HOW 'TO USE THIS MANUAL

CONTENTS

This service manuel describes the service' procedures for the GBR900RR.

FQ,llaw the Maintenance Schedule (Section 3) racornrIl8:l1dOltions to ensure that the vehicle is in PS:;'i1 k operating condition and the ernlssfon ~evelsalr,e, within the standards set by tha IU.S, I;nvironnnsntal Profection Agency and California Air Resources Board.

Perform~n,g the t~rst scheduled maintenance is vary Important, It ecrnpsnsates for th~ lnltlal wear that occurs dUldng the break-in period.

Sections 1 and 3 apply 10 !he whole motorcycle, Section .2 illustrates procedures for nl!fnov,al/insta:llatlon of components -that may be required to perform servic.e described in the following sections"

section 4 through 19 describe parts of'tlhie motorcycle" group,sd according to loeation,

Find the section you wsnt on this pa'ge, then turn te the table of eentenra an the first pagel of tha s9c1!i'OIl.

Most sections start with e n assembly or system illustration, service inforrnatlon and troubleshooting for the section, The subsequent pages g'ive detailed precedures.

Ilf you don't know the source of the trouble. g,o to section 21, Troubleshooting.

z <f: g:;

IUJI :>

a:: 01

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C9

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GENERAL INFORMATION

_, ~ U

Ir IF U W ....I IlJ

FRA!ME/BODY PANELS {EXHAUST ,SYSTEM

:Lu.BRnCATIUN SYSTEM

FUEL SYSTE,M

COOLING SYSTEM

B·J:G~NE REMOVAlIlNSTAllATION

CVLliNDER HEAD/VALVES

GILUTGH/GEARSHIFT LINKAGE

CRANK'CASE/PISTON/CYLINDER

CRANKSHAFT {TRANSMISSION

FRONIWHEEL/SUSPENSION/ STEERING

REAR WHEEl/SUS!PENSION

IH'VDR'AULIC BRAKE

BATTERY ICHARGIING SYSTEM

IIGNITION S'YSTEM

ELECTRI'C STARTER

L1GHTSJ METERS/SWITCHES

WlRIING DIAGRAM

TROUBLESHOOTING

INDEX

.,r

Date of Issue; Decemb€r. 1995 (0') HONDA MOTOR CO ... LTD.

SYMBOLS

The :symbols used thn)ugholLit rhis manual shew speelfle servtceerooeouree. Ii' supplementary information 115 reQ'uin~d pertaining to these symbols, it would be explained 5per;:ific;(!liy in the lext without the use of the symbols.

d! Replace the DarNs) w~th W'I,I'lW one!s) bef,ore assembly,
IIioiijilll
-, Use recommended engine eil, unless otherwise specified.
-
~ Use molybdenum oil solution {mixture of the ,engiU'1G oil and molyb(lenum grease tn a ratio of 1 : t).
__w;;~ Use multi-purpose greaSE! (Lithium based multi-purpose grea:se N'LGI #2 or aquivalentl.
I Use molybdenum disulfide !Jr,e<l~p.lcDntaining morethan 3% rnolvndenurr, disulfide, NLGI #2 or
~ equivalent].
IExample: Me,tyk-otsO> S,IR-2 plus manufactured by D-ow Coming, U.S.A.
Multti-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide gre,ase (e,ontai'ninlg more than 3% mo'ybde'llurn disulfide, NLGI #2 or
equivalent).
,~ EXi!lmple~ Molyk,otelSJ BiR:-2 pilus, mi'lInlJlif.actmed by Dow Corning, U.S ,A.
Honda Moly 50 IU.S.A. onlyl
fI'or;:ol ASP rnanutacturec by Flot'Qllirn:ited, U.K,
R:ocollPaste manufactured by Surnico Lubricant, J;:.pi;ln
I ~ Use silicon e 9 reese.
I
I c:w Apply a locking ag'e'nt. Use a middle str'~ngth locking ag,ent unless otherwise speclfled .
.(1Q:ru: Apply $,eiil~nt.
I Use DOT 4 brake fluid. Use the recommended brSike fliLllid unless etharwisa specified.
Use Fork or Suspension Fluid .. - 1. GENIIERAt INFORM,ATION

GENERAL. SAIFETY ,., LUBRICATION & SEAL POINTS '·119
SERVIC'E RULES 1-2 CABLE &, HARNESS R:OUTIING '-22 .1
MODEll.. IDENTIFICATION '-3 EMISSION CONTROL SYSTEMS
SPECIFICATIONS 1-4 (U.S.A. ONLY) '-36
TORQUE VALUES 1-13 EMISSION CONTROL IIINFORMATION
LABELS IU.s.A. ONLY) 1-39
TOOLS '-17 G EINIERAL SAFETY

GAIR:BON MONOXIDE

If the anqlne must be rUIlr1ulIg LO do some work, make sure the area is well ventilated, Never run the eng'ine in an encloseo area.

• The exiruust r::-omuha POisQIWIA5 carbon rmmo:dde 8,al" Iba!

O:GIl o:atue lou ofconsciousness arid maJ' I,cad to deat1!.

Run the angilne in an OPSin area or with all exhaust evaeuation system in an elildosad area.

GASOUNIE

Work in a well vantllatad air-sa. Keep cigamttes;, flames or sparks away Ircrn the work area 01 when? gasoHne is stored.

,0 Gasoline is earemel» .fW.mmaM e and ls explosive under eerwill "QTlJilitm:>. KEEP OUT OF REACH OF CHJLDRE,~.

HOT COM PON~NTS

• ErJghff' Ii~n' eshaus! systeo» JIlJrH become ver), ho! n.rul 1ll11l0il.1 hot for smne time after the engine lias been runnillg. WelDI" insulated glln'es or Jr',l'1.il IUttiJ tIll! ,engill C (U,l.d exhaust sysrem' '~,,,.e cooled before hL1,J'1dlill~ theee parts.

USE.D ENGINE Oil

• Used engil1,£ oil lIta)' calj;i"C rkir~ COIIl:er if repoo:tedl_v reJI in cotuaa !S>illl the skin for prolimg,ed periods. Allilllu!:,i'I ~his I~ unlikely u1J11I~·s }'QU 'Iandlr lI~ed Qil on ,a dl.dly b~Hi>, ir is :JliIl advisable t.n thtlrrl".ghly 1t·I'l.~/1 ,our l>alld,~ with .HJap dna ""mer as soon as possible after lul1uifing used oil: KEEP OUT OF REACH OF CH.ILDREN,

BRAKE DUST

Never use an air hose or dry brush to clean the' brake assemblies. Use OSHA-iipprm/ed vacuum cleaner or altsrnata method approved I:w OSHA, d~sigll/;'ld to mimirnize the hazard caused by airborne asbestos fibers,

J I

• Inhaled as/U!SlOS fibers have been !otl./ulllJ cause respir-tU01'jl disease and cancer.

BRAKE FLUID

CAUTION

Spilling flrJid nn p,clllIlni, plastic m- n,MJeF parts will damage them. Place Ii! clean shop towel ,In;er these oans wh~nel'.er the system i~ serviced, KEEP OUT OF REACH OF CHILDREN.

'GENERAL INFORMATION

SA ITERY HYDROGIEN GAS & ELECTRO LYTlE

'I .! .. L_ ~

• Tfw battery gives off explosive gases; keep sparks, JWlJW~ cmd cig,anttes away. Proviat aJkquafe ventiletios: wke« t;hllrging,

• Tlu: baiter} .e,ontaj~l~ su.l/uric acid (elIN:troiytc), Cmuee: wish skin fir IlJ'IIS IIIQ:J' C(!I1SI1 sel'ere bums. "'eaT proler:tI'.',e' dolhi.ng and u [ace shielil.

- TJ decunlJ'il' gets (III yo!.!,. ,~kiJl, Ji'IL~h with ",utero

- Jj electrolyte gets in your eye~ s flush with water for at least 15

mi'lUfes and cali a pll.V5iclat, ImmediarelJ'.

• E,IIU:troiJI[,f! ,is poisonous.

- If swallowed, Jrir&. lm-ge qaantities oj" wale" or milk and [ol,low willi milk ~f mag,nesia or lIegetaMe oil and call a physi.cian, KEEP OUT OF REACH OF CHILDREN.

SERVICE RULES

1. Use 'gen~ine I'IQNDA or HONDA-recOnlITI,ended parts and lubricants or their equiv<'llf!n'is" Parts that don't meet HONDA's design specifications may cause damage to HiP. mororcvele.

,_ the the special tools designed for this prouuctto avoid damage and incorrect assernblv.

3, Use only rnetnc toots when servicing the moterevcla. Mstri'iG bolts, nuts and screws are not interchangeeble with English tastsners.

4. i.lIstalll new gasket's,. O-rings, cotter pins, and lock plates when reasseml'llil1lg.

5. When tightening bolts or nuts, b"'9in with the lar,ger diameter or inner bolt first. Then tighten to the specified torque

diagonally in incremental steps unless ,1:1 particular sequence is, speci'fi.ed.

6 .. Clean parts in c.lssning solvent upon disassembly. Lubricate anv slitlil19 surfaces before reassembly, T. A.fte r rS',cISSI;!III oly, c heck all pa rts fer proper installation arid ope ration.

S. Route all electrical wires as show on pOlges 1·21 thrna.lgh '-31, Cable and Harness R,auting,

.J

MODElIDENTIF~CATION

GENEHAL INFORM.ATION

(2) The engine serial number is stamped on the right side of the upper cran'kcase.

(4) The carburetor identi"fkation numbers an. stamped on the intake' side of the carburetor body as shown.

(1) The frame serial number is stamped on the right si:d!l' of the steering head.

,

(3) VEHICLE IDENT1FICATION NUMBER (VIN)

[3) The vehlcle ldentlflca ion Number (VIN~ is located on right side of the frame !I!i:l(lr ths steering head Oil' ~he SafEty Certification Label.

(5) The color label is attached as shown. Wh,en ordening Cl(1lor"cQped p.llrts, O'Ilways specify the designeted color code,

1-3

GENERAL INFORMATION

GENERAL

r- 1
ITEM SPECIFICATIONS
DIMENSIONS OV9l"alllength 2,055 mill (80_'9 in)
Overall width '96- '97: 675 rnrrr (20_6 inl
A'fter '97: 685 mm (21:1-9 ill)
Ov~nall height '96 - '97: 1,130 mm (44.5 in)
After '97: 1,135 mm (44,' in)
Wheelbase 1,400 rnrn (55.1 In)
Seat frei gilt 810 mm '311,9 iln)
Footpeg tl!~ight '96-'97: :mo mm nS.1J in!
After "97: 383 mrn ~15.,1 in!
'GFDund clearance 1'410 mm 15_5 in] -
DIY weight
'96 - '97: 49lstates!Canadii type 183 k,g ~403 lbs)
CaHfornla tVpe 186 kg ~410 Ib~)
Afte,r '91': 49 stateslCanada tYpe 180 kg ~397 los)
Calif-ornia, type 183 kQ (403 Ibs)
CUirb weight
'96 ~ 'g7: ,4:9 st,~lesjCanade type 205 kg 145~ Ibs)
Ctl,lii'orni;, type 208 kg [459 ibsl
Alter '97: 4!9 ststes/Cansds type 2G3 kg [448: Ibsl
Callfom ia tVi~e 206i kg [454 lbs]
Maximum weigllt capacity
'96-'9'1: ~9 Btai9s!Canad!!l type' 161)1 kg ~3S3 ~b:s~,
Call'forn~a wpe 160 kg (353 los)
After '97: 49 states/California tYpe Hit) I:g (353 lbs)
Canaan tripe 164 k'Q (352Ibs)
FRAMe Frame Iyp-e Diamond.
Front suspension Teteeooplc fork
Front wl1eel1ravel 110 mm 14.3 in)
Rear suspension Swing,arm
Rear wheel travel 1.25 mm 1,4_9 illl
Re',ir damper N'itrogen 9i!S--lil~ed rlam~er, wj1h resi'!i'V,e tank
Fro lilt ttre size '96- '97; norm ZR 16
After '97: 130/70ZR 161'61 W)
Reer tire size '95-'97: 1SQ/55ZR 11
Atter '97: 180/66 ZR H 113 WI
11r", br,md
Bddgestolle Front: BTS'SF RADIAUiRear: BT56R RADIAL G
Midlillin Front; TX15/Flea,r: TX2S
IFront brake Hydraulic double disc: brake
REN~r bmk'il Hydraulic 511191", dlsc brake
Caster angie 24~
Trail I Bngth '96- '91: 90 rnm (3,.5 In)
After '!l7: 95 mm (3.7 in)
Fu~.1 tank Gllpa.city lEW liter (4.76 US gal, 3.96 Imp 9011)
FI."I tan.k reserve CI'lPIlChty 3.Sliltr:r ~(I.92IJS gal, 0,7'1 Impgalll
ENGINE Bore and stroke 7UJ x 58.0 mm 12.80 )C 2..28 in)
Dis pi a r.;-I:!meln! !H9 cm~ (56.1 eu-ln)
Compre.ss[on ratio lUI: 1
Va1ve train Chain drive and DOHC
Intake valve opens Hi" BIDe all II III I (O.1l1 inllift 0" nroc r 1 md.>4 ;,' '"
closes 35< ABDC tI,r'I:l'r '97 3i" AI3DC After '97
Exhaust \(~ lve opens 39' IBBIDC ' 49 stame~C;l!n<lda type 4.0° BBDC Californill type
IclJoses 1P A"nDC and 'SS - '97 all Ly~,es 0' Arne
tucncetion system Forced pressure' and wet sump
Oil pump type Trochold
Cooling system uiQuid-<;oola,d
A.ilr filtration Paper fi'lt,er
Crankshaft type Un'~t type
Engine dny we:ight
'96 - '97: 49lstateS/Caoade type 66,.9 k'!!i [141.5,lbs.
Califomi~ type 66.2 kg {1IS().4 fbs.
After '97: 019 stat"s/Canad~ tyIJI! 66.3 kC 04!6.Z ibsl
- Califomil'! type 87.B kg (149.1 ibsl
Cylinder !lrril'llg!:!rm::!IIl F'1II r cylinder. inline 1 A

G.EN~RAL INlfOIRMATION

- IGENERAllCont'dl

ITEM

SPEClf'ICATIONS

CARBURETOR

Carburetor type Throttle bar"

CV (Constant VeJo(_i1y) type, wifh flat valve 3Bmm 11.~5Iinl

DRIVE THA'IN

Clutch system

Ctutch operation svstem Transmr~sion

Prima rv reductio n

Final reduction

Gear ratio

Gearshift panern

MlJ~tj-rlijte, wet Mechanical type Conslsnt mesh, €i-speed 1.520 176/5()'l 2.687143)16}

1 st 2.727 (3011111 2.769 136/13)

2nd 1.933 129m'l,1 2.000~26!13)

3rd 1.6001,24}1:5) '96 _ '97: 1.600124/15) Aft '97

4th 1.<!.00 12.8/20l 1.368 (26/1'9) " er:

5th 1.263 (24/19') 1.,227127/22)

6th 1,,167!21!mJ 1.130 (26/.23)

left foot operared return system" 1 - N- 2. - 3 - 4 - 5 - 6

ELECTRICAL

Ignition system Slarltlng, system Ch"H!~ing system Reg u later/rectifier Ughting system

Full transietor diglital igni'trr,on Electric starter motor

Triple r;h~~!;! IJ U !!Jul alternatcr

SCR shorted/tripte phase, 'full wa,ve rectification Batterv

..

1-5

GENERAL liNFORMATION

lUB'RICATIION SYSTEM ---- ---

Unit: mm lin)

,..... --- I I
rTlEM ,STANIDARD SERVICE U'MIT
Engine oil capaettv At draining S.5 liter 13_7 US qt, 3_' Imp qt] --
At disassembly 4.4 liter (4.6 US qt, 3_9 Imp qt] I
--
At oil filter change 3,.6 liter {3.8 US qt, 3,llmp qt] ~
Recommended €l'Igine-oil HONDA 4-stroke, oil or equivalent
rnmor oil
API service classification Sf, SF or SG --
Viscosity: SAE 10W- 40
Oil pressure at oil pressure switch 490 kPa (5.0 kglf/cmz, 71 psi) at --
6,000 rpm (min- I/nJQoC/116"F)
Oil pump rotor Tip clearance CL 15 - 0.22 10.006 - 0.008 I 1),.20 IQ .. OO8l
1S00dy clearance 0.15 - 0.22 1,0.006- CL009) I 0.350 (0.014)
-
Side clearance 0,02 - 0.07 (0.00 1 ~ 0..0(3) 0.110 10.00.4) r- 'FUEL SYSTEM
'ITEM - SPECIRGATIONS
Carburetor idenliiica- 49 states type '96- '9'l: VP888
ticn number After '97: VP8CP
r---
California til",e '96 - '97: VPI:l8A
After '9'7; VP8DA
Caneda type '96: VP88A
I '9'7: I VP88B
Aft,!'!:F '97: VPBCB
f--
Malin jet 49 states type '96-'97: #11515e'8 page 5-1111
After '97: #120
California type '96 - '97: #115
After '97: #120
CanElda type '96: I #1115
'97: No.1, 4: # 11I5/No. 2. 3: 1f118
Aftew'9': #120
Slow Jet 1 #4.0
Jf'!t needle number 49 states tvpa '96 - '97: No.1, 4: J5FB/No. 2, 3: J'5FA
After '91: No .. 1. 4: J5FHjN:o, 2.,3; J5DD
Calitornia type '96- "97: No.1, 4: J5fB/NO. 2, 3: J5fA
l After '97: No, 1,4: J5FAlNo. 2,3: J5FC
Canada type '96: Nn_ 1,4: J5FZ!No. 2. 3: J5FY
! '97: No.1, 4: J5fB/lNo. 2. 3: J5FA
After '97:; I No.1, 4: J5FHfNi"l. :2,3.: ,J50D
--
Pilot screw initial '96 - '97: 3 turns out
openin9 Except California type After '97: 1 - 5J81tlLlrns out
-
Catiforrtis type 2 turns out
--
Float level 13.,,7 mm (0,54 in)'
Idle speed Except Calitorriia tyPE! . -~ 1.10p± 1'00 rpm
Caljfomia tvpe I -, 1.200± roo rpm
Throttle grip free plsv I 2 - 6 mm (1/12 114 inl GENERAL INFORMATION

COOLING SYSTEM

~ I' --
ITEM SPECIHCATmONS
Coolant capaeitv Radii'l~or and el'lgine '96 -'91: 2.77 liter 12.93 US qt, 2.4~lmp qtl
,After '97: ,2.6,4 liter (2.79 US qt, 2.32 Imp qt)
Restlrve tank '96- '97: 04:5 I'iter (0476 US qt, 0.396 Imp qt)
After '9'1: 0.35 liter (0.370 US qt, 10.3'11] Imp qt)
R",rliatQr cap rellisf pressure I '96- '97: 1,08 - 137 kPa 0.1i -1 ,,4 kgfJcm~, 16 - 20 psi)
I A'fter '97: I 107.9 kPa ~ 1.1 kgf/cm·. 116 psn
I r -
Thermostat !Begin to open 80 - 84~C (176-183°F)
I IFul~y open 9'5°C (20n';'
Valve lif! El mm ([}.3 in) rninirnum CVUNDER IHEADNALVES

Unit; rnrn lin!

- I ..
ITEIM STAINDAR,D SERVICE LIMIT
Cylinrler cnmpression '96 - '97: ',177 kPa {12.0 kgf/cm2, 171 psfl tJ:t
-.-
'500 - 600 rpm
After '91: 1,2 kPa (l3,Q kgf/cm.2, 185 psI) at
--
I 3:50 rpm
I Cylinder hc,ad warpage -- o.io (0.004.)
Valve,. f Valve clearance IN 0.13 ~ 0.19 (0.0'05 - 0.007) I -~-
valve gluidc '96-'97: EX 0.19 - 0.2.5 10 .. 007 - '0.010) I --
After'S7 EX 0.22 - 0.28 (0.009 -'0,0111) 1
~~
Valve stem 0.0. IN 4.475 - 4.490 (0.1762 - 0,17681 4.465 10 .. 1758)
EX 4.465 ~ 4.480 (0.1758 - O. l7i64) 4.455 10.17541
VBlvegulde 1.0. I~N I 4.500 - 4 .. 512 (O.U7:2 - 0.1776) 4 .. 540 (0.11871
EX 4.500 ~ 4.512 (,0.177:2 - 0.1776) 4.540 (0. H87J
Stem-to-guide clearance IN 0 .. 010 - 0.037 (0,.0004 - 0.00'5) I --
EX 0.02.0 - 0 .. 047 CO.OOOS - 0,.0(19) ~~
Valve guide projection above 'IN 14.60 - 14.80 (0.:575 - 0.5831 ._-
cyl inder head EX 14.80 ~ ~5.00 (0 .: 583 - 0.591) --
Valvil, seat w~dth IN/~X 0.90 - 1.10 (0.035 - 0.043) '.5W.OBI
Valv€" spring Inner IN/EX 35.77 >(1.408;1, 34,071'.3411
free length Outer IN/EX ,39.69 (1.5,631 37.79 (1.488)
Valve lin'ill Valve lifter O.,[), IN/EX 25.978- 25.9'93 [1.0'228-1.:02331 .25.97 ~ 1 . .0:22)
.
Valve lifter bore I.:D. ~N/EX 26 .. 010 - 26,026 ! 1.(11240 1.024'61 26.04. n.025,)
Camsh,afi. Cam Ilobe Exc'ept California IN' 36.04.0 - 3fH80 (L4m9- 1.4283) 36,0111,418}
height type EX 3:5.800 - 3>6.040 ~'.4094 ~ 1.41 B9) ~ 35.7111 .408)
CaIifon11a IN 34.940 - 35.18011.3756 - 1.3850) 34.91 (1.3741
type -
EX 35.100 - 35.340 ll.3S19 - 1 .. 3913:) 35.107 !U .3811' I
Hunout ~~ 0,05 !O.0021 I
I Dim r.learance I 0.020 - 0.062 (0.0008 - 0,0024] 0.10 (0.004) 1-7

GENERAL INFORMATION

CLUTCH GE SH· . UNKAGE

Uilit mm (in)

1- - -~ I I I AR'· 1FT I
ITEM STANDARD SEHVICE IJMIT
Clutch lever 'free ploy 1iO-20 (3/8-3/4) --
Clutch spring free length '96 - '97: 50.2 (1.98) 49'.2 (1.931
After '97: 4H.B (1.92) 47.0 l1.8:5)
Clutch disc thickness '96 - '97: 2.13;2- 2.78 (G, 103 - 0.109) 2-3 ~O_O9)
I Arle~ '97: 2.92 - 3.08 (0.11 - 0.121 2.8 (0.1021
Clutch plate, we rpage -- 0.30 (0.012)
--
Clutch outer guide 1.0. 24.90935,-25.0035 (0.98399 -0.98451) 2,5.018 (0 .. 9849)
0.0. 34.975-34.991 {1i.3170-1.3776l 34.965 (1.3766)
Maillshaft 0.0. at dutch outer guid'e 24.980 - 24.993 (O.9835 - 0.9840) I 24.96 (0.983)
StMt."orl~, Fork I.D. 12.00{J ~ , 2,(121, (0.47241- .0.4133) 12JjiJ (0.474)
fork shaft Claw thickness 5.93 - 6.00 (O.2S3. - 0_23,61 5.9 (10.:2'3)
1-,
Fork shaft 0.0. 1 " .957 - 1 1,,968 to.4707 _, 0.4712) 11.'95 (0.410)
I AL1iERNATO R/STARTER CLUTCH

Unit: rnm ~~nJ

r-r-' I ' I
ITIEM STANIlARO SERVICE LIMIT
Starter (iriv,en g'e,ar boss 0.0. 51.1)99 - 51.718 '[2.0354 - 2.()361l 51.684 (2.0348) CRA'NKCASE/PISION{CYUINIDER

Unit mm (in)

- I ,
ITEM STAiNDARD SERVICE LIMIT
Cylinder I.D. 71.000 -71.015 (2,7953 - 2.7963' 7UO !2.795)
Out or reund '---' 00.10 (0.0004)
. - -
Taper --, 0.10,[0.004)
WarpaQa -- 0.05 0(0.002)
Piston, piston Piston mark direction I "IN" mark factng toward the intake side --
rings Piston 0.0. 70.965 -70.985 12_7939 - 2.7'941) 70.9012_7:91}
Piston O.D. measurement point 15 mm {G.G ill) from bottom of skirt ~
Piston pin bore I.D,. 17.002 - 11.008 W.6694 ~ O.6696} 17.03 W.670) I
Piston pi n O.E). 16.993 - 11.000 10.6690 - 0.'6693) 16.:9'8 W.669)
Plston-ro piston pin cleorance I 0.002 - 0.01510.0001 - 0.1)006) --
Piston riIfIQ-to-riln,g Top 0.030 - (l.065 (0.0012 - 0.00026) {lOB (0.003)
groove, clearance Second .0.015 - 0.045 (0.0006 - D.Oa1SJ 1107 (O.003)
Pis.tol"l fln'9 end gap rop .0.2.8 - 0.38 1.0.011 - O.()I151 0.5 (O.D2)
Second 0.40 - 0.55 (0 . .01 6 - (1.02:2) 0.7 (0,03)
f-- -
Oil lside ram ,0,,2 _ 0.7 {0.011 - 0.03} .0.9 (0.04)
Cvlind'er·to'p~5ton clearance .0.'015 - 0.050 ~O.0006 - 0.0020:1 I ~~
Connecting rod small end I.D. 17.016 -17,.034 (0.6699- 0.6106) 17.0.4 (0.671)
Connecting rod-to-piston Din clearance Q,CJ1I6 - 0.041 <0.0006 - (1.00161 I --
Crankpin oil clearance D. D3D - 0.052 ~O.0012 - 0.00201 I 0.06 {O.aDZ) 1-,8

GENERAllNFOfllMATlION

CRANKSHAFT ITRANSMISSION

Unit~ mm lin)

r-t- , -
_. -
rTEM STANDARD SERVICE UMIT
-
Crankshaft SidE! clearance 0.05 - 0.2010,002 - 0,008\ 0.30 (0,0121
Fhmuul[ -- 0.30 (0.01,21'
Main journal oil clearance 0 .. 017 - 0.035 (0.0007 - 0.0014) I 0.05 (0.0021
T ransrn ission Gea,r I.D . I M5,'6 28.000 - 28.021i ~1.10201 ,_ 1.1032) 28.04 n.l04J
.
Cl 2-1.000 -24.02 ~O.9449 - 0.9457 I 24.01l {094fil
C2,3,4 31.000 -:;.11.025 {1.2205 -1,22151 31.04 (L2.22)
Bushing D.O. MS,6; 27.959 - 27.98011.1007 - 1, lOU;1 27.94 (1.10!)~
-
C.2 30.955,- 30.98011.2187 - 1.2197) 30.93 (1218),
C3,4 30.950- 30.97511.218.5 -1.2195) 30.93 Ilo21S}
Bushing 1.0. M5 2,4.985 - 25.006 (0.9837 - 0.9845) 25.02 1O.9SS}
C2 27,985 ~ 28.006 (j .1018 - 1.1 (26) 2BJ)2 (U03}
G ear-to-bushing M5.6 0.020 - 0 .. 062 [0.000'8 - O.OO24~ O. o (OJm41
clenrancc C2 0.020 - 0.070 (0.0008 - 0.0028) 0.11 (0.004)
C3,4 0.025 - 0,07'5 (0.0010 - 0.0030) 0.11 10.004)
Mainsh?Ft 0.0. MS 24 .. 967 - 24.980 (O . .983Q - 0.98351 24.96 ('0,983)
Cllu1ch outer guide 24.980 ~ 24.993 (0.9835 - 0.9840) 24.96, (D,983)
Countershaft O.D, e2 27.967-27.9'80 (1.1011-1,HlHl) 27.m;, ~1.1011
Bush ingl-to,-shalft M5, 0.00'5 - 0.039 (0.,0002 - 0.1)015)1 0.08 (0.0031
clearance C2 I 0.005 - 0.039 (0.000'2 - 0.(015) 0.08 (O.O!l3,1' 1-9

_ FRONT WHEElfSUSPENSIO:N/STEER:I:NG _,----- ~ _ _____,_--U-r'-il:-m-· m_(in---,~,

ITEM

STANDARD

SEIRVICE LIMIT

1-510.06!

I Gold tire pressure

Up to 90 kg (200Ib) load

I 250 kPa 12.50 19f/cm2,36 psi)

Un 1,0 maximum w'<lighl lj

... 250 kP,s 12.50 I<;gcfJcm~. 36 PElT)

capacity

Axle rum-out

- -- -

Wheel rim rune ut

-+ I 0.20 10.00131

-'-R~I-- - -- --------------r---2-.0-· -10-.0-8-'-----1

Axla~ 2.0 10.0:8)

Fork

24-5 .. 2 19.651

Spring tree lenglh

'96 - '9'7: 248.2. 19',,711

After ':91: 250_2 W'-851

243.2 (9.571

Spring direction With the tapered end facing down

Tube runout I -_--_-_. ---t __ O_,.2_0_IO_.O_O_8_1----l

,Recommended fork fluid ho-Honda SUJ'spellsir:m Fh,dd SS-8

iFltlld I'eyel n4 ± 4 14.5 ± 0.2)

Ifl~iO capacity '96 - '97: 561 ± 2.5 em] (19.0 ± 0.02 US OZ, 19.7 ± 0'.09 I mlP OZ)

Aftor '91:

540 ± 2.5 cmJ 08.3 ± 0.02 US oz, 19.0 1 ± 0.09 I rnp oz)

Pre-load adJu.ster setting

12 rnm 10.5 in) from top offorlk cap 1

Rebound adjuster setti!1g

" tum from full hard ,I

Compression adjuS1ier sen~ng

'96 - "97~

1 turn from fillil hSird

After '97:

".5 tum from lull 'hard

Un]t: mm (in) .- R~AR W'IHIEEL./SUSPEN'SION --------,-------------r---------,

ITEM

Steering head b8aring ,preiosd1.0 - 1.5 kgi (2,2 - 3_3 lbf

------------ -------------~.---------------------------~----------~

Minimum lire tread depth

STAN[)AHn

SERVICE LlIMII 2.010,08'

Cold tl re preseu re

Up to 90 kg (200 ~b) load

290 kPa 12.90 kgf/cm', 42 psJ)

Up to rnaximum wp.igllt capacity

290 kPa ~2.90 kgf/cm',42 psi)

Axle runout

2_0 (0.08)

Wheel rim runout

Radial

0.20 ({I,QOB)

Axial

Shock absorber

Sprirng free length

'96 - '97:172.6 (l.i80) After'S1': '161.7 (6,.60)

2_010.081 169.1 (6.'66} 1'64.3 (S.H)

Spring direction

Pre-Io,ad adju:ster setlllng

'96- '97:

W~th the tupcrecl clndrocing up

2ndl position

3rd position

Compression adjuster setling " tum from full hard

'1 turn from frilll hard

After '97:

Retll)lmd adjuster setting

Size/link DID DIEl525HV GC&B -120ZB

RK RKGB525ROZ1 - 120LJi-"

26- 313 11.2 - 1.6)

GENERAL IINIIF'ORMATION

Unit: rnrn (in) ;- HYDRAUUC BtRAKE ~~~~~--~~~~~~~~~~~~~~~-~~~

ITEM

STANUAR'D

SERVICE LIMIT

Front

SpecifiM brake fluid

oor 4

Brake disc thickness

4.51O,1S}

8n'lkt'! disc runout

R31l ~O_D12)

,Master cylinder J.D.

Milister piston 0.0.

'96,- '97:

14_000 - 14_043 'ICL55t2 - 0_5529)

14,055 (0_5.5.33)

13,,945 (0.54901

I Al'1oll '97: '96-'S7:

15.870 - 15.91:3 ~O.6248 - 0.6265)

--- --

13.951- 13.984 <IO.!5495 - a.5S0e}

15.92510'.6.27)

Afir:e~'97:

30'.29 fl.l193)

15.827 - 15.854 {a.52311 - 0.62421

15.81510,623)

Co ripercyii n der J.D.

A r '96- '97:

I Aiftt:e~ '97:

30.230 - 30.280 [1'.1'902 - 1.1921 I 32 . .03 -32.08 n.261 -1.263)

B l '96~'97: ~ Aifiter'97:

27.000 ~27 JJ50 ~ 1i-OB30 ~ '1.0650) 33Jl6 -,34_01 (037 - 1_3.391

27.06 ('1.065)

Cal:ipel piston 0.0.

30_'140 (1.1 86'61

A ~ '96 ~'97: rAner '97:

30_148 ~ 30.,19.8 01.1869' ~ 'j,1889) 31.965 - 31JJ98 '11' .2685 - 1.25981

B t'96 - '97:. ~After '97:

26.935 - 26 .. 968 <11.06·04 - '1.06171 33_895 - 33.928 11.3344, -1.33,511

26.9.27 (1.0,6" 01

, Rear

Specified brake '!_Iuid

011,0 ~O. 1 6)

Brake disc thickness

DOT II

5J) 10201

6filke disc runout

Mals~er cylinder LD.

, 5_870 - , 5,,:9131'0.6248 - 0.62651

0.30 ~O.ot2) 15,925 (0.62101

Moster piston O.D.

, 5.827 -15.:854 [0.6231 - 0.6242)

15$15 (0,62261

Caliper nylinder I.IJ.

3R1B-38.23 !1.503 -1.5051

38.24 (1,506)

Caliper piston O.D.

38_ 115 - 38.148 11.5006 - 1.5Q191

;- BATTERY ICHARG~NG SYSTEMI ~~-----,,-------------~~~~ ITEM

Battery

Capac.lty ClJrrent~eaJ.mge

SP'~IGIFI[;A nONS

12V""8Ah O.~ mA max.

VOltiligl': (20°C/68QF)

Furly chBr<ged

13.0 -1'3.2 V

Need.s r.hllrging

Below 12.3 V

Allsm.flOI

C.apacity

384 Wf5"OOO rpm ----------------~

0.' -,0,3. 0

0-9 Al5 - HI Il,

Quick

4.0 NO.5 h

Chorging cotl resistaneu (20~CI68~FI

RI8{IU later/rectifier r,egulat,ed voltage

13.5 - 15.5 V/5,000 rpm

1-11

GENERAL INIFORMATION

IGNITION SYSTEM

'r-
ITEM S,PECIIFlCATIONS
I---c::-- I
Spark pluig NGK DENIISO
Standard CR9EH ~9 U27FER 9 I
Optional CR8EH 9 'U24FER 9
SpMk plug g.ap 0.80 - 0,90 rnrn W.031- 0.035 in)
Ignition coil peak voltage 100 V minimum
IYlnution pulse generator peale volt.aglfl 0.7 V minimum
f- j
Ignition limi:,rng I flF" mark 10° BTDC at ldle EL:ECTiRIC STARTIER

Unit: 111m ,(in)

Stalter motor Ibrush Ie

IUM STANIilARD SERVIOE LIMIT
ngth 12.D -13.0 (O.47 _ 0.51) 4.'5 {O.1S) UGHTS/METERS/SWITCHES

r- I
lTiEM SPECIF'ICATI'ONS
Bulbs Headlight (High/low bearm 12 V - 45145 W x 2
Posirtiol'1,lig,h1 12.V-5W
Brake/t~illlight I 12 V ~ 32/3 cp
Front tum signaVruI'1nirP91igl1t 12 V - 3213 cp
Rear tum signaillight 12 V - 3.2 cp
-
l.lcenae I,'ight 12 V - 4 cp
Instrumen light '96 - '97; 12'V-',7Wx3
I After "97: 1.1 Wx z ,
Tum signa.l indicator '96 - '97: 12 V~ 11.7 Wx 2
After '97: 12V-1.1Wx2
High beam indicator '96 - '97: 12V-l.7W
After '97: 12V-l.1W
Nautral indicator '96,-'97; 12 V-1.7 W
After '97: 12V-U W
Oil pressure indicator '96- '97: 12V-1.7W
After '97: 12V-1 .. 1W
Side stand indicator '96 - '97: I 12V-"1..7W
-
Coolant ternoerature Aifter '97: I 1,2. V _ 1.1 W
g.3Jugle light
Fuse Main fuse 3QA
Sub fuse lUA X 4, 20 A X 1
[ Fall motor switch Start to close (ON) 98 -102"C (208 _ 216'F)
t-.
Sto'p to open '~B - 97~C (HJ9 - 2(JrF~
Coolant temperature sensor resistance (20~C/68°FI I 45,~ 60 n 1 1?

GENIERAL WINFORMATIION

TORIQUE VALUES

I 10RQUE I

Nm Ikgi'm, IbUtl

TOROUE

N·m !k!gf·m. IbHtl

4 (0.4, 2.9)

9 m.9, 16.51

91 ~o.'g, :6.15) 1211,2,9)

26 (2 . .7, 201 39 (4 .. a, 291

FASTENE.R TYPiE

FASTENER. TYPE

5 mm hex bolt and nut 6 mm hex bolt and lim 8 rnrn hex bolt and nut 10 rnm hex bult and nut 12 mm hex bolt IHH'l nut

5 (0.15, 3.6) 10 n.o. 71 22 12.2, 16) 34 (3_5.25) 54 (5.5, 40)

5 mm screw

6 HIITI screw and fl.mge bolt (SH type) 6 mm flangle bolt IB rnm hearil

6 mmflange bolt (10 rnrn head) and nut 8 rnrn 'flange bolt and nu

"0 mm rlauge bolt and nut

• Torque specifications listed he,low an'! for lrnportant fasteners,

• Others should be tightened to standard torque values Ilisted! above,

NOTES: 1. Apply sealant to the threads,

2. Apply a lockinq agent to the thraarts.

3. Apply modybdenum d ~SIJ lfida oil to the t'h reads and 'flange su rtaea

4. Apply grease to the threads. 5 .. Stake.

6, Apply oill to the threads andfl.ange surface. 7'. Apply c.~ean engme nil to the O-rinlg.

8. U-nut.

9. ALOe bolt: replace with a new one.

r- ENGINE
ITEM a'TV THREAO DIA. T'OROUE REMAR:KS
[rnrn] N'm Ikgforn, IIM·tt),
MAINTEiNANCE:
era nkshaft hole (:<'Ip 1 45 18 ~1 .. 8. 13) NOH: 01
Spark plug 4 ~o 12l1,2,8.7)
LUBRICATION SYSTEIM:
Oil drain bolt 1 12 29 (3 .• 0, 221
Oil filter cartridge , 2:0 10 (1.0, 7.21 NOTE 6, 7
Oil rump driven sprocket bolt 1 6 15 (1.5, "'1 NOTE 2
Oil cooler boss 1 20 54 (6.S, 47~ NOTE 2
COOLING SYSTEM;
Wate'r pump coverbolt 3 16 1311.3,9'.4)
Coolant temperllltur,e sensor 1 IPT1/8 1011.0, "_2) NOTE 1
FUEL SYSTEM:
Carburetor assembly bol~ .• 6, mm ., 5 5. ~O.5. 4.)
6 nun 1 6 10 (1.0, 7.2}
Vacuum plug for synchroninltion 3 5 3.0 (0.30, 2.2)
Boost joint [or fUB'1 val.v·e 1, 5 2.5 ~O,.25. '_8)
Carbureter tneulator bane screw 8 5 See below 114.51 (1.5 mm

--"1 l.... .

~

t l__~.

I

ENGINIIE SIDI!;

lnsu lator band screw tig htl'!·rn i ng~

CARBURETOR SliDE

Hl.S ± 0.5 mm

1-13

GENIERAL INFORMATIION

~ ENGINI; ICont'dl - - - I
ITEM Q'TV I THREAD DIA. TORQUE REMARKS
(I"I1ml N<m (kgf·m. IbHt)
ENGINE MOUNTING: I
Drive sprocket bolt 11 10 54 (5.5, 40)
CVl..IIN'DER HEADlVALVES:.
'8re<!\hfoH pl<lle fI.,lrlge boll :3 e 1.2 !U~, 8.71 NOTF2
Cyiinder head stud bolt 8 B 25 (2.6, 1: 9')
Cy'inner head cover special bolt 6; 6 10 (1.0, 7.21
Camshaft holder flonge bolt 10 6 1211.2,8.7)
Cylinder hsad socket bolt 10 9 48 (4.8, 35.1 NOTE: (i
Cam sprocket belt 4. 7 2'012.0(14) NOTE 2
Cam chain tensioner lifter mounting holt 2 S, 12 (1.2. 8.71
Air bleed tube joint 1 10 2.5 (2.5, 18)
CLUTCH/GEARSHIFT lINKA.GE:
Right crankcase cOII!'!r SH boll 7 6 12 (1.2, 8.7)
Clutch center leek mii 1 22 ~28 (13.1, 94.81 NOTE 5, 6
GeMshift pedal spring stopper 1 8 2.2 '(2.2, 16)
Shift: drum center bolt 1 8 23 ~2;31 17) NOTE 2
Shift: drum bearing set plate bolt 2 6, 12 (1.2, 8.7) NOTE 2
AL TERNA iOR{Si A RiER CLUTCH:
Lelt c:r~nk:r..aSe cover SH bolt 10 6, 12(1.2,8.7)
Fly\"heel flange bott 1 1'0 93 (9.5, 69) NOTE 6
S ator mounting socket bolt 4 6 12 (1.2, 8.7}
Starter cns-wav clutch socket boll 6 6 ',6 (1.6,171 NOTE 2
CFlAN'KCASE/pISTON/CYLINDER:
Crankcase bolt, 10 rnrn 1 ,.0 3'9 14.0, 29)
9mm 10 9' 36 {3.6, 26) NOTE 6
3mm 2 8 2412.,4. 17)
6mm '8 6 112 I U.1l7J
Con ne(;ti ng rod nut B 8 3413.5 .• 251 NOTE 6
tower crankcase sealing bolt, 20 mm 1 20 2913.0.22) NOTE 2:
18 mm 1 18 44(4.5, 33) NOTE 2
CRANKSHIAFT /TRANSMISSION:
Mainshaft bearhng set plate bolt 2 6 12 In:', 8.7) NOTE 2
IIGNmo.N SYSTEM:
Ignition pulse QCrI.cmtor cover SH bolt 8 6 12 (1.2. 8.7) NOTE 1
Ignition pulse galneraitor rotor special bolt 1 10 59 (6.0,. 43)
LlGHTSJMEiERS,JSWliCHES:
Neutial switch ., 11 (J: 1211.2. B.71
Oil pressure switch ., PTl/8 1211 .. 2,8 .. 71 NOIE 1 GENERAL INFOIlMAlrnO'N

FRAME

r-
I I -
ITEM an THREADDIA. TORQUE REMA'RKS
[mrn] Nm I(kwm, IbUtl
FiRAMII:/80DY PANELSIEXHAIUST SYSTEM:
Upper 'cowl stay rno untl ng boll :2 B 26 12.7,20)
Front fender rnoumting bolt 8 6 5 (0,!5, 3.61
Exha.ust pipe joint nut 8 7 12 (1..2,9.7)
Muff,ier moum]ng, bolt/nu, 2 8 2512' .. 6,. 19)
Step holder rnountinq bolt 4 8 ,26 (2,7, 20)
Foo1pe9' mounting bolt 1 10 44 14.5" 33) NOTES'
B Bin k sensor 2 8 10 (1.0,7.2),
Handlebar weight screw 2 6 10 fLO, 7.2)
FUEL SYSTEM:
Fuel valve 1 .22 34(3 .. 5,25)
Sub-air cleaner mounting bolt 1 6 7 {O.7, 5 .. H
COOUNG SYSTEM:
Fan motor nut 1 5 2.5 (0.25, 1.1:1) NOTE 2
I Fan motor switch 1 PTlIa n~ 11.8, 13J NOTE 1
Ili:NIGINI: MOUNTING:
lett engine hang er bolt 2 10 3914.0,29)
RI'ght engine hanger bolt ~ 10 44 t4,.5, 33)
E,'ogine hanger nut (Rear/upped 1 10 3914,.0,29)
(Rear/lowef) 1 10 3914.0, .29)
Engine hanger adjUJ,sting bolt 1 22 11 (1.1, 8)
Engin@ hanger adj!U1sting bolt lock: nut 1 22 5415.5,40)
Engine hanger plate bolt 4 8 2612.7,20)
IFRONT WHEEL/SUSPENSION/STEERING:
Steering stern nut 1 24 103 (10.5. 76) ] Se~ pa§l~ lS-:28
Top thread A I 1 26
Top thread 8 , 2,6 _ J
Fmk top Ibridge, pinch bolt '96- '·91: 2 8 23: ~2.3. 17)
After '97: 2: 8 22 (2.2,16)
Fork bottom Ori-.l91:! pinch bolt '96- "97: 2 10 49' (5,.0, 36)
After "97: 4 A 27 12.H, 20)
Front 1'1 lotI I'! bolt 1 14 591 (6,.0, 43)
Front axle holder bolt 4 8 22 (2.2,16)
From brake disc mounting bolt 12 6 20 (2.0,14) NOTES
Fork cap '96- '97: 2 42 23 (2,3, 17)
After '97' 2 ,42 22(2.,2, Hi)
Fmk soekst bolt '95- '97: 2 8 2'012,0. 14) NOTE 2
Aha. '97: 2 10 34 13.5,. 25)
I BEAR WHE,ELJSUS,PE'NSI:ON:
Rear axle nut 1 18 9·3 191 .. 5,. 59)
Rear brake disc rnountinq bolt 4 8 4214.3,31.1 NOTE 9
Driven sprocket nut 5 12 108 (11.0, 801 INOTE 8
Rear shoct abserbar upper rnourninq nut 1 10 44(4,5,33) NOTE 8
Shock arm plate nut 2 10 44 (4.5, 331 NOTE 8
Shock link nut :2 10 4414.5,33) NOTES
Swinganm pivot adjusting bolt 1 30 150.5,111 See page 14·.~2
Swingarm pivot lock nut , 30 64(6.5,471
Swingarrn plvot num , 18 :93 (9.5, 69) NOTE B
Drive chain slider bolt 2 6 9 ('0.91, 15.5) -.

1 ~,'15

GENERAL INFORMATION

FRAME Ie 'd)

r- -- ont ~ ~ -
ITlEM O'TV THREADDIA, 'TIORQUE IR'EMAflKS
[rnm) N'm Ikgf.m, Ibf-ftl
HYIDRAULIC BRAKE:
Front brake caliper mounting boll 4 8 30 (3,1, 221 NOTE 9
Front brake pipe rnountlnq bolt 2 10 l' 0_7, 12l
Front brake caliper assernblv torx boll '96 - ''97: 8 8 - 32 (3.3,. 24) NOTE 2
Atror '97; 8 !1 23 (2.3, H}
Front oi I cu p mounting n Lit 1 6 6 (0,6,4\..31 NOTE 9
Brake lever pivot bolt 1 6 1 (0.1,0.7)
Brslke levsr pivotnut 1 6 6 {(L6" 4_3)
Br1!k@ hOSE! oi] bolt 5 io 34 (3.5, 215)
Pad pin '96 - '97: 3 10 18 (1.8. 13~
After '97: 5 10 18 ~1,8, 13)
Pad pin plug '9,5- '97: 3 10 2.S 1(0.25, 1.BI
I After "97: 1 10 2.410.24,1.71
Brake caliper bllAed,er 3 H 6 (0,6, 4.3)
Rear brake Ihose guide bolt 1 6 12 (1.2, 9)
Rear master cvtlnder joint nut 1 8 is u.s, 13)
Rear rnaster cylinder hose joirrt screw 1 tI- 1.5 (0."'5, Uj
'Rear brake caliper pin bait 1 12 21 (2.8,201
RI'!!H brake ea liper bo,~t '96 - '97: 1 B 23 (2.3, 11)
After '97: 1 8 22. (2.2,16)
Rear caliper clamp bolt 1 6 9 (0.9', 0.5) NOTES
LIGHTS/METERS/SWITCH ES:
Side stand mounting bolt 1 10 10 (1.0, 7)
Side stand. lock nut 1 10 29 13.01 • .22)1
Side stand switch mcuntinq bolt 1 6 10 (1,0, 7) NOTE 9
Side stand bracket bolt :2 10 44 (.4.5, 33) 'NOTE 9
Ignition switch mounting bolt 2 3 25 (2.5, 18) NOTE 2 '1 11 e:;;

'GENERAL IINFORMATION

TOOLS

NOTES: 1, Equivalent cornmerclailv avaltabls in U,S.A ..

2. Nor avallablaln U.S.A"

3. Alternative- loot

4. Newly provided tool.

Carbur Oil pre Oil pre Clutch Flywhe Rotor D

Adjust Attach Attach Attach Attachm Driver Inner d Pilot. 1 Pilot, 2 IPilot,3 Pilot, .2 8,eil·rlng Bea.ring Driver Valv~ s Valve s

Seat FI~l Flat IntI'! Gun

Pi10151::

Pivot e Snap r

Sle"rin

Beering -Rem

-Rem

-Rem

Ball rae

DESCFlI'PT1ON TOOL NUMBER REMARKS FI.EF. SEC.
etor ftoat level ga,uge 074J01-'00100!)Q 5
ssura gaugle attachment 074006 - 00301]OC! NOTE 1 4
ssura ga,ugs 01506 - 3000~OD NOTE 1 4-
canter holder 0772.4 - 005,0002 NOTE 1 9
el holder 07725 - 0040000 NOTE 1 10
uttar 07733 - 0020001 NOTE 3: 10
07933- 395'()OQQ
able valve guide (jriver 01743 - 00120000 INOTE 2 8
rnant, 31 x 4(J mm 017 46 - CHH 0200 9,14
rnent, 42 X 47 mm 01746 - 0010(3.00 9, 13.,14
rnent, 52 x 55, rnm 077 46 - IJ 01 04011 14
ent, 24 x 26 mm 077416 - 001Or700 14-
B 07746 - 00301,00 12
Iriver, 25 rnm 017'46· - 0030200 '12
7mm 077 46 - 004040"0 14
0111111 01746 - 0040500 13,14
5mm 07746- 0040800 9
Bmm 0'7746- 0041100 14-
remover shaft 0774.6- 0050100 n.14
remover head, 20 mm on4.S ._ 0050600 13,14
011-49 - 0010000 '9, 13, 14
,pring compressor 0776·7' - 0010000· S
eat cutter NOliE 1 B
cutter .• 27.5 mrn (45Q IN/EXI 071.80 -IJ01020D
cutte·r,30 mm (320 ~N) '!llnso - 00122.0 [I
cutter,27 mm (.32u EXI (17780 - 0013300
rior cutter. 30 mm (60~ IN/EX) 07780 - 0014000
er holder, 4.5 mm 0778'1 - 00'10600
r'6VV wrench 07'90B - 4220201 0790B - 4730001 5
(Except Cellfornil.l type)
djilMtng wrench 07908 - 4690003 14
ing pliers 079'14- SA50001 NOTE2: 15,
07914 _ 3230{]Ol
gl stem socket 07816 - 3710101 NOTE2: 13
01916 - 3710100
remover set 079'36 - 371 0001 14
rover handle 0793,8 - 37101 00
over head, 20, mm 07936- 3710600
over wleight 07741- 00102011 NOTE :2:
07936 - 3710200
07936 - 371020A(U.S.A. only)
e remover 'set 07946 - KM90001 NOTE 2: See page 13-27
er attachment, A 079~-KM90100
er attachment, B 07946 - KM90200
ar shaft ~s;sembly 07946 - KM90300
rng 'remover, A 07946, - KM90401
i~g remover. B 07.s~6 - KM9_0500
rnblv base 019&6 - KM90600 . -Driv

I-Drill' -Driv

- Bsslr

- Bea,r

~As.st!

GENERAlllNFORMATION

DESCRIPiilON TOOL NUMBER I REMARKS l REF. SEC.
Steering stem driver 07946 - MBOOODO 13
Driver shaft 07946 - MJOO100 NOTE 2 141
Valve spring 'compressor attachment 07959 - KM301 01 8
Driver shal'l 07964 - MIBOO200 '12
P:i n driver 07GMD- KTBOlOD NOTE 2 '14
Slilocklllbso!rber cornpressor 07GM'E - 0010000 14
Inspection adaptor 07GMJ - ML80100 NOTE 2 17
Oil tllter wrench 07HAA - PJ701QO 4:
Peak voltage adaptor 07HGJ - 0020100 NOTI2 17
Lock IrWE wrench 07HMA - MR:70200 NOTE 3: 7
07VMA - MA T01 00
!E.xc'epl U.,S.A.~
07VMA-MAT010A IU.SAonlyJ
Needle bearing remover 07HMC,- MR70100 NOTE 2 11.4
Valve guide dnver. 4.5 mm 07HMD - MLOO101 8
Tappet hole protector 07HMG - 'MR70002 NOTE :2 is
Valve guide reamer, 4.5 mm D7HMI-I- MLOO101 NOTE 3: 8
07HMH - MUlO1DA
DriV'8 chain tool set 07HIVI'H - MH10103 NOTE 3: 3
01HMH- MR1010B (U.S.A.
unillyl ,
Pilot screw wrench 07KMA - MN9(l100 07KMA- MS60101 wijfh 5
1}7PMA - MZ201 10
ICllIl.ifornili rvoe)
07KMA - MV9010A (U.S.A.only)
Fnrk seal driver. 45 mm 01KMD - KZ30100 NOTE 2: 13
07KMD- KZ30iDA
Nel'edle bearing remover set 07'LMC - KV3m1 00 NOTE 4 14
Shock absorber compressor BHachmell1it 11J17NME - MY70100 NOTE 2 14
Compression gauge attachrrrent 07RMJ - MY501(J!) NOTE 1 8
Analog tester ISAINWA) SP ~ 150 NOTE 1 16., n, 18, 19
AnalQg tester I KOW.AI TH - 5H NOT!? '1 16 .. 17,18.19 GENERAl.. INfORMATION

LUBR,ICATION & SEAt POINTS

ENGINE ~~~~----~--------~--------------~--------------------,

LOCATION

MAtERIAL

RiEMARKS

, -

Crankcase mailing surface j liquid sealant

!Th~e€ Bond 1207B or j

________ .. __ ,._ _ _ _ _ _ .. ~.~.~.t~~.I_~:.~._ .-_ _ _

,

,I \t "\L

~! ~ J ~Oy

...- ",\~=v/g,

I -

o

l , ~ .. _ .. _.~._~._~~_ ~ .. _ _ _ _ -= _ _ _. __ - ~-.~-~------------- .---------.-_---------------.----.-----------.---

E E

E e

I o

. ~ ~ ~

~~-:o'-'-

_. '. '.'1'r,:~~O ~ I

:~

I a

Oil pan mating surface

Igll~t'ion pulsa glolruH",:llJr cover bolt thre;,Hj~ (marked "fl.")

011 pressure switch threaee

Do not applvto the thread head. 3-4mm

(0.1- 0.:2 in)

Thermo unit threads

GENERAlINF'ORMATION

- ENGINE [C'olilt'd) LOC.ATI:ON

M.ATERIAl

REMARKS

Cy~indcr head sernl-clrcular Cut-out

5- 10 mm

~

1 ... ~'0mm

IL-

J

Cylinder head belt threads and seating surface Camshaft lob,,~olJmi>ls

Valve lifter outer sliding surface

Valve stern (valve guiJde sliding surface] Connecting rod small ,end

Piston pin slidinq surface

Main journall bearing surface Connecting rod be;ilr~ng surtaca CrBrlkshaft journals

M3/4, C5, C5 shifter geM [shift fork gronves) 10 x 44 mm pin outer surface

Primary drive g:e~r and sub gear slidiing surfaca

?' ArrL Y ARE:A

APPIYAAEA ~

Clutch outer need Ii!'! hp.a(lng

Piston ring slidinq area

M"lin journal 9 mm boll threads. and sealing surface {after removing antl rust oil addi1:,ivel

Cy~inder head special bon (1:lher r!':!mCl,vinganti-rust oil addiitivt!)

Ooil strainer lPacting

Oil' r.oolfH center bolt threads and 5eming surface Oil filter cartridge threads and O-rijn~

FlywheElI bolt rhraads and seatinq surface

Starter one-way dutr:1i sliding surface Connecting rod nut threads

Clutch center lock nut threads

Clutch disc surface

Each ge'~r teeth and rotating surface Each bearing

EllCh O-ring

Other rotating area and sliding surface I---

Crankshaft hole cap threads

Ei:lch oil seal lips

I M u!_!i-purpose gr,easc

__ _L __ ~ ~ ~~~

Sealant

Molybdenum disul'fide alii (a mixture of 1/2 engirl!':! oil and 1/2 molybdenum disulfide grease)

1-20

Engine oll

GENERAL INFOR,MAlION

r NGINE ICont'dil
LOCATION M.ATERIAl REMARKS
Cy'linder hearl :-;"allng bolt threads Locking agent
Cylindelr head cover breather [olrtt threads
lower crankcase se,illing bo~t threads
St<trtl;!r crie-wav clutch outer bolt threads - Coating w~r1tI1~ 6_5 + 1 mm
Oil pump driven sprocket bolt threads -
S~ift drum set plate- bolt threads, -
Shift drum C,EH1ier boll thread's , -
lMainshait bearing set plate Lull threads -
Cam sprocket bolt th reads -
Cylinder heed cover breather plate bolt threads -
Air suction valve ti,ghtening' bolt th rea dis r-F AMIE
LOCA~TION MATERIAL RIEMAIRKS
-
Steerilng head bea'ring sliding' surface Mul'Li-PUrpose grease
Steer~ng head dust seal lips
Swlnqarrn pivot bearing and dust 'seal lips
I Wheel dust seal lirs
Reslf wheel side collar inner surface
ShOcik absorber needlel bearing and dust ssal lips
Shod link nl;!~dle bearing and dust seal lips
Footpeg sliding area
Passenqer footpe'g sliding area
Rear brake pedal pivot sllding area
Throttle pipe slidin·g ;;m;lCl
Clutch lever pivot
Pi I lirm se.<tt catch hook
I Pillion scot pivot
Gearshift padal llnk pivot
Giearshif1l pedal link tie-rod ball joints
Side stand pivot surface
Throttle pipe cable end area Mo:lybderll.lm dlsulfirle
grease
Shock absorber spr'infl adiusrer ca rn Sl1rf1lC:~ Molybdenum paste
Sl<:!ering stem topthreads Engine oil
[)iriv,en sprQ(Jn~t ntrl thre;<!(js and seating surface
Throttle cable cosing1nner
Choke cable casing inner
Clutch cable casing inner
Brake pip'" joint ti!lr,ea,ds
Brake master cylinder t.;IJf1s DOT 4 brake fluid I
Brake caliper piston seala
Brake caliper dust seals Silicone g'rease
Front brake I'ever pivot ami plston tips,
Hear master cvlinder boot inside <lind push rod tips
Brake caliper slide pin surface
Front brake caliper assernblv tOI'X bolt threads; l.oeklnq 8!gent
Fork socket bolt ~hrp.;:llil<;
Handle grip rubber inside H!onda Bond A or
Honds Hand GiriD
. GEl'ment (U.S.A. only) --
fork Clip O-Irilng Pro-Honda Suspension L
Fork oil !sea,llips Fluid S5-8 -.
- 1-21

GENERAL INFORMATION

CABLE & HARNESS ROUTING

m FflONl BRAKE HOSE

~5'1 COMBINATION ME EA 4P

'96 - "!I7':

m CLUTCH CABUE ~...._

~0-D '0

(1J POSITIO UGHT CONNECTOR

r:

I -

IB) HEADUGHT SOCKETS

(1Q) RIGHT HANDLEBAR SWITCH 6P IRED) CONNECTOR

~161 TURN SIIGNA!L RELAY

1111 HEADLIGHT REl.AYS

" •..

(15~ fUSE. BOX

(H.) RIGHT TURN SIGNAL CONNECTORS

~18IlEFT TURN SIGNAL CON rt: T GAS

GIENERAL INFORMATION

(31 TUR _ SIGNAL RELAY

nz) FRONT POSITION LIGHT CONNECTOR /'

r/./ /

6~~ (//

(4) HEADLIGHT HIGH RELAY

(5) CHOKIE.C.A.8LE

(7l COMBilNATION METER 20P CONNECTOR

~110'1 RIGHT TURN

SIGNAL CONNECTORS

(9) HEADLIGHT 'SOC!KETS

I I [:8) LEFT TUFIN

SIGNAL CONNECTORS

(21IRIGHT HANDLEBAR SWiTCH 6P (RED.) CONNECTOFI

(1) LEFT HANDLEBAR SWITCH

6" (NATURALI CONNECTOR~

"

{3J RIGHT HANDLEBAR SWITCH 2P (RI::D) CONNECTOR

(5) FUSE BOX

1-23

,GENERAlINFOIRMAiION

'96,- '97:

(3) IGNITION SWITCH WIRE

(2) RIGHT HANDLEIBAR SWITCH WIRE

(6) FUSE BOX

(5) MEA[»LlGHT SOCKETS

<.

\

-"

1-24

GiENEIRAL INFORMATION

After '97:

(2~ CLUTCH SWITCH CONNIECTORS

(1) THIROTHE CABLES

(3) LEIFT HANDLEBAR SWITCH WIRE

14) CLUTCH CABLE

(S) FUSE BOX

"' ......

"-"-', .: [,6) f-IEAOLIGHT

-, SOCKETS

'\

(7) MAl WIRE HARNESS

1-25

GENERA'l

, . INFOI£)Mft'n···"

III I,""" II ONI

'96- '97:

(2) Tli-WROITLE CABLES

131 CHOKIE CABLE

(61 TURN S~GNAL 'RELAY

1-2,6

GENE'RAL INFORMAT10I\I

After '97:

(9j FRONT POSI'TION LIGHT WIRE

13) LEn HANDLEBAR SWITCH WIRE

(5) CHOKE CABLES

~ (6\ HORN WIRE

(71 LEFT TURN SIGNAL CONNECTORS

1-27

GENE.RAL INFORMATIIION

(4) WATER PUMP TD-CYlJNDER

./ !=lEAD HOSE

fSI OIL COOLER WATER TUBES

"'-"51 WATER PUMP

I

@1

! '

' •• -~7, ~ RCAR VIEW

'/~

~

(1) WAHR P~MP

TO-CYLINDER HEAD

HOSE L

(1) WATE'R HOSE

W THERMOSTAT

CASE (3) WATER

BYPASS HOSE

1 ")a

'96 - '97:

GiENEIRAL INFORM.ATION

{3) AIR BLEIED TUBE

(4~ SIPHON TUBE

(6) UPPER RADJIATOR HOSE

(4) SIPHON TUBIE

'GEN'ERAl INFORMATION

1 .. 30

GENERAL INFORMATION

(4) THROTIlE CABLES

,I' 1~ MAIN WIRE HARNESS

~2) STARTER IRELAY SWITCH

15) CHO KE ,CABLE.

(1) FlEGULATORJRECTIFIER

m [IGNITION PULSE GENERATOR WIHIE

(8) OIL PRESSURE SWITCH WllFi!:

1101 OVERFLOW TUBE.

(91 FUEL. TANK DRAIN TUBE

1-3,'

GENER,AI. INF:OIRMATION

(11 CRANKCASE BREATHER TUBE

12) CARBURETOR AIR VENT TUBE

(3) FUEl!. VAlve VACUUM TUBE

{ttl FUEL TANK BREATHER TUBE

(5) fUEL TANK DRAIN, TUBE

(6)l-WAY JOINT

-:

11 ... A?

GEINER,AlINFORMATION

'96 - '9'1;

18) BA'ITERY NEGATIVE CABLE

~:3) CLUTCH, GABLE

(111 THROTTLE CABLES;""""""=f7t=:;t::===TfI---:-_..::.___",-,,,,.,,,,, (10) fAN MOTOR SWITCH WI?;

II

191 NEUTRAL SWITCH WIR~

14) 3T ARTER MOTOR CABLE

Afte:r '97: III SPEED SENSOR WIRE

1-33

GENERAiL IINFORMATION!

~1'1 ilGNITION CONTIROL MODULE

(8) BRAKE Uf;·HT SWITCH WIRE

(2) REG U LATOR/RECTiFI ER

(3,1 STARTER RELAY SWITCH

14) BAlTERY NEGAT~VE CABU~

(51 BATIERY POSITIVE CABLE

(6) MAl N WlRE HARNeSS

1~34

GE.NIERAL INFORMAnON

SECONDARY AIR SUPPILY SYSTEM ROUTING (CALIFORNIA TYPiE. ONLY),

·96 -'97:

(6) AIR CLEANER HOUSING

After '97;

131 EVAP PURGE CONTROL VALVE

111 :EVAP CAV CONiTROL VALVE

__."..~

(2) EVAP CANISTER-

1-35

GENERAL IINf:ORMATION

EMIISSION CONTROL SYSTEMS ~U.S,.A. ONLY)

The u.s. e:nvlronmen1al Protection Agency and California Air Resources BO.<'I,rd (CARB~ require rnanulacuuers to certify that their motorcycles comply with appllcabte axhaust emissions sti'lndarrds during their useful life, when operated and maintained accoral ng 1:0 the instructlons pi ovided, and that motorcycles built after J.anual:ry 1, 19,83 complv wuth app~;C3ble nolse emlsslon standards for one ye.ar 0T B,.OOO km [,3,730 miles) after the time of sale to the uttimate purchaser, when operated and maintained <lc:c.nr-ding to the instructions provided. Ccrnptiance with the terms of the Distributor's limited Warranty fn'r Honda Motorcycle' Em~s·sion Control Systems is necessary in order to keep the arnissiuns system W;;lmmty in effect.

SOIURCE OF EMISSIONS

The combustion prOC'9SS produces carbon monoxide Clmi hvdrocerhorrs. Controlling IhydrOC'iI,rbon emissions is very ~mpor tant because, under certain conditions, ~heV react to form phctocbarnicat smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic ..

Honda Motor Co .. Ltd. utilizes lean carburetor settings ~'S well 8S other systems, to reduce carbon monoxide' l'l • .nd hydrocarbons.

CRANKCASE EMIS·SION CONTROL SYST'EM

The ,engdne is equipped with a closed crankcase syst.em to prevent discharging crankc~rse emissions .into the atmosphere. Blow-by gas is returned !1 the combustion chamber through the air claaner and carburetor.

/ ( 1) AIIF! CLEANER HOUSI!NG

¢ : (3) FRESH AJIR

.. : (.41 BLOW-BY GAS

GENERAL INFORMATION

EVAPORATIVE EMI·SS,I'ON CONTROL SYSTEM ICALIFORNIIA-TYPE ONLYI

This model complies with California Air Resources Board eVilporative ernissson requirements.

Fuel vapor from the fuel tank and carburetors 'is routed lrrto the aveporative ernlssion (EVAP) canister whar s it is absorbed and stored w:hila the emgine is stopped. Wlum thO! engline is runni:ng and the evaporative emission (EVAP) purge ccrurul valve is open, fuel vapor in the' EVAP canister is dlr(lwn infO fhl'! e'ngine thmugh the carburetor, At the same time, the ifVAP 'i:.i!:rbureh'i'r BOr vent (CAVI ecntrol valve is. open and air is drawn into the carburetor throuqh the valve.

(11 EVAPORATIVE EM1SSION PURGE CONTROL VALVE

{EVAP PURGE CONTROL VALV

(2)FU'EL TANK

c: <:::::::J 13) FRESH A~R

......... ---::-_....L.....I~

'96 - "87: "" After '97: *2

II I

fr\

m VA.POR.ATIVIE EMISSION CARBURETOR AIR VENIT CONTROL. VALVE

~EVAP CAV CONTROl VALVE)

<:;::=J 15,) F'R,ESH AI R. ~I (6)FUEL VAPOR.

(41~EVAPO:RATIVE EMISSION ,'EVAPl CANISTER

NOISE EM.5S.0N CONTROL SYSTEM

TAMPERIIING WITH THE NOISE CONTROL SYSTEM IS PROHIIBITED:: federal law prohlbhs the fo]low'~ng acts or the t;~iU5irlg thereof; 0) Thl;! removal ur rffilluf;l·riny inoperative by anv person, ol~u;lrr ilia" for purposes of maintenance, repair or replacement, 'of any dp.llice or f'·lement of design incorporated into any new vehicle tor thE'! purpose of noise controtprior to Its sale or del.ivery to the ultimate aurchsser or whil,eit is ill use; III the useof the vehicle after such device 0 r element of deSign has been removed or rendemd lnoperatlva by allY person.

AMONG THOSE ACTS PRESUIMED TO CONSHirUTI TAMPERING ARE THE ACTS USTEO BIELOW:

1. Removal of. or puncturing of the muffler, baffles, header pipes or ~my other component which conducts exhaust

gases.

2. R~lI1oval or, 01 puncturing of any part of the i~take svstem,

3. Lack (If proper mainferilil:nr.l;~_ _,

4 .. IReplacing any moving ports of the venictc, or parts of the exhaust or lntakc system, w1th parts omer than those specified by the manufacturer.

1-3'7

GENERAL INFORMATION

EXHAUST EMISSION CONTROL SYSTEM IPUlSE SECO'NDA.RY AJR INJE:CTION SYS'IlEMI

The exhaust emission control system incorporates a lean cerburetor setting and! no adjustment should be madeexcept idle speed by using the-throttle SlOP screw.

(CAUfORNIA DNIL'V)

The exhaust emtssion control system consists off a secoriderv air suppl.y system which introduces filtered alr into the exhalJst gases lnthe exhaust pert, Fresh air ~6 drawn lnte the exhaust port whenever there is a ne.gstive pressure pulse in [he exl,au~1 sy~ll;lm. This dl,,:rg!;! !,II fr!;!!;>!1 air promotes burninq or ~~H, unburned Hxll;i!us! ~F~s~s and chanqss a considerable amount of hydrocarbons and carbon monoxide into rei,atively harmless carbon dioxide and water vapor.

This model has the pulse secondary air i!"ljectiGfl (PAm) control valve; it consists of check valves built into the pulse MC ondarv air injection !PAIR) control valve .. A Dulse sccendarv air lnjeetlon (pAIR I checif{ valve prevents reverse air flow through the system. The pulse secondary air injection (PAIR)contrQI valve reacts to hiqh int<lk!J 1I1:1!nifold vacuum and wi II CUe off the su pplv of fresh .a i r rl uri ng engine d acalsration, thereby preventing aftarburn in the exhaust system.

No adjustment to the pulse secondary air injection system should be mode, nlthough periodic inspection of the cornponsrrts is recommended.

C1 I~NTAKE PORT

. --------13~ CAR B UFilnOR

(6) EXHAUST PORT

(2) PlILS!E SECONDARY AIR INJECTION WAm) CONTROL VALVE

(4)PUlSE SECONDARY .AiR ~NJlECTION lPAIRI CHECK VALVES

I

'~ : (5) FRESH A~R

1-38

GENERAL III,NFORMATION

EMISSIONI CONTROL INfORMATION' LABELS (·U.S.A. ONLY)

An Erl!ission Control information Li3lbel is locahnl VII the side wall of the storage compartment as shown.

The passenger seat m~st be opened to read it.

It provrdes base tune-up speciflcBuio,ns.

VEHICLE. EMISSION,CONTROLINFORMATION UPDATE LAB!EL

Aher making a high altitude carburetor adjustment, attach lin update label on the side wall of the storage compartment 05 shown.

lnstr u ction s for obte i n in 9 the u pdat,e I abel af~ Ig'ive n in ServBI':p. Lettt'!f No. '132.

When raadjustlnq the carburetors back to the low altitude sl)e<:ifiLalirln'S-, be sure to remove this update label.

VACUUM IHOSE ROUTING DIAGRAM LABEL ICALIIFORINIA TYPE ONLY}

The VaCUbi,1TI Hose Routing Diagr<llrn t.abe: ts on the a1ir cleaner housing covar as shown.

The rueJ tank must be removed to read it. Reier to pag,e 2·2 fo r fuel tank remov"L

VACUliM HOSE flOUTING DIAGRAM EI'f6J i'lL r "'tilLY x.xXx

EV':'I'm;;:l. IT vE F Al'Ill Y - XX'i1.

C~,L 1.F,011I'<I,I, VfHICLf

1-39

FR.AME/BODV PANELS/EXHAUST SYSTEM

BODY PANEL lOCATIONS

(51 PllL!lON SEAT

(4) SEAT

(6) R~AR FENDER

(9) MIDDLE COWL

2-0

s. t'tiAIVlt/DIUU' r.MI\I[L~/[AnKU" I ~ I \) 111:.1'1

BODY PANEL LOCATIO!N.S SERVICE INFORMATION! lIiiROU BILES HO OnrNG SEAT IfUEL TANK

PILLION SEAT/S;IIDE COVIER MIDDLE/lOWER. COWL

2·-0 2~1 2~1 2-2 :2.-3 ,2-6

UP'PER COWL

FRONT FENDER

REAR FENDER

SEAT RAIL MUFFLJER/EXHAUST PIPE

.2-7 2-13 2·'1,4 2·15 2·16

SERVliCE IINFORMATIOIN

GENERAL

Gawlilll! is "Iln'ml!'Yfltr.flUlmb/~ ruzrl'~ (?rp.lO.'lil't! under c,erloin condition. KEEP OUT OF REACH OF CHIWllE

• Serlou» bH!'1l.~ rnll)' result if the txlJ(ms~ S)'8tel1! i~ .Illl'l· aEl(}w~d to CQt),llJe,fore CQm.pmleJ'lts IJ:~ rl!mln·l!'d or .l'e~"I'i.(wl

Work Ina waH ysntilatel! are'a .. Smoking or aillowing flames or sparks in the work DrOLl nr where gasoline is stored can cause <:t lire or explosion,

This section covers remove! and installlation etrhe body parte Is, fuel tank and exhaust system. AlwlllyS replace the exha ust D~P9 gaskets after r<em'oving the exhaust [pipe from thl'! I'!ng ine.

When lns.mlling the ex hau st svstern, loosely install all ot the· exhaust pipe fasteners. Always tlqhtan the' exhaust clamps flrst, then tighten the mOllmllt-ing fasteners. If yml tighten the mounting fasteners first, the exhaust pipe may not seat properly.

Always Inspect tne exhaust system for leaks <liter installation.

TORQUE VALUES

Upper cow'] stay mOIJi'uing bolt Front fender mourning boll Exhaust pipe joint nut

Mutfl!er mounting holt/nut Step holder mounting bali Footpeg mounting 'boll

Ba n'k sensor

Side stand brilcket bolt

26i N'm (2.7 kgf.'nl. 20 ItMtj 5 N·m (0.5 tgf·m,3.B lbf-ft) 12 N·m (11 .. 2 kgfm. 9 libHt) 251 N··m j2,'6 kg·f·m, 119' IbHtl 26 N'm ~2.7 k.gf·m, 20 Ibf.ftj

,44. N'm '(4.5 kgf'm, 33 lbf-ft) ALOe bolt 10 N·m 11.0 kgf-m, 7 Ib,f.ft)

44 N-m 14.$ kgf·:m, 331bHt) ALoe bolt

TR.DUBLESHOO'TIING

Ex c,ftssive ex:h!lu st n olsec

,. Broken axhaust svstern • E;;xhaust gas leak

Poor peliorl1'lance

• Deformed sxha ust svstarn

• Exhaust gas leak.

Clogged muffler

,2-1

FRAME/BODY PANELS/EXHAUST SYSTEM

SEAT/IFUEL TANK

REMOVAL

RemOVEllM two seat mounting bolts behind the seat.

Slida the seat back and then off.

Ca ~()line is e x.lrcrlw~l' flam.m~fl:lJfe and is e xpl(}sive under' certam cOlldiiUms, KEEP OUT OF REA£H OF CHff.DREN.

NOTE

• Bl;lfure di!;>'cOfln!;H,;tirJ'g the fual tube. turn the fuel valve lever OFF.

Turn tile fuel' valve OFIF.

Remove tha screw andfuel valve laver.

Remove the fU1i!1 tank rear rna u nling boll, washer i'OIno CQIIi;l r .. Remov!'! thp. fH~ I t;'!nk front m(ll.mtina bolts. and washers

Discm'mect the fuel tube anrl var.uurn tube from the fuel valve.

Disconnect th e breather tube ;:ll!'ldoverfl ow ru be from the fuel tank. then remove the fuel tank.

!21 VACUUM TUBE

(3i BREATHIER TUBE

2~2

FRAME/BOIDY PANELS/EXHAUST SYSTEM

INSTA'LLATIION

(1) FUEL TANK

11) VAOUUM TUBE

(5) FUEL TUBE

[6) OVERFL,OW TUBE

Make sure the seat setting collars are in plac-e.

After fuel tank instelletlon, turn the fuel valve ON and make sure there is no fuel leeks.

Installation is in the reverse order of removal.

NOTE

A,lign the seat hook with the frame bracket and install the seat.

lnstell and tighten the scat mountlng bolts,

PILLION SEAT/SIDE COVER

REIMOVAL

rlllGNITION KEY

c::

Opent:ne pillion seat using the ignition ~ey.

2-3

FRAME/B,OD'V IPANELSJEXHAU'Sl SVSlilEM

Remove the two mounting baits, nuts and pillion scat assembly.

Remove the \'wo joint clips.

aemove the foHowing: -Screw;;

-Speci,,1 bolt

- Side cover setting bolt

Sening collar - Setting ~f.l1:I{;er

S1'!pllrate and remove the side cover.

(21 PILLION SEAT

/

. 11~ SCREWS

fRAMElBODVPANELS/EXHAUST SYSTE,M

R.emove tile screws and rear cowl.

~2' REA~R COWL

/

Remove the tvvo bolts end remove the tail/braks ngh~ asse m

blv ~rnm the rear fender. -

(2) TAlil/l'lRAKE UGHT ASSEMBIL Y

IDiscon nect the tail/brake .llight3P (Nslti..I rail) con nector ;;lInd remove the ts il/brllJke I ightassemb:ly.

INS1ALLATION

\1) RIGHT SII)I;; COVER

lnstalletion is in the r,everse order of removal.

2-S

FRAiMEJBODV IPANELS/EXIHAUST SYSTEM

NOT[

" At lnstallation, "ljgru the' hooks between the side cover and rear cowl,

MliDDLE/LOWER COWL

REMOVAL

Tum the quick fasteners counterclockwise and release the fasteners.

Hemove nUl rnlddle cowl.

Remove the six spacial bolts and lower cowl.

NOTE

., During rerncval and installution, support tile lower cowl securely.

,2-6

FRAME/BODY PANELS/EXHAUIST SYSTIEM

FI.·em lJ INl lilt! l;U I;!WS .8,11 d s pe.ci8i~ 00 II, then SI; pa r .de UHl lower cowL

(2) lHT LOWER COWL

INSTALLATION

insrauatlcn is in the reverse order of remcvat.

~11 FHGHT MmDLE COWL

(3) LOWER COWL"

UPPER COWL.

R:EARVIEW MIRROR 'REMOVAL.

Remove !tile rearview mirro» pivot beat ('96 - '97).

Flem(lvc the followIng:

- SHI bolts/nl!.lts ('96 -'97;)

- Bolts/nuts (Afh,r '97:)

- Rearview m lrror

- Min'o~ plot,e f'9·6 '97:1

- Rubb91' cushion "96 - '97':)

FRAME/BODY PANELS/EXHAUS1 SYSTEM

UPPER COWL REMOVAL

Remove the right arid left: middle COWI!S (Pfl91'! 2-61

Remove the trim dip, special bolts, collar and riqht upper cowl inner panel.

fiernove the trim clip and re-lease [he, connector holder from the upper cowl.

Disconnect ~~H~ right turnsiqnal connectors.

Re'm()vl;! [he trim dip, special bolts, t.ollflr' ,l'md left upper cow] inner p .. np..I_

Remove thp. trim clip and release the relay holder bracket ('96 - '~n:l 'from the upper cowl.

Dis(:onnec1 the left turn signal t.(in"l~ecmor,s_

Disconnect the position light ecnnector.

,RRAME/BODV PA1NELS/IEXHAUST SYSIIEM

Rel<l<lse the retai ni r1!l tabs and remove the headlight sockets,

Remove the setting bolt <lind remove the upplin cowll forward.

NOTIE

Remove th e n ut, scttinq plate and tLJ rn .si,g nal unit.

iRemove the rrim elipsandinnsr middle cowt,

2-9

FRAME/BODY PANIIELS/EXHAUIST SYSIIEM

WINDSCREEN REPLACEMENT

Remove the screws, plastic washers and rubber washers,. Remove the windscreen and! setting nuts.

'96- '97;

INISTALLATION

'96,- '97:

~)

f (3) INNEI1 PANEL

(4) TURN SIGNAL UNIT

After '97:

UPPER eOWL INSTALLATION

FRAME I 80 DY PANE LS IEXHAUST SYST,IEM

Install the inner middle cowl and secure it wiith the mm cllps. -

Instill! the turn signal unlit, set plate and nut.

Route the ~urn s'ignar wine into the in'l'lp.t middle eowl as shown.

Install the upper cowl, .aligning the bosses on tim headlight unlit with ihe rubbarqrornmats on the upper cowl stay.

NOTE

Route [he win. harness into the UPDln cowl properly (page 1-21~.

Be careful not to pinch the po.siti!on Ii ght wire bi1itIA.'een the upper cowl and cowl stay.

Install and tiqhtsn the setting bolt,

(1) TRIM CLIPS

rn NUT {21 SEITING PLATE

,-

2-11

FRAME/BODY IPANELS/EXHAUST .sYSTEM

Connect the turn signal connectors,

Instal'l the relay holder aligning its boss with the groove in he inner middle cow! as shown ('96 - '97:),

Secure tha holder wi!lllll~ u im clip.

Install the rp.l1ly hQ~lder using the same procedure.

Install I the 1I ppp.~r cowl inner panel! and secu re it with the trim clip.

Install and tlqhtsnthe special bulls,

NOTE

• Befo're installmion, install thl;l !;u!l<lIT onto tlw inner panel.

,REARVIEW MIRROR INSTALLATION

SI;l! !h~ r u boer cushion ('96 - '971, mirror pl1ltp. ('96 - '91:~ and r<!MVI!?W mirror.

I nsta II the bolts £lnd nuts, then lighten the nuts while holding the bolts.

Install ill!'! ubber boot securely r96 ~ '97:1.

2-12

IFRAME/BODV PANELS/EXHAUST SYSTEM

FRONT F'ENDE'R

REMOVAL

Hernove the spacial belts. brake hose clamps and fork '(}OVers,

Remove the front fender fo rward.

I NSTALLA·nOIN

5 N'm (0.5 kgf'm, ~_~ __ 3.6 lbf-ftl

(1) FORK COVER

~I

(3) FRONT FENnER

(2) FRONT FENDER STAYS

. ~ 5 N·m (0.5 kgi·m, 3 .. 6 Ibf·ft)

~~

I

Iinstallation is in t~e reverse order of removal.

NOTE

Install the front fender stays and brackets as shown . • , lnatall ilia long bolts into Ibl;! ~rtJnt IO'lll~r side,

TORQUE:

Front fender' mouMwng bolt: 5 N·m 10.5 klgf·m. 3.6 IbHtl

2-1·3,

FRAIME/BODY PANELS/EXHAUST SYSTEM

REAR FENDER

REMOVAilL

Remove the side cover (peg,s 2-3). Remove the bstterv ([)i:I~!;l 16.151.

Remove the rear shock absorber reserve tank band. Remove the reserve tank from the rear fender groove.

Disconnect the fol1lowing:

- Side stand swi'lch connector

- AIternaLm connecter

Remove the leM (ignition control rnecutel. Remove the wire harness clamp screw.

R~llIO\i'e the bolts, nuts and regulator/rectifier. Disccn nect th,!'! reglllalor{recttTier connector.

Remove ths starter relay switch and "eleQs~ the wire harness Irorn lhll I'e!al' lender,

Remnve the bollt and rear brake reservoir.

Disconnect thp. turn sigln.al and license light connectors. Remove the recr fender mounting bolts and rear fender.

2,-14

FRAMIIEIBOD,Y PANELS/EXHAUST SYSTEM

INSTALLATION

(1) BRAKE RESERVOIR

(5.) REAR FENDER

Install the rear fender into the s'sat rail. while aligning the front groove of ith a mar render with I.he s u b-frame.

• While installing the rear ftlniiJl;!l r route the wire harness properlv ~ Pc'i:lge 1-211.

Install a ndtjghtel1 the rear fender m,ounl'ing bolts.

install the removed parts in the reVerSp. D,rtler of removal.

SEAT RAIL

REMOVAL

RemOVE! the rear fenner ('page 2.-,'14).

Release the harness wire clamp.

2-15

FRAME/BODY PANE.LS/EXHAUST SYS,IiEM

IRemo'le the following:

- Muffler rnuuntinq boll/nut

- Plain washer

-Collar

Remove the seat rail rnountinq bolts" nuts and seat rail,

INSTALLATION

Install the seat rail in the' reverse crder or rflmvv,d.

NOTIE

• R(lUlte the w~rlEl harness properly and clamp it.

MUFfLER/EXHAUST PIPE

REMOVAL

.' Do lUll sen1ic~ 'fie cxha ust system wli:ile ,it is hat.

Remove the exhaust pipe/muffler mounting bolts,

Remove the, fol'lawirng:

~. Muffler mOILlI ILing, belt/nut - Washer

- Collar

-l'iu,bbl;1[ bushing

~·Mumer

- Mufller gasket

2-,16

Ramov!;! llui! rnlddle/lower cow! Ipage 2-6).

FRAMElBOQV PANELS/EXHAUST SYSTEMI

Rp.move the exhaust pipe Joint nuts,

Remove the fullowing:

- Exhaust pipe mO'llnfilng bolt/nut ~ Washer

- Collar

-IRubber bushing

-IExhillust pipe

~ Exhaust pipe gaskets

INSTALLATION

RIGHT:

!LEFT:

\c

12 N·m 11.2 kgf·m, 9 ~hf-ftl

2-17

FRAME/BOD\, PANELS/EXHAUST' SYS1i:EM

lnstall the exhaust pi~~ and I11Um~r, andternpcrarltv tiCJhtsl1 the all mounting bolts and nuts.

NOTE

Alwa,ys. replace -the exhaust pipe and muffler gqskets with newones.

Tighten the' exhaust p~pe lcmt nuts to the specuied torque.

TORQUE: 11,2 N'm (~.2 1I:9f.m, 9 Ibf.ft)

Tng~ten the muffler/sxha List p~ pe mounting bolts.

Tigl"lten the mufflel'/exl'laus,t pipe nne u ntl n g nut to the specified torque.

TORGUE: 25 N·m [2.1:i kgf'm, 19 Ibf-f;t)

Install the rniddle/lowsr cowl (page .2-6).

2 .. 18

3,. MIAINTENANCE

SERVIICE INFORMATION MAINTENANCE SCHEDULE FUEL liNE THROTTLIE OPERAT~ON CARBLIRETOR CHOKE AEHCLEANER SPARK PLUG VALVE CIII..!EAIRAN'CE ENGIN,E OIl/Oil FILTER CARBUl R ErO:R SVNCH RONIZATION ENGINE IDLE SPEED RADIATOR COOLANT COOUNG SYSTiEM SECOND'ARVAIR SUPPLY SYSTEM

{CALlF'ORNIIA TYPE ONLYI 3-16

,3-1 EVAPORATIVE EMIIISSION CONTROL
3-3 SYSTEM (CALIFORNIA, TYPE ONLY) 3-17'
,3-4 DRIVE CHAIN 3-17
:3-4 BRAKE FLUID 3-211
3-5 BRAKE PAD WEAR 3,-22 ..
3-5 BRAKE SYSTEM 3·22
3~5 BRAKE LIGHT SWITCH 3-23,
:'3-7 HEADLIGHT AIM 3,,-23,
,3·11 CL.UTCH SYSTEM 3:·2.4
,3-13 SIO:E SIANID 3,·25
3-15 SUSP'ENSIOINI 3·,25
3-15 NUTS, BOLTS, FASTENERS 3-27
3·16 WIHEELS/TIIRES 3-28
STIEERING HEAD BEARINGS 3-28 SER:VICE INFORMATION

GENEHA,L

• Ga!>Cllirie is eXli'emeij'_(illlllllrobJ.e ami is ".'l:plflyfp~ urliJer t:erltdll clmdiliom. Work ill ,a weli rollflu{lJted area. Smalei",!: or ailowi'lg flames or sparks ill' tlre work urea Q/" where fin! gll5oli7l!" ls s~(lred call caus« a fire or explosian:

• 11 th» i'"gi"'_~ mud be running to ,rJ,U some work, make SlU·C the area is well vlI,ntflared. Never rUII Ihe /!n.gim! in tIn t"ndfJ~",d <rrf!f1:. 7"fl£. exhaust cont{Jins POiSOllOIJS .carinm /tl,(}l'Wxi.de gas 'liar may ,ca~~e Jns~ oj (.'·ofl~ci(.l/'I.\'I1t'~'5 I1mi 111:(1.1' led In deatr z.

----------------

SPECIFICATIONS

ITEM SPEC.FICA TIIONS
Till ottle gri p -I,se play 2 - 6 rnrn [1/12 -1/4 ln]
Spark plug NGK NIP'PONDENSO
Standard ORgEl-! 9 U27FER 9
CRBHI19, -
Optional U24FEIR 9
Spark p.iug gap 0.80 - 0 .. 90 mm (0.031 - 0.035 in)
Valve clearance IN 0.13 - 0.119 rnm ((LOOS - 0.007 in!
EX "9:6 - '97: 0.19 - 0,25 rnrn (0.007 -0.0'10 in)
After '97: 0.22 - 0.28 mm (0.009 - 0.011 in) 3-1

MAINTENANCE

liTEM SPECIFICA"J;IONS
engirle oil capacity At n raming 3.5 liter (3.7 US qt, 3.0 Imp qt)
At disassembly 4.4 liter (4.6 US qt. 3.9 Imp Qt)
At oil filter chanqe 3.6 liter 13.8 US qt. 3,,2 Imp qJt)1
R.ecomrnendad engine oil HONDA GN4 4-stroke oil or equivalent motor oil
API service ctassltlcatlon SF or SG
Vi sees ity: S.AE 10W - 40
Englin'8 idle speed Exr.ept Ca~ifQrni8 type I, H~O ± 100 rpm
California type 1. ,200 ± 100 rpm
Drive chain sleek I 30 - 40 mm (1-1/8 -1,1/2 inl
Recommended brake lluid DOT<ll
C~lutch lever free play 110- 20 mm (3/8 ~ 3/4 in)
Tire size '96 - '97: Front 130/70 - ZRn 6
Bea,r 180/55 - ZR17
After "97: Front l30na - ZR16 (61 W) I
Hear 180/55 - ZR17 (73 W)
-
Tire brand Bridg estone Frcrrt BT5BF RADIAL
R'€ar BT55R RADIAL G
Michelin Front TX15
Rear TX25
Tire air pressure Up to 90 kg [.200 lb] Front 250 IcPi;I (2.50 kyf/cm:l, 36 psil
load Rear 29'0 kPa (2.90 kgf/cm2, 42 ps~)
Up to maximum P'r<Clnt 250 kPa 12.5·0 kgf/cm2, 36 psi)
weight capacity Rear 290 kPo (2.90 kgf/~ml. 42 IPs'i)
Tire minimum tread depth IFro,nt 1,.5 mm W.Os, in) I
Rear 2.0 mm W.OS in' I TORQUE VAILUES

Cransshett hole cap Sliar~ plug

Oil drain bolt

Oil filter c':!lfll"idge

vacuum plug fOIi synchronization Hoar axle nut

18 N·m (1.8 kgf·m. 13 ~ bf-ft) 12 N·m (1.2 kgf·m. 9' IbHt~ 29 N'n'] (3,0 kqf-rn, .22 lbf-ft) 10 N'm (1.0 kqf-rn, 7 Ibf-ft)

3.0 N'm ~0.30 kgf·m, 2.2 Ibf.ft) 93 N·m (9.5 kgf·m, 59I1bf.fi)

TOOLS

Oll fllter wrench Drive chain tool set Vacuum gauge set

07HAA - PJ70100

07HMH ~ MR10103 or 07HMH - MR1010B (U.S.A. only)

07L'MJ - 001000A (U.S.A.. only) or M937B ~ 021 ~ XXXXX (U.S.A. nnly)

3-2

MAINTENANCE

MAINTENIANCE SCHEDULE

Perform the Pre-fide inspection described in tllh,e Owner's Manual at each scheduled maintenance period, I: Inspect and C~e(iln. Adjust. Lubricate or Replace if necessarv, c: Clean. R.: Replace. A: Adjust. L: Lubricate.

Tb e following items: require some rneehanleat knewlsdqe, Certatn ihmls (part'ic:ula"ly those markad ., .and **) mav require mote teehntcal lnfcrrnatlon and tools. Cornu;lt y,our authorized HONDA dealer,

----------------------------------------- FREQUENCY INOTE ODOMETER READlING (NOTE 1) REFER
D- Xl.OOO mi I 0.,6 I 4 8 12 I 16 20 24 TO
m::MS ---- _____ X1,OOI] 'km 1 I 6 12 18 ! 24 30 3,6 'PAGE
. ____
...___ .
"" FUEL. LINE I I I 3-4-
-
H THROTTLE OPERATION I II I 3·-4
I -
it- GAR,BURETOR CHOKE I I I 3-5
,
,If) .. AIR CLEANER INOTIE 2. R R 3-5
'~
lJJ SPARK PLUG I I R i R I I A 3-5
~ I
c '" VALVE CLEARANCE I I 3·7
j::
<i ENGINE DIll I R R 'R R: 3-11
...J
w EN'GINE OIL FRTER R ~ R I iR I 3-H
!;!;
Z jj; CARBURETOR SYNCHRONIZATION I I I ~ 3:-i3
0
u:; ., ENGINE IDLE SPEEID i I I I I I I s-rs
t.r.I
s t--
w 'RADIATOR COOLANT NOTE 3, 1 I R 3-15
I -
fI COOLING SYSTEM I I I 3-i6
,
., SECONDARY AIR SUPPLY SYSTEM NOTE 4 II I I 3-16
i! EVAPORATIVIE EMlSSION CONTROL SYSTEM NOIE4 I I I I 3-17 I
DRIVE CHAIN I EVERY.500 mi (BOI1 km.J). L 3·17
en BRAKE FLUID NOTlE3 I . I R. r. ~ J R 3·21
~
w BRAKE PAD WEAR I I I I I I 3-.22
!::
Cl 6RAKE. SYSTEM I I I I I 3-22
w
~ lo} BRAKE UGHT SWITCH I I 'j 3-2.3
«
...J
U! '" HEADLIGHT AIM r I I 3-.2:3
rr:
Z CLUTCH SYS.TEM l r i- 1,'" I I I 3-24-
0 ,
ii5 I SlIDE STAND ~ r I I, 3-25
~. ,
.". .. ~ SUSPENSION . ~ . I a 3-26
..:: .
ill
, .;:, NUTS,. BOLTS" FASTENERS I I I 'I '3-27
z
0 ~"'. J
z WHEELSfTlRES I" ."I 3·28
!I'll- STEERING HEAD BEARINGS I ~ I t I .1 I 3-28
'-- " Shculd be serviced by an authorlzed HONDA dealer, unless. the owner has proper toots and service data and is

rnechanicallv qualified. I

h 1111 the interest Df safety, we recommend these hems be servleed 'only by an authcrized HONIJA dealer,

NOTES: 1. At higher odometer realdlng, repeat at the frequency interva,l estetniahed here,

2. Servioe more frequeRt!y when riding in unusually wet or dusty areas.

3. Aeplae:,e every :2 'years, or 3itindi,ca'ted odometer interval, wllilchever Domes first Replacement requires mechanical skill.

4. Califomia lype anlly.

3-3

MAINTENANCE

FUiEL LINE

Check the fuelIines for deterioration, damage or laakaqe. Replace the fuel line ir necessary.

Also check the fuel valve vacuum tube for damage. Replac-e the vaCUILJm If necessary.

THRUrrtE OPERATIO N!

Check for smooth throttle qrip lull opening and automatic full closing in all steering positions.

Check th€ throttle I':ai."lles end replace them if they am dererlorated, kinked or damaged.

'If throule operation is not smooth, lub ricate thp. throttle cables.

Measure the free play at the, thrcttl <!J grip nijlnge.

!'ABE PLAY; 2 ~ 6 mm f1/12·_ 1/4 lnl

Throttle grip free play can be adjusted at elthor end of the throttie cable.

Minor adjustments are made wM:h the upper adjuster. Remove the dust cover from the adjuster,

Adjust the free play by loosening lh" Ilu!':k nul and tuming the ad] uster.

Major adjustrnsrrts are marla with lhe lower adjuster.

Rf!mave the air cleaner housinq (pa,ge 5-41.

Adjust the free pl .. y loos.anirlg thetock nut and turn the adjuster.

After adjustment tighten the lock nut securely.

Recheck tha throttle uperation.

'Replac·" any Oilmi'lgp.rI ri'lrts, if nf!ces,<;ary.

3-4

CARBURETIOR CHOKE

MAINTENANCE

The choke' system U!'ifOS a fuel enrichment circuit ccnrrolled by a starting cnrtehment !SEI valve.

The SE valve opens the enrichment circuit via a cable when the choke knob on the top bridge is pulled Lip.

Check. for smooth choke knob oparatlon and lubricate the r:h eke cable if required.

Inspect the CiiJhle for cracks wh~clh could alhow moisture to, enter.

Rep~,ace the cable lf necassarv,

AIR CLEANER

Remove the fuettarik (page 2-2j,

Remove the nine screws anri air cleaner housing cover,

RemO\i,e and discard the air cleaner alemen in accordance wlth the rnalmenance s:chedulll:l.

Also replace the air cleaner element any time it is excessively dirty or damage.

Install the' removed parts in the revl;;lr~<J' order or removal

SPARK PLUG

Removerha middle cowl (p.age2-6).

Disconnect the s.pl'lrk plug caps.

OTE

Clean around the spark pl~:g bases with compressed air before removing, and be sura, that no debris is. allowau toenter the '!;ornuust~un chamber,

CAPS~

,3-5

MAINTENANCE

--.

ARK Pl.lU WI\ENCH

Remove the spark phlg using a spark plug wrench.

Inspect or replace as described in the maintenance scheoule.

IINSP'ECTION

Ch~cCk thefollowi ng and replace if nsccsse ry I reco mrfu:l:ruded spark plug: pagfl 3-' I.

• Insulator for dam"g~

• EIi:cttrodes for wear

• Burning condition, coloration;

- dark to light brown indicates good condltlon,

- excessive Iightm;!,~lS indicates rnalfunctioninq i9Ul1ition

system or lean mixture,

- wet or black sooty deposit lnurcatea over-rich mixture,

REUS1NG A SPARK PLUG

Clei'ln the spark plug electrodes with ,a wire brush or special plug cleaner.

Check the gap betwE!cen the c8111ter and side eler:tmrJes with a wir~·tYIPi! feeler gauge.

If necessary, Ddjust the gap by bending 'the side electrode caretul 1)/.

SPARK PILUG GAP: 0.80 - O.SO mm 111.031 - 0.035 ill)

CAUTION

Tn f'r~W'_nl dmllagf' to the cylinder head, hWid-,I~gltu:1l tile spark plu(f be/ore using' a wrench to righlC/l to the ~pecifi(!d TOrque.

IReinstr!ll~ the spark plugs in the cylinder head and hanrt tjoh en, tnf!1) torque to specificetion,

TORQUE; 12 N·m 11.2 kgf'm, '9 Ibf·ltl

REPLACING A·SPARK PlU'G

Set the pluq !Wp tu spaelficatjon with a wire·type feeler g.auge (see above).

CAUTION

lnstall and hand [~glnBn the new spark piug, lhen 'liyl1tren it about 1,12 of a tum after the sealing washer c(,mt .. cts the s~lIt of the plug hole.

(1) CENTER ELECTRODE

- (2) SIDE ELECTRODE

"

~3) INSULATOR

3-6

MAINTENANCE

I NSPI:GTI.ON

NOTE

• Inspect and adlust me valve crcerance while the engline is t;old( uO!I t,lW 35cC195~Fl"

R!'!move the mirlrllp./low.er cowllpage 2-6). Romove the cylinder head! cover (page 8·4~.

R.emove ihs 'cam chain h~!H;i:onerlift9f saalil"l'9 bolt and w<Jsher.

Turn tha (;<l:m chain tensicner lifter shaft fully and secura it us.ing the stopper tool (See page 8·8).

Remove the crankshaft hole r:ilp and O-ring.

Turn the crankshaft cleckwlse. alllgn the "T" markon the Iqnltlon pulse qenerator rotor withthe index mark 'on the Hgnitio!ll puise generator rotor cover.

3-7

MAmNTENANCE

The timing marks (~IN~ and "t::X") on the earn sprockets must be flush with the cyli !'Ide r haad ~u rface and faci no outward as shown.

~r the' timing marks on the com sprecket facJng inward, lur n hp. crankshaft clockwise ona 'ull turn {SBO') and realign the 1imil'lg marks with the;ll:yl1nder head surface so they sre tacing outward.

Insert the feeler gauge between the valve lifter and lhe cam lobe,

Check the valve clearance for the No.1 anrl No.3 cylinder intake valves using C'I feeler gauge.

VAILVE ClEA.RANCE; IN: 0.13 - 0.19' Illin (0.01ll5 - 0.007 in'

NOTE

Record the clearance lor each valve for reference in shim Sl;llet::tion if adjustment is requirar].

Tum the. cranksha+t clockwise 1/2 tum !180~), align the mdsx line an the ignition pulse gemmnor rotor so that il i!; facingl up as shown.

Check the valve clearance for the No.2 and No. <1 cylinder exhaust va lives u-sin!:l <I fE;!~~lo!r g.auge.

VALVE CLEARANCE:

EX: 0.19 - 0.25· mm 1.0.000'- 0.010 in~ '96 - '!!1'1: 0.22 - 0.28 rnrn 10.009 - 0.011 ill1l)1 After '97:

DIE

• Record th e clear ance for each valve Tor referle:nr.p. ilish~ rn selection if adjustment is required.

MAINTENANCE

Turn the cranksh an ,olockwise 1/2 tu rn 11 BOD), alig n tile' "T" mark D'i11 the ,igl1iilion pulse ,generator rotor with thp. index mark on the ignition pulse gerne-rator rotor cover,

Check the valve clearance t'Qr the No.2 and Nlu. 4- cylinder intake vatves using feeler gaugH.

VAL VI:. OLEARANCIE: liN: 0'.13 - 0.19 mm ICI.006 - (iU}07 in I

Turn the crankshaft clockwisa 1/2 turn (180°1. align the index line on the ignition pulse generator Irutur rO;l!;ing ue as shown.

Check the valve clearance for the No. , and NCL 3 evllndsr exhaust valves usin.g a feeler gi:u~ge.

VAlViE. CLEARANCE:;

EX: 0.19-1)1.25 mm 11J.007 - 0_010 iii' '96 ~ '97: 0.2.2- 0 • .28 mm 10.009 - 0.011 inl After '91:

-~

EXHAUST VAL VES

3-9

MAINITEIMANCE

ADJUS1MENT

RI;/IT lo .... e the: camshaft (poge 8-5). Remove the valve lifters and shims.

NOTE

Shim may stick to the Inside of the v<llve 'lifter. Do not a,l~owthEl shims to tall into the crankcase .

• Mark all valve lifters and shims to ensure correct reassembly in tJlleir origilnal locaticns .

• , The valve ntrer can be e,ll!dly removed with a valve lapping tool or rnaqnet,

• The shims can be ~asily removed with a rwsezers or magnet.

Cle,an the valve shim contact <are a in the valve lifter with compressed air.

Measure the shim thick ess and record it.

NOTE

Sixty-fiVe! drfferent thickness snlrns are avaltable from HIlI'! thinnest 11.200 mm thickness) shim tID the thickest 12.BOO mm thickness shim} in intsrvalsof 0.0.25 mm.

Calculate the new ahirn thickness using the equation below.

A = 18 -CI + D

A: New s~irn thlckness

B: Recorded valve clearance C: Specified valve dt!'illrance D: Old shim thickness

NOTE

'. Make sure of the correct shim thickness by me<l!;uring the shim by micrometer.

Hefncc the valve ssat if carbon deposits result in <I, ealcu lated dimension of over 2.800 1'i111).

Instal! the newly selected shim on the valve retainer, Apply molybdenum disumde oil to th-e V<llw! lifters.

I nsta ~I the valva lifters into ttlP. velve lifili,er he les,

NO lIE

Install the shims ano valve lifters in their origill"la~ 10c;:Itions.

3-10

(1) VALVE LIFTER

~ ~

ee

1.80 rnrn

1..825 mm

1.85 "Irll

1.875 mm

lrtstall the camshaft Ipage 8.-20'1_

MAI.NTIENAN'CE

Rotate the carnsbatts by rot-Elting the, crankshaft clockwisa seve-wei times,

Recheck the valve clearance.

1r1!;tal'l the l!"'lew sealing washer and earn chain tensioner sealing bolt

Tighten tha bolt securelv,

I nsta!l the rem oved p!His in the reverse order of removal.

ENGINE OIl/Oil FILTER

OILILEVEL INSPECrllON

PIOIce lhe rnotorcvele om ~E!vel gro !.Und.

Check. the oil level through the insredion-windcw.

If me oll Isvells bel:ow or near tile lower level Ilne, remove the I) i I filler cap <l nd add the recommended oil up <0 the UpPE!~ level,

R'ECOMMEND,ED EN.GINE OIIL;

HONDA GN4 oil-stroke oil orequlvalant motor oil:

API service, cia ss'iiic;'lfill iii: SF [It SG \I.iSCOBity: 10W - 40

NOTE

Other viscosltiesshown 1m 1thic chrm may be used when {he average tarrrperature in YIJur !riding area is wirthin the'

indlcated n;mge. .

1'\C,j nsta.l~ the, fi~ ler caa,

~1) CAM CIIAIN TE:NSION!A LIFTER

Oil VISCOSITIES

, , i, ,'I,
._ ,~

"
,. J

0 20 ~b 60 eo 100 'F
!20 -10 0 10 W JO 40 'C 3· .. 11

'MAINTENANCE

ENGINE on. & IFll TER CHANGE

il@W"";

If the eugine must be rUJ!tlil!~ to ,do sums work. mt.ike ~'Iue the area is II'cll-vl!ntil.at.ed, 1""'1111,(!,. rim the r.ngi.nl{ ill 1W mdfl'!i.,d area. The ex/l.(lItst contains poisonons rod",,, I1wlUu:.ide gas r!tal may "uln'c loss (If eansciousness and may lead to deai/I.

Wi':lfm up tlie enginEi.

NOTE

• Change the engine oil with the engine warm and the motorcycle on levi'll ~ruund to assure complp.te draIning.

Remove thp. lower cowl (poge 2-6).

StOP the angJine~lrlGJ remove the oil filler cap and drain bolt. Drain the oil completely.

CAUTION

• Urea' engine oil may nwse skin. r:(lJJal" I]' repeatedly lift in contact wish rile ski" frw prn/(mgl':d' penods. IIWw!I.gil 1M3 is Imlikely wuess :mu handle used 01/ on a daif:y basis, Ii is Slill advisable to thor<Jilghly wash ,'OLlr lialld$ ,(,jIll soup and wu(er as £oem. n:;; possible after handling. used uil.

[Remove and dlsr.a rd the oil filter cartridge usi ng the specl al tool.

TOOL.;

Qill fllter wrench

07HAA - PJ70100

Check thaI the sealinq wesher 011 me drain bolt is in ·good condition, and replace if necessary,

Install and lighlsil the drain bolt.

TORQUE: 29 N·m '13.V kgf-m. zz Ibf.f'tJ

A ... 1 ?

Apply oil to the new oil filter 0 ring.

lnstall the new oil filter and tighten it to thE specified torqrre.

TOOL:

Oil filler wrench

1l7HAA ~ PJ71nOlli

TORQUE: HI N-m n.o kgf-m. llbf1t1

Fil.l the crankcase with recommended ang;ina ell.

OIL CAPACITY:

3_5 liitter ~3.7' US qt, 3.0 Imp qt] at ar,aiming

3.6 liter r3.8 US qt. 3.2 Imp qt)1 at 011 fll'tel' change

lnstall .lhe (Iii filler cap.

Sta:rt the engine and r 01 1t idle for 2. to 3, rnl n utes,

Stop the engine and check that the oil level IS at lheJ upper level line ill lh~ inspection window.

Make sure there rtf,f~ no oil leaks.

CARBURETOR'SVNCHRO IZATION

NOTE

Synchn:miH! th ff!' carburetors 'with the engi n fl <It norrnsl operati ngl temperature, the transmission in neutral a nd the motorcycle supported securelv on (I level surlacs.

Remove the TH..Iel tank and middle caw I ISectiol'n 2].

Re:mov,nhe vacuum plugs from the engine intaks ports,

MAINTENANCE

m VACUUM PLUGS

3-13

MA,IIN"fENANCE

Screw the adaptors in the intake ports,

lnstsll l:hl;J g-W(l,¥ [oint to lhe fuel valve vacuum tubs. Connect the fuel tube and vacuum tune to thp. H'!I tank.

Connect the vacuum gauga 'tubes to the adaotors arid 3-way lolnt,

TOOL:

VacuuJm gouge set

07LMJ - I)OUJOM [U,S,A. onlv) or M9'37B - 02.1 - XXXXX rU.S.A. onlv!

Start the engine and adjust the idllc speed by turning the throrrlestoe !'H::rew.

IDLE SPEED:

Except California. type: 1,100 ± lOU rpm Callifornia type: 1.200± 100 rpm

Check halt each carburetor jntak~ vacuum pressure is wirthin 20 !TI1l'l (0.8 in! Hg of the base carburetor.

NOTE

• The No. 3 carburetor cannot be adjusted; it is the base carhuretor.

The INa. 3 cylinder intake vacuum pressure is the base vaouu rn prsssu ra,

Svnchronizeto specification by turning the adjllisting sr..r~w with the phillips screwdriver as shown.

Recheck the idle ~PI'!I:!U a mJ e,8ch cyl i rider intake V<lCU:U m pressure so it 'is within 20 mm (D.A iri] Hg of the base carbureto r readi n:g after snapD1 n g the throttle glr~p 3 - 41limes.

(1) VACUUM GAUGE

MAINTENANCE

Remove the vacuum g.aiJg e tu bes,

Install the vacuum plug.s into the intake ports, and tigij-irte'n rham securelv,

IEINGIINE, IIDltE SPEED

If the ,engino': mus: iJe nmniflg w do ~onu: work, make UlI'Itl the area.is '!Vel( l'l!lItiJated. Neverrun. the crlgilll! in G.I! elwitlseil area. The .g;rJl(J.w;:t eontains pUi.!lOnllll~ carbon monoxide gu~' lbo' I1ItiY I ea It~f! lays ofco 'JSd!ilIISm~Ss and TIl.u.~ If<<d fa df!f11h.

NOTE

Inspect and adjust the idl,e speed atter all other engine rneintenence items have oeeW! performed and EIre within spet:ffications.

• The 'I;lfl~in!;l mm;;t bewarrn for accurate ldle speed inspecticn and adjustment.

Turn the throttle stop screw as requir-ed .0 obtain the specified idle speed,

IDbE SPiEE,[iI;

Except California type: 1.100'± 100 '1Prn {:,alifomi.8 type·: . 1,2110 ± 100 rpm

HA.DIATO:R COOLANT

Check the coolant level of the reserve' tank wnth the engine run n jng at norma I operating temperature.

The' ~eval Sh.OIUld be between ~hf:l "UPPER" and nLOWER" lavsl lines ..

111 VACUUM PI.UGS

3-15

MAINTENANCE

I'f necassa ry rem ave th f!: re~er\il'! t.1I n k cO'l r Cl nd till to t'h e ~ UPPiER" level line with 50/50 mixture of distilled water and a:ntiheezEl.

Re·instaU the cap.

enOUING SYSTEM

Remove the middle and lower cowl (page 2-6).

Ch.l'!<:.k thl'!, rFldi1'lT<:Jr Atr pa~<:;ages for c'lcngginU or dama.ge. Str1lighten benefins. and remove insects, mud air other obsrrucuone with. cornpressedalr or law water pressure. Rep.lace the radiator if the air flow is re!lliricled ,ov·er more tha n ?O% of the r1JJdi<Jiting Soli rface,

Inspect the radiator hoses for cracks or deterioration. and replace if neeassarv.

Check the tlqhtness of all hose clamps and raSL!;!rH;Hs.

SECONIDARV AIR SUPPLY SYSTEM (CAUFORN~A TYPE ONLY)I

NOTE

The sf!cond;:lry air sllpply ';"I$tem introduces fil~ered air into cxboust g.oses in tneexhaust port. The seconderv air is drawn Into the exhaust port whene· v er '[hem is ne·gative pn=5sure pulse ill the exhaust system, This charqed secondary air promotes bur ninq of thl,e unburned I'!xnBW'it gases and con ... ertsconslderable amounts ef hvdrccarbens and carbon monoxide into rr:ll;;ltivl;1ly h<ll1Tlless carbon dioxide and water.

·R.emave the fuel tank and lower cowl (SectIon 21.

ChP.cK the air injection hoses and pipes between· tthe pulse seccndarv air i niecti 0 n I PAIR) control valve Bin d exh Bust porttor deterioration, damage or 100:'Oe eenneetlons. Make sure lhat the hoses "II'! IIU I craekad.

NOT!::

MAINTENANC'E,

If the hoses shew any siglns of heat damage, inspect the PAIR check valve in the PAIIR control valve for (llllm,age.

Check: the air suction hose between the air filter, air chami:nP.f and PAIR control valve fo~ d:e·[IH~Ori3rion. darnaqe or loose connections. Make sure that Lhe hosesare not kinked, plnehad or cracked ..

EVAPORATIVE EMISSION CONTROL SYSTEM (CAUFORNIA TYPE ONLY)

Check the tube betw,een the fuel tank, EVAP canister, IEVAP purge control valve: and carburetor for d9t9r~oratiomr damage or loosa connection,

Refer III tha Vacuum HOSI;l RQu~ing 'DiaglHlnl Label and Cab:le 8:1 H<irness IRouting ~lPag'E! 1-25,) for tube connections.

DRIVE !CHAIN

DRIVE CHAINI Sl.ACK INSPECTION

Never inspect fJlid adju8t r.he dril'e chaill wnih the (!nginu is run'1 tn.:.

Turn the ignition switch OFF, placc tbe motorcycle on its side stand and shift the transmlsslon into neutral,

Check the slack in the drive chain lower run midwOly hp.hNe,en ths sprockets,

CHA.IN SLACK: 30 - 40 m.m (1-118.-1-1/2 in]

CAUTION

IDxf:!;s!VI~ chain stac«. 40 film 0-11.2 i1'l) or more, mil)' dIJl1wgl! dw frame.

Lubricate the drive chain with Fro Honda chain lube deslQned specifically for use with O-rIng chaios, Wipe off the eX[;E!SS chain lube.

(1) EVA? e,~.NISTER

3- 17

MAINTENANCE

ADJUSTMENT

Loosen the rear axle nul.

Turn both adjustinq bolts until the correct drive chein slack IS obtained.

Make sure the index marks on the both adljusters are aligned with the rear end (If the sVllif'lg,arm.

Tighten the r'B" r a)(18 Pl.ut to the speclfiad torque.

TOROUE: 93 N·m, [9.5 kgf·m. 69 Ibf·ftl

Recheck the drive cha in slack and free wheel rotation. LlJbrl(:~ti': the drive chain with Pro Honda Chain Lube designed 5pe:cif~coily 'for use with O-ring chalns, Wipe off [he excess chain lube.

Check Lilt;! drive chain wear indicator label attached on the left drive chain adjuste r.

11 the red zone on the label ,aligns with the arrow mark on the swingarm. replace ttle drlve chain with a new one (page 3·19}.

GLEANING AND I.UIBRilCATION

Clean the chain with 1'l soft brush LJs'ing CI non-Harnrnahle or high flash point solvent and wipe it dry.

Be sure l,he chain has dried completely before lubri,c:alinlg.

Inspect the drive chain for possible damage or wear. Replace anv chain thet has damaged roll ers, loose 'fitting links, or orherwlse appears. unservlcesbte.

lnstallirrq a new chain on badlv worn sprockets will 'cause' the nB'W cha in to we,n quickly.

lnspect and replace sprocket as necesssrv,

Lubricate the drive chain with Pro Honda Chain !Lube desiqned specifically for use on O-rmg C 811n5.

Wipe off the excess chain lube.

(::l) NON-FLAMMABLE OR HIIGH FLASH POINT SOLVENT

(1,1 CLEAN

(1I1UBRICA E

(2) PRO HONDA CHAIN iJJB'E

3-18

MAIIINTENANCE

SPROCKIETS INSPECTIION

Inspect he drive and driven sprocket teeth for wear or damage, replace if nacassa ry.

N'l;1ver use a new drive chain 011 wom sprockets,

Both chai n a nd sprockets m 11'.lit Inl'! in gnod, condition, O~ the new replacement chaln wlll wear rapldlv,

Check the attaching !JO]l!> <lIIJ !lULS on the drlve and driven sprockets.

If IIny are loose, torque them to the proper soecificetions,

REPLACiEMENT

This motorcvcle uses ill drive chain witll a staked master link.

Loosen the drive chaln tpaqa 3-17). Assel11ble> the special tocl as shown.

TOOL:

Drive ch:alln roel set

07HMH' _, MR10~O'3 or 07HMHI- MFl101(1,8 (U.S..A, onlyll

NOTE

When using the special tool, follow the manufacturer's lnsrructlo n.

[21 NOR.MAL

(

(1) ~RIVE CHAIN TOOL SET

MA.INTENANCE

Locate the crirn red pilri ends of the master Ii nk from the nutside of the chain. ,and remove the link with the drive chain tool set ..

TOOl:

Otive chain 1001 set

1(]1HMH - MR'1010J or G7HMH -MR1010B IU.S.A, onlvl

R~mov~ the drive chain.

I'i.Blllove tile exc·ess drive chain links from the new drive chain with the dr'!VR dlCli,. tool s.~t.

NOTE

lnelude the m.'lster link when YOLI (.01101 tile (hiv!'! r.:hi'Jiri Ijn~3.

STANDARO LINKS; 120 links REf'LA.CEMENT CHAIN:

DID: DID52.5iHIV GC&.B - 12nlB RK: RIKG,B525IROZ1 - 120UF

CAUTION

Never reuse the old drive ciwil1, muster Nllk, master link puue al1d O-rilt8J

Install the new drive chain ~nI:o theswlnqarm as shown.

CAUTION

Insert du! muster Nr!J./wm Ihf! inside of Ihe driv» chuln, £ll"nl in.l !.ldl lire plate wiill th» idenlijictlfirJl] II!llrkjar:iltg ti,~ outside.

Assemble and aat the drive chain tool set.

TOOL:

Drive chain. tool set

07HMH - MR10103 or OJI-I'MH - MR1010E!

(I .. LS.A. onlYI

Make sure that the master lin!: pins are lnstalred properly. M~Msure tlw master link pin lerlgLI, projected from liT!";! plate,

STANDARD LENGTH:

DID: 11.15 -1.55 nun [0.045 -.0.0611 in~ RK; 1.20 -1.40 mm 10.1)47 - 0.OS5 in!

Stake the master linl( pins.

(2.) MASTER LINK

11) DFlJVE CHAIN TOOLSET

13! MASTER LINK

(1) LINK

~~-~--(2110S LINK ---~-..,

DRIVE CH,AIN

----------------------------,

(2l0-RIING (3) PlATE

L

r:m

Make sum that the pins are staked properly !Jy II1<!8;:i>lllLri,ng the dlarneter of the staked area using a slide caliper,

DIAMETER OF THE STAKED AIREA:

DID: 5.5 - 5.8 mm (O.22 - 0.23 in)

RK; 5.49 - 5.9'4 mm (0.216 - 0,.233 in]

After stalking. check: the staked area of "the master link for cracks,

Ir there is any crackinq, replace the master link, O'ringsl'lnd plilt~_

CAUTION

BRAKE FLUID

CA.UTION

• Do lUll mix diffitT<'1'll lyP{!~' (!1J1J~id. J1.l' In,,), ute (WI compatible with each othrr

Do IIO! all I foreign ma~erial to enter the system whcfI filling Ihe reservoir.

• !I void spiiUnR fluid on painted, plasiic or rubber purts; FlUL'/! u mg I)"~'F ih,,!;; paris wileJJ!TL{(,'- ,ho:: .rys-t''''l i. <,nlJlned.

NOTE:

Whim the fluid !lwei us low, ChAt-I< the brake pads for wear

(see next page,l. A low fluid level m_ay be due to wea.r of rne _

br,ake :pads. !f ]:he brake pads ara wcrn.tbaeallper prston is pushed ou I, a nd th is accounts iffolr a bw resarvoi r level.

If the brake pads are not worn lind the fluid leve] is Ilow, check -entwfiE':l svstcrn for leaks {sec next p,age!.

FRONll BRAKE

lIrn tl'1e handlebar to the left so that the reservoir is leve'! and check the front brake reservolr level through the sight qlass,

Ii the level is naar thp. ~olfller leve,~ lii'ilf!. check nle bIT'ake pad wear (see next page).

REAR BRAKE

Place the motorcvclo on a level surface, and support lit upright poshlo n.

C11OId: the' rear brake fluid reservoir level,

If the lp.v~1 is near fhe lower level ll ne, check the ,8rn1:ce pad wear (sec next page),

\1J SLIDE CAlIPER

(1l GOOD

121 'NO GOOD

(3) CRACKEID

3-21

MAINTEN.ANCE

BRAKE PAD WEAR

'96 - '97:

FRONT· BRAKE PADS

Remove the brake pad covers ('911, - '97).

Check the brake pad for wear,

Replace the brake pads ,if ",hl1~r pad Is worn to the bottom of WI;)1Ir limit gr·oove.

Refer to page 15 5, 6 for brake psd replacement.

Check Lli.O!I brake pad for we'ar.

Replace the hrake pads If either pad is worn to the bottom of wear limit groove.

Refer LQ vage 1 5~8 for brake pad replacement.

BRAIKE SYSTEM

INSPECTION

Firmly npplv the brake lever or pada'l, and check that no air has entered the sysL~m.

If the lever or pedal feels soft or :,;pongy when operated, hlMt1 the sir from the system.

Inspect thbl 'blake hose and fittings for deterioration, cracks and signs of lp.ili<:i'l9'''.

Tighten any loose fittings.

R,eplace hoses and.fittinqs as requimd.

Reter to pl'lg,e 15.3 for brake bleeding procedures.

After '97;

BR.AKE LEVER ADJUSTMENT

MAINTENANCE

The distance between he top of the brake, lever a"d the grip can be adjusted by tuminq the adjustar,

DIR~CTION IJ.: Brake lever fmther away' 'from the grip DIRECTIION B: Bralke lever closer to the Qirip

CAUTION

AligJl Ilu! allownnce on tilt' brake lever wirlr the index mark OT1 IIII! w:ij"'lter.

BRAKE. PEDA.I!. HEIGHT ADJUSTMENT

Loosen the lock nut and! turn the push rod until tne correct pedal height is obtnined,

BRAKE LIGHT SWITCH

NOTE

• The front brake light switch doe.s not reQ"Jire <BJ.ju·slment.

Adjust the brake light switch so that the briike light comes on just prior to the brake actll<llly being engragcd.

IF the lig ht fa ils to corn B on. adj ust [he switch so that lin e li!Jht comes on at the proper tlrna,

Hold the switch body and tlUlll the adjuster, On not tum the switch bodv ..

HEADLIGHT AIM

! r

ft." ilnprope.rry adjll ~r~d ',car#igJI( /i1IUY MimI' (>1'-(:rlm illg drivers, or it 'ilia.\' .fail to' Ugh' ~"'I! .rfJ'a« /(1'" a .mJe distance,

-----------------

NOTE

• Adjust the h,eadlight beam a,s specified by local taws and Ireg !Jlat·ions.

Place the motorcycle on a level surface.

,Adjust the hp.<!dlight beam vertically by turninq the· vertical beam adjustin!J screws.

A clockwise rotation moves the basrn up.

(1) VERTICAL BEAM ADJUSTER 1'96 - L!::!_ORIZO!:'l_TAlBEAM ADJUSTER 'lAtter '97:)

3-2,3

MAINTE.NAiN!CE.

A

Horizontal hP.MTi adjllstments are m.ade UJ:sing the" orizorita I beam adjusting screws.

A clockwise· rotatlon moves tihe iJ·eam toward the right side

ofthe rider. '

'96-'97:

Horizontal beam Bdjusts'r

A

Vertic!!1 :i:lea.m adjuster

Afiler '97:

'96- '97:

B

Alter '97:

Horirontal beam adiuster

CLUTCH SYSTEM

FREE PLAY: 1 Il - 20 mm ~31B - 3.14 i~~1

Minor adlustmcn[s arc made usingtth:e upper adjuster att the dutch lever.

Loosen the lock fI wet and turn tha 1jidjusH. r.

CAUTION

The IJJjf.j~·ler mu,\' be dW1U:Wed if if is poshi01Wd 100 far ow, lea~'ing 1.,ull"lInJ ~fmmd ~T18"gel~e,'~t.

If the adjuster is th readed (JUT near its I1mit a nd the correct f.res pl!a"l'c:~nnol b~ obtai!1ed, tum tha adjumer all ~he wey in <lml niJck out (me turn.

Tight,en the lock nut and me.ke ... major adjustment as described below.

Maltoradjus[msms are performed atthe clutch arm,

l.oosen the lock 11 ut and turn the adjusting nut to adjust free play,

Ho Id the oo1j ueti ng n ut secure Iy wh i le tighten ing the lot.k nut,

If proper ftl'!!!: pl~)' c:<'!nnot be obtained, or the dutch slips during the test ride, disaasernble and inspect the elutch (see seclil,JfI 9),

3-24

STING1]

SIDE STAND

Support the rnotorr.yde on a level surface.

Check the side stand spring for darnaqe OI luss of tension. Check the side stand essemhlv for freedom 'Of rnov~ment a nd [ubricate the side st;l nd pivot If necessary.

Check the, side stand iginition cui-ofli system:

- Sit astride the' motorcycle end raise' the side stand,

- Start the e I gine with the f1rl'l,n~misslon in neutral. then shift

tha transmission into gem, while s{Jueezing rhe ,clutch lever. - FuUy lnwer the side stand.

- The engilne shuuld slop as the side stand is lowered,

If thfm'! is a problem with the system, check the side stand switch 'soctijon 191.

SUSPENSION

L(),(J~e; worn or iUlmagcd' su~p'em;irm; parl!.~ impai'r mofQl'CJ>c1e 810.bUi/,)' Imd cururo]; Repair or replace ,lin], damaged ,c:umpUIlp.llts be/ore riding, Riding- a motorcycle wilTr !(mit)' suspension i1lufuse5 j";I.IJ:r risk. fiJian accidellt and possible itljury.

FRONT SUSIP~NSrON INSPIECTIOIN

Check the action of tol'lP. torks :by operating the, front brakes and compressilng 'tlie iirol"lt suspension several times.

Check the entire assembly for Si!=lT1S ui lealks,. darnaqe or loose fasteners,

Reprace d<lm<lgp.:ri components which cannot be reoolrcd, Tighten all nuts and bolts,

Rerer to sactiun 13 for fork service.

FRONT' SUSPENSION ADJUSTMENli

NOTE

To adjust both Sides equaljv, settho rilght and left dampi n,g ad] ustsrs 10 tine SOl me position,

SPRING PRE-LOAD AIlJUSTIER

Spring pre-lead can be adljusted by turnlnq the adiuster.

DIRECTION A.: [ncrease the spring pre-I,llailil DIRECTION 13: D,f!crease the' spr'ing p,re-Ioad

PR.E-LOAD AD'JUSTER STANDARD POSITION: 12 mm (0.5 in) from, top offolrk c-ap

STAND SWITCH

3-2,5

MAINTENANCE

CQ'MPRESSIION AND REBOUND DAMPING ADJUSTERS

CAUTIION

AIWI1Y., 'sfl1'-r <"l ft-" /om:a >Ii/WI) adjusting' !fr .. dampi1l8_

1)0 nat tum rlie adjuster scrcw,~ more than tile giVCI1 positions VI" llie adjusters may be damaged,

• Be sure iluu Ihe rebound I'm] compression mijrl~-rl:!l-J- om! firm/."

Jvca",J in 11 d""I'IJr, (lllti lim hrtwren ,f'""ifirllH.

The compreselon and rebound damping can be adjusted by turninq the adjuster s,

D'IR.ECTION H: lncrease the damping terce DIRECTIQN S: Decr,ease the dampilil,g force

Turn the compression adjuster clockwise until itstops, than turn ths adjuster ceunterclockwise.

COMPRESSION ADJIJSTER STANDARD POSITION:

l.S tum outfrom full 'hard

'96 - '97:

11 turn out from full hard

Aftp.r '97:

T'urn the rnhound adjuster clockwise until it stops, then turn the adjuster counterclockwise.

REB'OUNO ADJUSTER STANDARD POSITION; 1 tl1rn, D1I1 from ful.! nard

REAR SUSPE.NSIION INSPECTION

Support the motorcycle securely and raise the re<lr whp.p.! ott Ubi'! ground.

Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the vvh~~1 sid!;! to side,

Replace the bearinqs if any looseness is noted.

Check the action or the shock absorber bv cornpressinq it several times.

Check rhe entl fe shock absorber assern bly for signs of leaks. dumaqe or loose fasteners ..

Replace ,d,;rm<l9I;;!U components which 'COiT1IIU'L ue repaired. Tighten <III nuts and bolts.

Refer to sectlon 14 for shock absorber service ..

\

\ \

\

\

IREAiR SUSPENSION ADJUSTMENT

MAIINTENANCE

SPRING P;RiE-1..0AD A!DJUST'ER

Spring pre-load can be iJ1djl.Jsted by !tIming rhe tHljustp.r using a pin spanner.

DIRECTION A: Irll::mas;e I:he spring pre-lead I')IRiECTION B: Dle,cre~se itihe s:pri!lllg pre,·loaid

IPRE·LOAD ADJUSTER STAND'ARJD POSfTION: 2nd g'r'O'O'l'9' QIiI1ihe adjuster: '96 - '9'

:3rd groove IOJlI the adljolls1er: After '97

COIMPRESSION AND REBOUND DAMPING AIDJUSTERS

CAUTION

Alwayx start Or! full hard ~I'hm a4Jumng !ht: dampmg,

Do nor trim The adjusler screws more than the given positions or the adjuSl(!r,~ "1.111' be damaged.

The compression and rebound damping can be adjusted by turning the adjusters.

DIRECTION H: Imcre<!Se the damping force DIIRECTION S: DeCrea!Hl the damping force

Turn the compression adjuster clockwise until il stops, LlII~1I turn the adjuster counterclockwise.

!COMPRESSION ADJUSTER STANDARD POSITION: 1 turn out 'from full Iilard

Turn the rebound cU1'jllsii'!'r elockwiss until it stops, then tum the adjuster counterclcckwlse.

REBOUND ADJUS'TiER ST ANDA!FI.D POSITION: 1 turn out 'f'rom fulll niilrd

NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tighteoed to their correct torque val ues (page 1-131.

Gl'lecK tl'ruot all satetv clips. hose clamps and cable stays are in place and properly sucured.

3-27

MAINTENANCE

WHE~EllSfnRES

NOTE

-----------------------

• Tire pressulre shou~d be checked when the tires are GOLD.

RECOMMENDED TIRE PRESSURE. AND TIRE 8.12.1:::

FRONT

REAR

TIre p~Fes,sure

kPa Ikg'f/cm~, psll

250 12.50, 36)

2.90 1.2.90, 421

TIre '96 - '97:

130/70-ZR16 130nO-ZR16 1611 w.~

180/55 -ZR17 180!55 - ZR17 P3W)

size

After '91:

snr56F: RADIAL

B1'56R RADIAL G

BrwdgBSlO!111

Tire: brand

Michelin I

TX15

TX26

Check. the tires for cuts, embedded nails, 0 r other damage .. Chao].:: the front and re'ar wl'1:asls for trueness (refe'f to section 13.ilJnd 14).

MSS3lHS the tread depth atthe center ofthetires,

Replace tn.s tires when ina tread depth raaches thafollowing limits"

MINlMIIJM TREAD DEPTH:

FRONT: 1.5 mm II),Q6Inl REAR: 2,1)1 !TIm UII,O! inl

NOTE

Check that the ccrrtrel cables do mot tntertere wid1 nandlebar rotatlnn,

Support the motorcycle $i'M:D1rpJy ilJnd raise the front i.i\the~1 off the: ground.

Check thai the ha ndleba r moves freely from side to sida.

If the handlebar !TI!}V(,!S unevenly" binds, Of lTtas vertical movement, inspect 'the steering he~d beafings (Section 131.

3-28

MEMO

ILUB,RICATION SYSTEM

LUBIRICATION SYSTEM DIIIAGRAM

r-

-:

141 CRANKSHAFT

H31 COl) NTIERS HAFT

lSI Oil FilTER

19) PRESSURE RELIEF VALVE

~1~)OILI"UMP

<,

(10) OIL STRAIN[R

4-0

4. LUHKIl;AI,IU

:iY~ IltM

L.UBRICAT10N SYSTEIM DIAGRAIM SER,VICE INFORMATION

TROU BLESIH OOTING

OIL PRESSURE INSPECTION

4-0 4-' 4·2

4-J

OIL STRAINERIIPRESSURE RELIEF VALVE

Oil PUMP

OIL. COOLER

4·4 4--6 4-,10

SERVICE INFORMATION

GENERA'L

• If tlile etlg-lne rnU;17 be running I!J' ,dM l· ... ml.' work, mfJ~-f'- su ... ' lll~ area L, we.ll-iNmtilated. Never nm the c,ngine in till ,enclosed area. The exJUJIl~'ll:uniuj'j5 pOi5!1'1_QU_< "arlIl1l1 mllIlo~:idl': gas thilt maJi CQFjsr: tos« of C(},ll!Scill'u:>m!sg and may II)'M to ,death. Run #II! ~'jgb.e i,,- nl~ 0W~I~ nrea nr wilJr an: exhaust. ,ev(1c-u/lti()lt ,;ystem ill an enclosed area;

Used en,giue oil rna)' cause skin CJ1tlCU tIN!pe'tItedly left in I:Ii'lIwd willi ih~,d:i1Jfor pml(!Jlgedl'l'riod'r. AlihougJll1lis is l!1ItilwlJ .fIlI:le~s _vou 'umd/~ us~d (Iii 01'1 II tinily 1m~;h, it j~' frill ml~i.mM£ to' tlwwughly west: yQur lIond's with smIp' ,a.m11'i'ateT as soon as possible aJI!!r handling [!-"ltd oil_

The' oil pump can be serviced with the engine installed in the frame.

• The servlcs procedures ill lids section must be performed with the engine oil drained.

• Wlum removing and installing thE! oil pump, use care not to allow dust or dirt to antsr the I;lllgir~e.

• ~f <my portion of the- oil pump is worn beyond the sp,ecified service lirnlts, replace the oil pump as an 1'!Ssp.mb'IIY. ,. After the otl pump has been installed. ehack thatther s are no oil leaks and that oil pressure is correct.

SPECIFICATIONS

Unit: mm (in)

I1iEM STAND'ARID 1 SERVICE LIMIT
Eng,ine oil cap<lciw At draining 3.5 liter 13.7 US qt. 3.1 Imp qt) --
At disassembly 4.4 liter (4-.6 US qt, 3.9 Imp qt) --
At oil fi,lI.er chan,ge 3_6 liter (3.1:1 US qt. 3.2 Imp qtl --
-- -
'Recommended erilgine oil Honda GN4 4-st,oke oil or ecuivalcnt
rno oro"
API service ciass1fieation SF UI SG --
Viscl)~jty.: SAlE lOW - 40
Oil pressure at oil pressure swi,tch 490 kPa 15,[) kgf/cm~. 71 psi) at . -
6,000 rpm/(80°C/1:76~r)
Oil pump rrrrnr Tip clearance 0.15 -'0.12 (0_006- 0.,009) 0.20 (0.0081
Body clearance 0.15 - 0.:22 (0.006 - 0_009) 0.35 fO.Cl,l41
Side clearance I 0.02 - 0.'07 (0.001 ~ 0.003) 0_'.0 (OJJU4j TOROUE VALUES

Oil drain bolt

Oi~ filter cartrldqa

Oil pump driven sprocket bolt Oil cooler boss

Oil pressure switch

29 Nrn ~3"O kg'f'm, 22 Ibf·ft) 10 N·rn f1 ,0 kg f-rn , 7 IbHt)

, ~ N·m 11.5 kgf·m, 11 IbHtJ 64 N·m 16,5 kgt·m, 47 IbHt:) 12 N'm (1.2 kqf-rn, 9 I bHt)

Appl'y ail. to t.he new O-ring

App~y a lockirng agent to till'! threads Applva lockinqaqent to the threads .Apply sealant to the threads

TOOLS

r:

Oi t pressu re g.ougc

Oil pressure gaug'9 attachment Oil Iml:lr wrench

07506 - 3000000 07510- 4220~OO 07HAA- PJ70100

'-1- _.Equilfalent r.nmmarcially availoblc in U.s.A.

4-1

LUBRICATION SYSTEM

TROUBLESHOOTING

Engine oil level too low

• Oil consumption IExtl'!rfls,1 oil leak

Worn piston ring or incorrect plston ring tnstatlatlon

• Worn valve ~u[de or seal

Low oilpressm,e

Clogged oil strainer screen

• Oil pump worn or damaged

• lnterrral oil leak

J nco rrect oil hp. i rig used Low oil level

tow or no oi .• pressure .

• Clogged oi~ orifice

• Incorrect oil being used

High !Jil pressur,e

• Plu!Joed oil filter. gallery, or rneterinq orifice

• Incorrect oll beingl used

No oil press ure

Oil level too low

• Oil pump drive sprocket broken

• Oil pump damaged (pump shaft) Internal oil leak

4-2

OIL PR'ES:SURE INSPECTION

NOTE

• If the oil pressure indicator light remains on atew seconds, check thp. indicator system before checking the oil pressure.

--------~---------------------------

Check the oil 1'~vli!l (page3-11).

Warm up the ,engine to normal operating rarnparature ~Bpproxima!eIV 80'"C/176~FI.

sroc 'the engine alld disconnect the oil preS'l>LlI'If! switch wire connector from the switch.

Remove the oil pressure switch and connect all oi~ pressure gau_ge and attachment to the switch 'hole'.

TOOLS:

Oil pressure gauge 075116 - 3000001) IEquivi'!le~t c(lmmercial'y avarlable in U.S.A.I

0iI1 pressure ,galJge attadlme.liilil: 1)1510 - 4220100

IEquival,ent commercialliy av,aihlb~e in U.S.A.J

Ster thE ,enginle and increase the rpm to 6,OO() rpm and read the ell oressura

OIL PRESSURE:

490 IkPa (S.1l kgf/cml, 71 psi) at 6.000 rpmIl80OCI176°'f)

Stop the engine and remove the tools.

Apply sealant to the thre'!;Id~ or the !Oil pressure switch ..

lnstall and [ight911 it to ths specified torque.

TORQUE: 12 N-m (1.2 kg,f·m. 9 'lbHt)

CAUTION

- Tn p.-"verl1 crankcase damage. do not overtighten 'he 8'wi,ch"

Connactrhe oil prassu e switch connector.

ILUB:RICATION SYSTEM

Do not apply to the thrf!1'Irl heart 3-4mm

(0-' - [1_2 In)

4-3

ILUBR1CATION S,VSJEM

OIIL STRAINER/PRESSURE RELIEf VALVE

REMOVAL

Drai n the' engine oil (pag€! 3~ 12). Remove th e exhaust pipe (page 2-161.

Remove the' oil pan fI.~nge bolts .ilIHJ ell pan.

~emovti the pressure relief valve and O-ring.

Remove the orl strainer and gasket.

Clean the oil strainer screen.

IINSPECTIION

Ch,ecJ{ the operation of the pressure relief volve ,by pushing on the piston,

D,'is8ssemble the re~i·e'f v81v8 by r·sn1Oving the snap I' i O1g.

Inspect the plston for wear, sticking or damage. Inspect the spri rig for weakness or damage.

Assemble the relief valve in 'l'he reverse order nt riiMs..<il'!m-

bly. A

I o {4' RELIEF JAL VE BODY

~{ ~., {.I,

(U SNAP RING

INSTALLATION

Apply oil to the n~w yaslc.et and instell it onto the oil strainer. lnslall the oil strairrer into the crankcase while ilrligning its boss witli fih,!'! g,roove in the ere nkcase.

Apply oil to the new D-rilnlgand install it onto the relief valve, Install the relis,f valve imo the crankcase,

elsali The oil pan mating surface thorouqhlv,

ApplV Th rae Bond 120113 or an f!q tl~valent to the mating su rf<J,r.f!_

CAUTION

• Dn nat aprly sealant marl:' ,haTlllccc'Ssary.

Install the oil pion and tlght,en the flange bolts lna crisscross plltti'!'rn in 2 -3 steps,

lnstall the exhaust pipe (page 2-17).

Fill the crankcase with recommended oil (page 3-13'1.

NOTE

• After install ation. check that there arc no oil leaks.

LUBRICAtlONI SYSTEM

_"'

4-5

LUBRICATION SYS:TEMI

OIL. PUlMlP'

REMOVAL

Remove the clutch osscmblv !page 9-4}.

IR.emove the oil pump driven sprocket bolt/washer.

R,emolf,!'! UII': faPlowing:

- 0[1 pump driven sprocket

- all pump drive chatn

- Oil pump drive sprocket

~ Drivp. sprccke! collar

Remove the [I<lrlYH bolts <HHJ uil PU'IllP assarnblv.

DISASSEMBLY

OTE

It ,lIny portion nf thE'! oil pump IS .worn beYCi.nd the specifled service limit. replace the 011 pump as an assembly.

Rerrmve the bolt, oil pump COII,er and dowel pin,

(3) DOWEL PJN

{1lBOlT

//

4-6

1.21 COVER

lUBRliCATION SYSTEM

Remove the thrust washer and drive pin. Dis3ssemble the oil pump.

INSPECTION

Tempo ra ~ilV install tile 0 i~ PI;) rnp sheft,

lnstall Ihe cuter and inner rotors into the oil pump body.

Measure the tip clearance.

SEFIVIOE LlMIi:. 0.:20 mm (0.OD8 in]

Measure the !Jump body (;I~(H<:IUW.

SERVICE UMIT: D.35 mm 111.014 lnl

Me.rs.ure the side clearance using< a straight edge <lind feeler gauge-

SERVICE ·LIMiT: 0.10 mm (0 .. 004 il'!}

(2) DRIVE PIIN

(1) WASHEIR

, C"_li :nON SYSTEM

LUSRI M _

ASSEMBLY

- R ROTOR

l'IOU1E TOR

(21IN'NER RO

(3) GOVER

-

- - rrnp bady .

. to the oil pi d _ and

dinner rotorsin oil pump bo y

I stal I the (I uter an iC, aft th roug h the

ns . oil pump g"

Install the

inner rotor.

UTER ROTOR

PIO _

..... _ ~". / ?NNER ROrOR

- . _ me pump shaft and

I . . to the hole '"' toe as s huwu.

d - e 0'111 1.rI ' in th inner ro _ __

lnsts H th e. :th the groove In t _1;1 _

align the PH' .

st washer.

lnstal I the th rIIS _

OJ DRIVE PIN

LUBRlCA;TIOIN SYSTEM

Install the dowel pin and oil pump covP.r. then tighten the cover bolt securely.

INSTALLATION

h"l~tc!U the' oil pump into tile crankcase whi~e al'ignh19' the pump shaft lug with the water pump, shaft groove.

Install and iig hten the three flslnge bolt iS8cura~y.

App~y oil to rha oill pump cidve sprocket collar, drive sprocket and dr~ve chain,

Install the following:

- Drive s'Drocka~ collar

- Oil pump' drive sprocket

- Oi I pump drive chain

Oil pump driven sprocket

'(11 DOWEL PIN

(3) BOLT

m COVER

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