~m~ m~L
- '"
»
Cl
~
C'l s:
~621
~~
STARTER MOTOR
-,
~. .~m~ m~~ ~~>'" 0
::0
»
I~ .@ ~
~; m~ "0
~M
'u ~ ~
(~ JU ';!-j iJ-~ '-- BI-(]d-IM
-~,AlLUGHT
-
"~"""
~
,~ '05-'01:8u
m
.~.
~~ J;>.i~
~~ ~
'
I
Tl'SENSOR
.-
IGNtTIOH PUlSE GENERATOJI
ENGlNeSTOl'IIIJfTOfII
~§W
~
STMT'EIIS'MTtH
~
, - w
,
...
•
22. TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT HIGH

TO START ................................................. 22·2 SPEED ...................... .............. ................... 22·6
ENGINE LACKS POWER ·························· 22·3 POOR HANDLING ..................... ............... 22·7
POOR PERFORMANCE AT LOW AND IDLE

SPEED ························································ 22·5
22-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Fuel Line Inspection
Check fuel flow to carburetor.
Does fuel reach the carburetor?
NO - . Clogged fuel hose or fuel strainer
• Clogged fuel valve
• Clogged fuel tank breather hose
YES - GO TO STEP 2.
2. Spark Plug Inspection
Remove and inspect spark plug.
Is th tt spark plug wet?
YES _ . Flooded carburetor
• Throttle valve open
• Dirty air cleaner
• Improperly adjusted pilot screw
NO - GO TO STEP 3.
3. Spark Test
Perform spark teS1.
Is there weak o r no spark ?
YES _ . Faulty spark plug
• Fou led spark plug
• l oose or disconnected ignition system wi res
• Broken or shorted ignition coil wire
• Faulty ignition coi l
• Faulty igniting pulse generat or
• Fau lty exciter coil
• Faulty engine stop button
• Faulty ignition control module (leM)
NO - GO TO STEP 4.
4. Engine Starting Condition
Start engine by normal procedure.
Does the engine start then stops?
YES - . Improper choke operatio n
• Incorrectly adjusted carburetor
• l eaking carburetor insulator
• Improper ignition timing (Faulty leM or ignition pulse generator)
• Contaminated fuel
• Improper hot start operation
NO - GO TO STEP 5.
5. Cvlinder Compression Inspection
Test cylinder compression.
Is the compression low?
YES - . Valve clearance too small
•
•
•
Va lve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
•
• Seized valve
• Improper valve timing
• '05 - '07: Faulty decompressor cam
• After '07: Faulty decompressor shaft
22-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train In spection
Raise wheel off the ground and spin by hand.
Did the wheel spin freel y?
NO _ . Brake dragging
• Worn or damaged wheel bearings
• Bent axle
• Drive chain too tight
YES - GO TO STEP 2.
2. Tire Pressure Inspection
Check tire pressure.
Is the tire pressures low?
YES _ . Faulty tire valve
• Punctured tire
NO - GO TO STEP 3.
3. Clutch Inspection
Accelerate rapidly from low to second.
Did the engine speed change accordingly when clutch is engaged?
NO _ . Clutch slipping
• Worn clutch discs/plates
• Warped clutch discs/plates
• Weak clutch spring
• Sticking clutch lifter
• Additive in transmission oil
YES - GO TO STE P 4.
4. Engine Condition Inspection
Accelerate lightly.
Did the engine speed increase?
NO _ . FueVair mixture too rich or lean
• Clogged air cleaner
• Restricted fuel flow
• Clogged muffler
• Clogged fuel tank breather hose
• Carburetor choke is on
• Excessive carbon bui ld-up in combustion chamber
YES - GO TO STEP 5.
5. Engine Knocking Inspection
Accelerate or run at high speed.
Is there knocking?
YES _ . Worn piston and cylinder
• Use of poor quality fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advance (Fau lty leM )
• Lean fuel mixture
NO - GO TO STEP 6.
6. Ignition Timing Ins pection
Check ignition timing .
Is the ignition timing correct?
NO _ . Faulty ignition cont rol module OCM)
• Faulty ignition pulse generator
YES - GO TO STEP 7.
22-3
TROUBLESHOOTING
7. Cylinder compression Inspection
Test the cylinder compression.
Is the compression lowl
YES _ . Valve clearance too small
• Valve stuck open
• Worn cylinder and pisto n rings
• Damaged cylinder head ga sket
• Improper valve timing
• Faulty decompressor system
• '05 - '07: Fa ulty decompressor cam
• After '07: Faulty decompressor shaft
NO - GO TO STEP 8.
8. Carburetor Inspection
Check carburetor for clogs.
Is the carburetor for clogged?
YES _ . Ca rbur etor not serviced frequently enough
• Ca rburetor dirty
• Dirt getting past ai r cleaner
NO - GO TO STEP 9.
9. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug fouled or discolored?
YES _ . Plug not serviced frequently enough
• Incorrect spa rk plug heat range
• Incorrect spark plug gap
NO - GO TO STEP 10.
10. Engine Oil Inspection
Check oil level and condition.
Is the level correct lind good condition?
NO _ . Oil level too high
• Oil level too low
• Contaminated oil
YES - GO TO STEP 11.
11 . Over Heating Inspection
Check engi ne overheating .
Is the engine overheating?
YES - . Coolant level too low
• Excessive carbon build-up in combustion chamber
• Use of poor quality fuse
• Clutch slipping
NO - GO TO STEP 12.
12. lubrication Inspection
Remove cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
NO _. Fau lty oil pump
•
• Fau lty pressure relief valve
• Clogged oil passage
• Clogged oil strainer
YES - Valve train lubrication is normal.
22-4 •
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Pilot Screw Inspection
Check carburetor pilot screw adjustment.
Is the adjus tment correct?
NO - See page 6-27.
YES - GO TO STEP 2.
2. Accelerator Pump Inspection
Check accelerator pump for clogs.
Is the Bees/erator pump cioggBd7
YES - Accelerator not serviced frequently enough.
NO - GO TO STEP 3.
3. Intake Air Leak Inspection
Check for leaking carbu retor insulator.
Is there lesking ?
YES _ . Loose carburetor insulator band s
• Damaged insulator
NO - GO TO STEP 4.
4. Spark Test
Perform spark test.
Is thera wesk or Intermittent spark ?
YES _ . Faulty spa rk plug
• Fou led spa rk plug
• Loose or disconnected ignition system wires
• Broken or shorted ignitio n coil wire
• Faulty ignit ion coil
• Fau lty ignition pulse generator
• Faulty exciter coil
• Fau lty engine stop button
• Faulty ignit ion control module OCM )
NO - GO TO STEP 5.
5. Ignition TIming Inspection
Check ignition timing.
YES - Ignition timi ng is normal.
NO _ . Faulty ignition control module (ICM)
• Faulty ignition pu lse generator
22-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1. Fuel line Inspection
Disconnect fuel line 8t carburetor.
Does fuel flow freely ?
NO _ . Clogged fuel line
• Clogged fu el tank breath er
• Fau lty fuel valve
• Clogged the fuel strainer screen
YES - GO TO STEP 2.
2. Carburetor Inspection
Check carburetor for clogs .
Is the carburetor clogged?
YES - Carburetor not serviced frequently enough.
NO - GO TO STEP 3.
3. Ignition Timing Inspection
Check ignition timing .
NO _ . Faulty ignition control module oeM)
• Faulty ignition pulse generator
YES - GO TO STEP 4.
4. Valve Timing Inspection
Check valve timing.
Is the valve timing correct?
NO - Cam chain not installed properly.
YES - GO TO STEP 5.
5. Valve Spring Inspection
Check valve springs.
Are the vslve springs weak?
YES - Faulty \181\18 spring .
NO - Not weak.
22-6
TROUBLESHOOTING
POOR HANDLING
Steering is heavy
• Steering stem adjusting nut adjusted too tight
• Damaged steering head bearings
• Low tire pressure
• After '07: Faulty steering damper
Either w heel is wobbling
• Excessive wheel bearing play
• Bent rim
• Im properly installed wheel hub
• Excessively worn swingarm pivot bearings
• 8ent frame
The motorcycle pulls to one side
• Front and rear wheels not aligned
• Bent fork
• Bent swingarm
• Bent axle
• Bent frame
NOTE :
• For the following recommendations to be useful, the motorcycle must be adjusted as follows:
- Fork: compression damping at standard position, at standard f ork oi l quantity and viscosity, and air
pressure zero.
- Shock: nitrogen pressure 142 pSi, compression and rebound damping standard position, and
spring preload adjusted so t he bikes sags with rider seated· see Owner's manual for spring pre·
load adjustment
• The follow ing recommendations are given in the preferred sequence of adjustment
Front End Oversteers; It Cuts Too Sharply (such as in send)
• Increase the f ork oil capacity
• Use stiffe r fork spring
Front End Understeers; It Washes Out Or Pushes (such as on at tight track with hard ground)
• Lower fork oil capacity
• Use softer fork spring
Front End Hunts At High Speed; It Wanders Under Power
• Increase the fork oil capacity
• Increase the shock preload
Front End Shakes Under Heavy Braking
• Decrease shock preload
• Increase shock rebound damping
• Increase the f ork oi l capacity
Front End Hops Over Bumps In Smooth Turn s
• Ch ange to lighte r fork oil
• Decrease the f ork oil capacity
• Decrease fork compression damping
• Use softer fork spring
Rear End Hops Over Bumps While Accelerating
• Decrease shock compression damping
Rear End Gets Poor Traction White Accelerating Away From A Corner
• Decrease shock compression damping
22-7
MEMO
23. INDEX
ADDITIONAL ITEMS REQUIRING FREOUENT CYLI NDER HEAD COVER REMOVAL ...... .. .. .. .. ·.. ...... · .. · 9-7
REPLACEMENT······················ ·································· ·· ····4·7 CYLIN DER HEAD DiSASSEMBLy .. ·.. ··.. ··· ·.. ··.... ··.. ·· .. · 9·27
AIR CLEANER········· ··· ···· ···· ·· ········ ······ ····· ········· ·· ···· ···· ···4· 10 CYLINDER HEAD INSPECTION .... ..... ....... ............... .. . 9-2S
AIR CLEANER HO USING ···· ··· ······ ···· ··· ··· ··· ··· ·· ··· ········· ··· 6· 7 CYLIN DER HEAD INSTALLATION· .. ·· .. ·.. ·· ·· .. ··· .... .. ···· · 9-36
ALTERNATOR CHARGING CQll ··· .. ·· .. ·· .. ···· .. ······.. ·.. .. 17·8 CYLINDER HEAD REMOVAL ... ............ .......... .......... ... 9-24
AUTO-DECOMPRESSION SYSTEM (After '07 ) ·· ··· ·· ····2·2 CYLINDER HEADN ALVES SPECIFICATIONS· .......... ·.. 1-S
BALANCER GEAR/BALANCER ························· ····· ····· 13·8 CYLINDER INSTALLATION········ .... ·· .. ·.. ··· .. ·.... ·........ · 10-10
BATTERy ······································································ 17-6 CYLINDER REMOVAL·· .. ·.... ·· .... ·.... ·.. ·· .. ···· .. ··· .. ······ .. ··· 10-5
BATTERY/CHARGING SYSTEM SPEC1FICATIONS ·.. 1· 12 CYUNDERIPISTON SPECIFICATIONS ........ · .... ·.. .. ·...... 1-8
BRAKE FLUiD ······················· ·· ······································ 4-29 DRIVE CHAIN ·· .... ····· .. ··.. ·· .... ··· .. ·· .. ··· .. ·· .. ·· .. ···· .. ·.. ·.. ·.... · 4·24
BRAKE FLUID REPLACEMENT/AIR BLEEDING ···· ·· ··· 16-6 DRIVE CHAIN ROLLER ....... .. .. ................... .... .............. 4-28
BRAKE PAD WEAR ···.... ·.. ··· ···· .. ·.. ·· .... ··.. · .. ···· .. ····· .. ··· .. ·4-30 DRIVE CHAIN SLIDER ........ .. ... .. ....... .. ............ ... .... ..... . 4-27
BRAKE PAD/DISC ·.. ·· .... ······ .. ···.. ···· ·.. ··· ·.. ·.. ··· .. ····· .... ··16-10 DRIVE SPROCKET ·.. ··· .. ·· .... ·· .. ············ .. ·· .. .. ······ ...... ··· .. ·· 8-4
BRAKE PEDAL·.. ····· .. ····· ·.. ·· ··.. ·· .. · .. ··· .. ···...... ··· .. ····· .. ··· 16-24 DRIVE/DRIVEN SPROCKET ...... · ............ ·.. .. ·.... ·.... .. .... · 4· 28
BRAKE SYSTEM ·.. ·· .... ·· .. ·.. ···· .. ·.. ·.. ···.. ·· .. ·· .. ··· .... · .. ···.. ··4-30 ELECTRIC STARTER SPECIFICATION ·.... ·...... ·...... · .... 1-13
CABLE & HARNESS ROUTING ('05 - '07 ) ·.. ·.. ·.... ··· .. ·· 1-25 EMISSION CONTROL SYSTEMS ·· .. ·· .. ·.. · .. ·.. ···...... ·· .. · 1-40
CABLE & HARNESS ROUTING (After ·07} ··· .... ···· ·.. ·.. 1-32 ENGINE & FRAME TORQUE VALUES ...... · .... .. ...... ·.. · 1-14
CAM CHAIN TENSIONERICAM CHAIN GUIDE · .. .... .. 9-25 ENGINE GUARD ·.. ·.. ··· .. ·· .. ··· .. ···· .. ··· .. ·· .. ·· .... ····· ·.... ·.. ··.. ·· 3-5
CAMSHAFT INSTALLATION .. ·· .. ·.. ·.... ·· .. ·.. ···· .. ··· ···· .. ··· 9-39 ENGINE IDLE SPEED··· .. ·· .. ··· ·.. ··· .. ···· .. ··· ··.. .. ·· .. ·· ··...... ·· 4-22
CAMSHAFT INSTALLATION ('05 - ·07)· .. .. · ............ · .. ·9-37 ENGINE INSTALLATION· .. ····· ·· ·· .. ····.. ··· ·· .... ··· .. ··· .. ·.. ··.. · S-S
CAMSHAFT REMOVAL ('05 - '07) ·.... ·.. ........ .. .... · .... ·.. .. ·9-S ENGINE OIUOIL FILTER·· .... ·· .. ·· ·.. ·· ·.. ·· .. ·· .... ·· .. ···· ...... ·· 4-19
CAMSHAFT REMOVAL (After '07) ···· ...... ··· .. ··.. ·· .... ·.. ·9- '6 ENGINE REMOVAL ·.. ·· .. ··.... ··.... ·.. ···· .. ··.. ·.... ·· .. ···· ...... ··.. 8-5
CARSURETOR ADJUSTMENT ····· .. ··· ...... ··· .. ····· .... ·· .. ··· 6-6 ENGINE STOP BUnON · .... ·.. ·...... ·.. ·............ .............. 20-7
CARBURETOR ASSEMBLY ···· .. ····· .. ··· ...... ··· .. ·· .. ·· .. ·· .. ·· 6-1S EXHAUST PIPEIMUFFLER .......................................... 4-33
CARBURETOR DISASSEMBLY .... ·.... ··· .. ·.... ·.. ·.. ·· .... ·.. ·6-13 EXHAUST SYSTEM .............................................. ........ 3·9
CARBURETOR INSTALLATION ...... · ...... · .. ·.......... · ...... 6-24 FLYWHEEL .... """"" " ", ,, ,, ,,,, ,,,,,,,,,,,,,,,, ,, ,,,,,,,,,, ,,,, ,, ,,,,,, 12-5
CARBURETOR REMOVAL .. ·· ·· .. ·· ··.... ·· .. ··· ···· .. ·· .. · .. .. ··.. ·6-11 FORK .. .. .... .. ... .. .. .. ... ....... .. .. .... ... .. ..... .... .. ... ........ .... ····· · 14-13
CHARGING SYSTEM INSPECTION ··· .. ···· ··· .. ·· .. · .... ·· .. ·17-7 FRONT BRAKE CALIPER······ .. ·· .. ···· ···· .. ·· .. ···· .. ·· .. ··· ···· 16-18
CLUTCH .. ·.. ··· .... ·· ··· .. ··.. ······· .. ··· .. ··· ·· · .. ··...... ··· ··· ····· .. ··· .. ·1 1-7 FRONT MASTER CyLINDER .. .... .. · .. · .... .............. .... ·.. 16-12
CLUTCH LEVER ··· .... ·· .... ··.. ··· ··· .. ···· ·.. ··· .... ·.. ·· ···· ·· .... ····14-52 FRONT VISOR ......... ..... ... ........................... ... .. ... ........... 3-5
CLUTCH SWITCH ......................................................... 20-S FRONT WHEEL ··· .. ·.. ·.... ·...... ·.. ·· .. ···· .. ·· .. ·.. ···· .. ·· .... ······ .. 14-S
CLUTCH SYSTEM ·.. ·· .... ····· .... ·· .. · .. ·· .. ·· .... ·.. ·· .. ···· .. ·.. ·· .. ·4-31 FRONT WHEEUSUSPENS ION/STEERING
CLUTCHISTARTER CLUTCH/KICKSTARTER/ SPECIFICATIONS ....... ........................ ... ..... ................. 1-11
GEARSHIFT LINKAGE SPECIFICATIONS ·.. ·· .... ·· ··· .. ·· .. · ' ·9 FUEL LINE ···.. ·.... ·· .. •.. ·.. ··.... .. ·.. ··.. ··· · .. ·· ····· .. ···· .. · .... · .. ··· .. · 4-8
COMPETlnON MAINTENANCE SCHEDULE .. ······ .. ··.. ·4· 6 FUEL STRAINER SCREEN ..... .................... ........ .. ......... 4-8
COMPONENT LOCATION FUEL SYSTEM SPECIFICATIONS .. ....... .................. .. ... 1-7
ALTERNATOR .... .. .... ·.. .. .. .. .... ·.. · .. .. · .. .. .... · .. ·.... · .... · .. · 12·2 FUE L TANK .. ·· .. ·· ·.. ·.. ············· .. ·· ···· ····· ·· ··· .. ········ .... ·· .. ·.. ·· 3-8
BAnERY/CHARGING SYSTEM ·.... ·.... ·.. · ............ · .. 17·2 GEARSHIFT LINKAGE····· .. ··· .. ···· .. ···· .. ·.. ·· .. .. ··.. ····...... 11 · 24
CLUTCH/STARTER CLUTCH/KICKSTARTER/ GENERAL SPECIFICATION S ·.. ·· .. ···· .. ·.. ···· .. ··· .. ··· .. ·.. ··· .. 1-5
GEARSHIFT LINKAGE ·.. ·· .. ··· .... ··· .. ··· .. · .... ·· .... ··· .... ·.. 1 1·2 HANDLEBAR·· .... ··· .... ···.. ·· .. •··· .. ··· .. ···· .. ·.. ·· .. .. ·· ·.. ··· .. ·.. · 14-33
CRANKCASEICRANKSHAFTfTRANSMISSIONI HEADLIGHT .. ............ ...... ..... .... .. ......... .... ... .... ..... ....... .. 20·4
BALANCER ·.. ······ .. ···· .... ··· .. ··· .. ·.. ·.... ··· ...... ·· .. ······· .. ··· 13·2 HEADLIGHT AIM ...... ... .. .. .... ... .. .......... ... .. .. .... ... .. ......... 4-31
CYLINDER HEADN ALVES· ·...... ·.... ··· .. ·.. ··· .... ··· .... ·· .. ·9-2 HOT START .. ·.... ·· .. · .. ··· .. ·· .. ····· ···.. ···· .. ·· .. ·· ·· .. ··· ····· .. · .. ··· 4-10
CYLINDERIPISTON ·.. .... ·· ·.. ··· .... ···· .. ··· ·· .. ···.. ··· ···· .. ·.. 10-2 HPSD (Honda Progressive Steering Damper): After '07
ELECTRIC STARTER ·.. ··.. ········ ··.. ···.. ····· ·.. ···.. ······ .. ·· 19-2 FRONT WHEEUSUSPENSION/STEERING .... ····· · 14-38
ENGINE REMOVAUINSTALLATION .. .. .. · .. .. · ...... ·.. ·.. 8-2 TECHNICAL FEATURE· ···· .. ·.. ·· ······ .. ·· .. ··· ·.. ·· .. ······· .. ··· 2-3
FRONT WHEEUSUSPENSION/STEERING .. ....... ... 14-2 HYDRAULIC BRAKE SPECIFICATIONS·.. ···· .. ··.... ···· ·.. 1· 12
FUEL SYSTEM ·· .. ·.... ·· .. ·· .. ··· .. ··.. ·.... ·.... ·.. ·.... ·...... ·· .. ··· ·6-2 IGNITION COIL ...... ·· .... ·.. ···· .. ··· .. ·· .. ···· .. ·· .. ·.. ·.. ·.... ·· ...... · 18·7
HYDRAULIC BRAKE ·· .. ·.. ··· .. ······· .. ·.... ····· .. ·· .... ·· .. ·.. ·· 16-2 IGNITION CONTROL MODULE (ICM) .. ·.. .. .... ·.. · ...... ·.. 18-7
IGNITION SYSTEM ··· .. ·.. · .. ·.. ···· .... ·· .. ····· .... ·· .. ······ .. ·· 18-2 IGNITION SYSTEM INSPECTION···· .. ·· ........ ·· .... ·· ...... · 18-5
LlGHTSIMETERISWITCHES .. ·· ·· .. ··· .. ······ .. ···· .... ···.. ·20-2 IGNITION SYSTEM SPECIFICATIONS .. ·.... ·.... .. · .. · .. .. · 1-12
REAR WHEEUSUSPENSION .... · ...... .. .... ·...... .. · .... · .. 15-2 IGNITION TIMING ....... .. ... .. ........ ..... ......... ....... .... ... ..... 18-8
CONTROL CABLES ·· .... ··.. ·.. ··· .. ····· .... ··.. ··· ···.. ·· ·.. ······ .. ··4-32 KICKSTARTER .. .. .. ...... · ...... · .... .. ...... · .. .. ...... · .... .. ·.. .. · .. · 11 · 15
COOLANT REPLACEMENT ... .. ... .... ................ .. ...... .. .. ... 7-6 lEFT CRANKCASE COVER INSTALLATION· .. ·.......... 12·6
COOLING SYSTEM ··· .... ····· .. ··.. ·· ···· .. ··· .. ····· .... ·· .. ··· .... ···4-14 LEFT CRANKCASE COVER REMOVAL .. · .. ·.. · .. ·.. · ...... · 12·4
COOLING SYSTEM SPECIFICATIONS .. · .. ··· .. ··· ...... ·.. ··· ' -7 LIGHTS/METER/SWITCHES SPECiFiCATIONS ······· .. '-13
CRANKCASE ASSEMBLY .... · ...... · .. .. · ........ ·.. · ........ · .. · 13-25 LUBRICATION & SEAL POINTS ·.. · ........................ ·.... 1-21
CRANKCASE BEARING REPLACEMENT ···· .. ··· ...... ·· '3· 16 LUBRICATION SYSTEM DIAGRAM ........ ... ... .. .... .... ..... 5-2
CRANKCASE BREATHER ·· .... ·· .. ···· .... ··.... ··· ·.. ··...... ·· .. ··4-11 LUBRICATION SYSTEM SPECiFiCATIONS · ........ · ...... · 1-7
CRANKCASE SEPARATION .. ··· .. · .. ·.. ···· .. · .... ·.. ··· ...... ··13- 'O MAINTENANCE SCHEDULE ('05. ' 06 ) ...... .. .. .... ........... 4-4
CRANKCASE/CRANKSHAFTfTRANSM ISSIONI MAINTENANCE SCHEDULE (After ·06) .. ........ .. · .. ··.. · .. · 4-5
BALANCER SPECIFICATIONS ('05 . ·07) ...... · ...... ·.. .... .. 1·9 MODEL IDENTIFICATION .............. · .... · .......... .. .. · .. · ...... · 1-2
CRANKCASEICRANKSHAFTfTRANSMISSIONI NUTS. BOLTS. FASTENERS .. · ...... · ........ .. .. .............. · .. 4-36
BALANCER SPECIFICATIONS (After '07} .. · .. .. ·.. ·.. ...... 1· 10 Oil JET ..................... ..................................................... 5·6
CRANKSHAFT INSTALLATION .... ·.... ·...... ··· .. ··· .. ·.. · .. 13-21 OIL PUMp ··· .. ·.... ·...... ··.. ··· .. ···.. ···.. ···· .. ·· .... ·.. · .... · .. ·.. · .... ·.. 5-7
CRANKSHAFT REMOVAL· ·· .. ·· .. ·····.. ···· .. ·· .. ·........ ·.. ··· 13-14 Oil STRAINER .. ·· .. ··· ·· .... ··.. ···.. ···.. ···· .. ·· .. ·· ·.. · .. ·.. ··· .. · .. ··· .. 5·4
CYLINDER COMPRESSION TEST··.. ···· .. ········· .... ·.. ·· .. ··· 9-7 OPTIONAL PARTS· ·.. ·.. ···· .. ···.. ·· ·.. ···· .. ·· .. ·· .. ··· ·· .... ·.. · .. ··· 1-37
CYLINDER HEAD ASSEMBLY·· .. ·· ··.... ·· .. ·· .. ·· .. ··· .. ·.. ··.. ·9-33 PilOT SCREW ADJUSTMENT .. .. ..... .. ...... .......... ........ 6-27
CYLINDER HEAD COVER INSTALLATlON·· .. ··· .. ·.. ·· .. ·9-42 PISTON INSTALLATION· .. ·· ··.. ··· .. ···· .. ··.. ·· .. ····· ·· ··· ···· .. · 10-9
23-1
INDEX
PISTON REMOVAL ....... ...................... .. ....... .......... .. ... 10-6 STEERING HEAD BEARINGS .. ·.. ·· .. ·· .. ·· .. ···· .. ···· .. ·.. ··· ·· 4-37
PRESSURE RELIEF VALVE ...... .. .. ....... ..... .................. .. . 5· 5 STEERING STEM ··.. ··.. ·· .. ······· .. ·· .. ··· ···· ··· .. ·.. ·.. ··· ···.. ··· · 14·47
RADIATOR ··········· .. ········· ·· ········ ·· ··································· 7·8 SUB-FRAME .. ·· .. ·· ·· .. ······ .. ······ .. ··· .. ·· .. ······ .. ·.. ·.. ···· ··.. ··· ·.. ·· 3-6
RADIATOR COOLANT ················································ 4-13 SUSPENSION ·.... ·· .. ··· .. ·.. ··· .. ·· .... ·.. ·.. ··· .. ·.. ·· .. ·· ...... ·.... ··· 4-34
RADIATOR RESERVE TANK ········································· 7-9 SWINGARM .. ·.... ·.... ·.. ··· .. ·.... ·.... ·· .. ·.. ·.... ·.. ·· .... ·· .. ·· .... ·· 15·36
RADIATOR SHROUD .................................................... 3-4 SWINGARM/SHOCK lINKAGE ·.... ·.. ·.. ·· .. ·· .... ··· .. ·· .. ··· .. 4-35
REAR BRAKE CALIPER ············································· 16-20 SYSTEM DIAGRAM
REAR MASTER CyLINDER ·········· ····· ······ ·· ······ ······ ·· ·· 16·15 BATIERY/CHARG ING SySTEM· .. .... ·· .. ·.. .. .. · ...... .. .. 17·2
REAR WHEEL ··························································· .. · 15-8 ELECTRIC STARTER .... ·.. .. .... ...... · .. · .. .... · .. •.... .. ·.. · .. .. 19·2
REAR WHEELJSU$PENSION SPECiFiCATIONS ···· .. · 1-11 IGNITION SYSTEM .... · .. ·.... ·...... .................... · .. .. · .. .. 18· 2
REGULATOR/RECTIFIER ·· .. ··· .. ··· .. · .... ··.... ··· .. ·· .... ·· ...... · 17-8 SYSTEM FLOW PATTERN .. ·· .. ·· .. ·· .. ··· .. ·.. ·· .. ·.. ·........ · .... ·7-2
RIGHT CRANKCASE COVER ....... .. ............................. 11-5 SYSTEM TESTING ·· .... ·.. ··· .. ··· .. ·· .. ·.. ·· .. ·· .. · .. ·· .. ·.... ·.... ·.. ·· 7-5
SEAT ..... .. ............. .. ..................................................... ··· 3-3 TAILLIGHT.. · .. ·· .... ·.... ·.. ···· .. ·.. ··· .. ·· .. ··.. · .. ··· .. ·.. ·· .. ·.. ·· ·.... · 20-6
SECONDARY AIR SUPPLY SYSTEM THROITLE OPERATION .. ···.. ··· ···· .. ·.. ··.. ·· ·· ··.. ·.. ·.... ·· .. ·· ·· 4-9
('05 and '06 California type, After '06) THROTTLE POSITION SENSOR INSPECTION ·.. ·· .. ··· 18·9
FUEL SYSTEM ··· .. ·.. ·.. ··· .. ···· .. ·.. ··· .. ··· ·.. ··· .. ·· .... ·· .. ····· 6-29 THROTILE POSITION SENSOR REPLACEMENT .... ·· 6·26
MAINTENANCE .. ··.... · .. .. ·· .... ·.. ·· ·.. ·· .... ·· .... ·.. · .. ·.. ·.... · 4-14 TRANSMISSION ASSEMBLY .. ··.. · .. · .... ·· .. ·...... ·· .. ·· .... 13·22
SERVICE INFORMATION TRANSMISSION DISASSEMBLY ··.... ·...... ·.. ··...... ·.... 13-11
ALTERNATOR · .. ·· .. ··· .. ·· .... ··· .. ·...... ·.. ·.. ·· ··.. ·· .... ·· .... ·.. 12-3 TRANSMISSION OIL ·· .. ·· .... ·...... ·· .............. · .. ·· .. ·.... ·.... · 4-22
TRIPMETER .. .... .. .. ..... .... .............. .. .. ........ ....... .... .... .. .. 20-10
BAITERY/CHARGING SYSTEM ... .. .................... ... 17-3
CLUTCH/STARTER CLUTCHIKICKSTARTER/
GEARSHIFT LINKAGE ............................................ 11-3
TROUBLESHOOTING
BAITERY/CHARGING SYSTEM· .. ···.. ·.. ·.. ·· .. ·.... ·.... · 17-5
,
COOLING SYSTEM ............................ ...................... 7-3 CLUTCHIST ARTER CLUTCHIKICKSTARTER!
CRANKCASEICRANKSHAFTITRANSMISSION/ GEARSHIFT LINKAGE .... · ........ ·.. ·.. ··· ·.... ·.. · .. · .... ·.. .. · 11-4
BALANCER ···· .. ·.. ·· .... ·.. ····· .. ·· .. ·· .. · .... ·· .... ·.... ·.. ·.. ·.. ·· .. 13-3 COOLING SYSTEM ...................................... ... .. ..... ... 7-4
CYLINDER HEAONALVES ............ ....... ..... ............... 9-3 CRANKCASEiCRANKSHAFTITRANSMISSION/
CYLINDER/PISTON .... .. .................. ... .. .................... 10-3 BALANCER .. ··· .. ··· .. ······· .. ··.. ·· ·.. ·· ···· .. ··.. ··· ·.. ·· .. ·· .. ··· .. ·13·7
ELECTRIC STARTER .. ··· .. ···· .. ·.... ·.. ···· .. ·· .... ·· .. ··· .. ··· .. 19-3 CYLINDER HEADNALVES ................................... ..... 9-6
ENGINE REMOVALJlNSTALLATION ....................... 8-3 CYLINDERIPISTON ·.. · .... ·...... · .... · .... ·· .... ·.. ·· .. · .... ·• .. ·· 10-4
FRAMElBOOY PANELSIEXHAUST SySTEM .......... 3·2 ELECTRIC STARTER .. ·.. ···· .. ·.. ·· .. ·· .. ·· .. ····· .. · .. ···.. ··· .. · 19-4
FRONT WHEEUSUSPEN$ IONISTEERING ........... 14-4 ENGINE DOES NOT START OR IS HARD TO
FUEL SYSTEM ......... ....... .... ..... ... ... ....... .................... 6-3 START··· .. ··· .... ·.. ··· .. ··· .. ·.... ·.. ··· .. ·· .. ·.. ···.. ·.. ·.. ·· .. ··.. ···.. · 22·2
HYDRAULIC BRAKE ... ... ........................ ............. .. .. 16-3 ENGINE LACKS POWER .... · .. .. .. .. .. .. .. ·.. ·.. ·.... · .. .. · .. ·.. 22-3
IGNITION SySTEM ···.... ·.... ·· .. ·· .. ··· .. ·· .. ···.. ··· .. ··· .. ··· .. 18-3 FRAME/BODY PANElSIEXHAUST SYSTEM .. ·...... · 3· 2
lIGHTSIMETERlSWITCHES .. ·· .. · .... ·· .. ···· .. ·· .... · .. ··· .. 20-3 FRONT WHEEUSUSPENSIONISTEERING .. ··· ...... · 14-7
LUBRICATION SySTEM ·.... ·.. ·· .. ··· .. ·· .... ·.... ·.... ·.... ··· .. 5-3 FUEL SYSTEM .... ·· .. ·· .... ·.. ··· .. ·· .. · ...... · ...... ·· .. ·........ ·· .. ·6-5
MAINTENANCE ........................................................ 4-2 HYDRAULIC BRAKE ·· .. ·· .. ·· .. ·· .... ·.. ·· .. ·.. ·· .... ·· .... ·...... · 16-5
REAR WHEEUSUSPENSION ................ ............... .. 15· 3 IGNITION SYSTEM ·· ·.... ·.. ·· .. ·· .. ·.. ··· .. ·· .. ·.. ·· .. ·.. ··.... ·· · 18-4
SERVICE RUlE$· .. ·.. ·· .. ··· .. ···· .. ·· .. ··· .. ··.. ·· .... ·.... ·.. ·.. ·.. ·· ···· 1·2 LUBRICATION SYSTEM ... .. ........... .. .. ........ .. ... .. ... .. ... 5-3
SHOCK ABSORBER .. ... .. ... .. .... ........ .. ... ..... ..... ..... ...... 15· 14 POOR HANDLING ................. ..... ... .......................... 22-7
SHOCK LINKAGE .......... · .... ·· .... ·.. ·· .... · .. ···· .... ·.. ·.... · .... 15-30 POOR PERFORMANCE AT HIGH SPEED·.. ·.. ··· .... ·· 22-6
SIDE COVER .......................................... ........................ 3·3 POOR PERFORMANCE AT LOW AND IDLE
SIDESTAND ...... ·· .......... ·· .... ·· .. ··· .. ·· .... ·.. ···.. ··· .. ·· .... ·...... 4-34 SPEED ·.. ·.. ··· .... ·.... ·.. ··· .... ·.. ··· .. ·· .. ·.... ·.. ·· .. ·.. ·.. ·· .. ·· .... ·· 22-5
SPARK ARRESTER .. ·· .... ·.... ··.. ··· .. ···· .. ·.. ··· ···· ····· .... ·.. ···· 4-33 REAR WHEEUSUSPENSION ·.... ·.. · .. ·· ···· .. ·.. ···.. ···.. · 15-7
SPARK PLUG ·.. · ...... · .. .. · .... · .............. · .. ·.. .. .. .... · .. ........ · .. 4-12 VALVE ClEARANCEiDECOMPRESSOR SYSTEM· .. ··4·15
STANDARD TORQUE VAlUES .. · .... · ........ · .... · ............ 1-14 VALVE GUIDE REPLACEMENT ·...... ·...... ·........ ...... .. ·.. 9·29
STARTER CLUTCH .. ·· .... ·.... ··.... ·.. ·· .... ·.. · .. .. · .... ·· .... ·.... 11 · 19 VALVE SEAT INSPECTIONIREFACING ...................... S-30
STARTER MOTOR·........ ·.. ·.. ·.... ·· .. · .... ·.. · .. ·.. ·· .. ·· .... ·· .... · 19-6 WATER PUMP .. ·........ ·...... · .. ·........ ·.... ·...... ·.. ·.... · ............ 7-S
STARTER RELAY SWITCH ·· .... ·•.. ··.. ···.... ·.. ···.. ··· .. ··.. · 19--1 3 WHEELSITIRES ·.. · .... ··.. ···.... ·.. ·· .. · .... ·.. ·· ...... ·.. · .. ·· .... ·.... ·4-36
STARTER SWiTCH ·.. ··· .. ··· .. ·· .. ···· .. ·· .. ··· .. ··· .. ·· ·.. ··· .. ·· .... · 20-9 WIRING DIAGRAM ................ .. ... ..... ... ... .. .. ............ .... .. 21-2
STATOR· .... ··· .... ······· ···· .. ··· .. ··· .. ·· .... ·.. ··.... ······ ·.. ··· .. ·· .... · 12·5
23-2

Manual de Taller CRF 450 X 2005 2012 PDF

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What is the purpose of the service manual?

What is the purpose of the service manual?

What sections does the manual cover?

What sections does the manual cover?

J

Pertorm,ng the '"5\ schedUled maintenance '5 very imiX'ftant. It

Your satety. and the safety of others. Is very impol1a n1. To he lp

""78 Use the recommended engine oil, unless otherwise specified.

~ Example: Moly\<oteJ!l BR-2 plus manufactured by Dow Corning U.S.A.

...-'iiSitI Use silicone grease.

.,('Illll! Apply sealant .

.. Use fork or suspension fluid.

ENGINE SERIAL NUMBER

The name plate (U.S.A.) or Safety Certification Label (Canada) is

Canada) or equivalent motor oil

Canada) or equivalent motor i

FUEL SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

Top 0.065 - O. lOa (0.0026 - 0.0039) 0.'15 (0.0045)

0.20 - 0.70 (0.008 - 0.028) 0.90 (0.035)

M5, C2, C3 0.020 - 0.062 (D.OOOS - 0.0024) 0.12 (0.005)

i, 9 clicks out from full in

REAR WHEEl/SUSPENSION SPECIFICATIONS

20.0 - 24.0 kgf (44. 1 - 52.9 Ibf)

10 clicks oul from full in

BATTERYICHARGING SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES

Cylinder head side insulator band (After '07):

Cylinder stud bolt:

Water hose clamp:

t 0 - 1.0 mm (0 - 0.04 in)

REAR WHEEL/ SUSPENSION

Alternator wire grommet sealing surface

STARTER SWITCH WIRE

FRelNT BRAKE HOSE

CLUTCH CABLE THROTTLE CABLES

HOT STAAT CABLE

STARTER SWITCH WIRE

ENG INE STOP BUTTON WIRE

, FUEL TANK BREATHER HOSE

OVERFLOW HOSE TAIPMETER CABLE

HOT START CABLE

ENGINE STOP BunON WIRE

IGNITION PULSE GENERATOR 2P

ALTERNATOR WIRE "",=::::...--- AlA VENT HOSES

SPARK PLUG WIRE

HOT START CABLE

MAIN WIRE HARNESS --\1~i~~~~

'05 a nd '06 Ca lifornia type, '07:

SPARK PLUG WIRE

HOT STAAT CABLE

MAIN WIRE HARNESS

THROTIlE POSITION SENSOR

PAIR AIR SUCTION HOSE

'OS and '06 California type, '07:

AIR VENT HOSES

I,""""'., -____ leM 6P (NATURAL)

STARTER RELAY SWITCH

Install the muffler by aligning the tab of the muffler -~~~~~~~~:::::::::::~