HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating concition and the emission levels are within the standard set by U.S. Environmental Protection Agency and California Air Resources Board. Performing the first scheduled maintenance is very impor- ‘tant. It compensates for the initial wear that ‘occurs during the break-in period. Sections 1 through 3 apply to the whole Motorcycle, while sections 4 through 20 describe parts of the motorcycle, grouped ac- cording to location Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The sub- sequent pages give detailed procedures. If you don’t know the source of the trouble, go to section 21 TROUBLESHOOTING. tie and without ncuringany abigetion whatever No parca hs publication may be produced with | out writin po HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION | LUBRICATION __ a 2| | mamvTENANcE E FUEL SYSTEM | CYLINDER/PISTON CLUTCH ALTERNATOR/STARTER CLUTCH TRANSMISSION CHassis. ELECTRICAL "| FRONT WHEEL/SUSPENSION/ |_ STEERING a _E _Atrenwaroristanren c.uron ES) | orancsHartisarancen TG) _ _ FAIRING/EXHAUST SYSTEM m3 L HYDRAULIC BRAKE _ Ww [15] BATTERY/CHARGING SYSTEM IGNITION SYSTEM Lm ELECTRIC STARTER SYSTEM | 13] LIGHTS/INSTRUMENTS/SWITCHES. E BH Date of Issue: September, 1088 @HONDA MOTOR CO., LTD.1. GENERAL INFORMATION GENERAL SAFETY 1 SERVICE RULES 11 MODELIDENTIFICATION 4-2 SPECIFICATIONS 13 TORQUE VALUES 15 GENERAL SAFETY If the engine rust be running io do some work, make sure the area is well-ventilated. Never run the engine in a closed area. The exiucist contains poisonous carbon monoxide gas that can cause loss af consciousness and may lead to death, Gasoline’ exiremely flammable and i explosive under certain conditions, Work in well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in your ‘working area or where gasoline Is stored. Brake dust may contain asbestos, + Inhalted ashestos fibers have been found to eause respirato- ry disease and cancer. Never use an air hoseor diy brash 0 ‘lean brake assembles. + In the Untied States, we an OSHA approved vacuin cleaner or aliemate method approved by OSHA designed 0 minimize the hazard caused by airborne asbestos fibers. SERVICE RULES ToOLs 17 CABLE & HARNESS ROUTING 19 EMISSION CONTROL SYSTEMS 1-16 EMISSION CONTROL INFORMATION LABELS |U.S.A. only) a + The battery gives off explosive gases: keep sparks, flames sand cigareites away. Provide adequate venttation when charging + Phe bertery concains sulfrie acid (electrolyte). Coneact wht skin or eves may cause severe burns. Wear protective clothing an a face shield. = W electrotte gets on vour skin, fush with water. = If electrolyte gets in your eyes, Pash with water for at least 15 minutes ond cal a physician. + Beare is poisonous. —If swallowed, drink large quantities of water or milk ‘and follow sith milk of magnessia or vegetable oil and call a physician. cauTion + Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods, Although this is unlikely unless you haredle used vil on © daily basi, 1 & st edtvisable to thoroughly wask your hands with soap and water as soon as possible ater hand: ing used oi 1. Use genuine HONDA or HONDA:recommerded parts end lubricants oF vieir equivalent, Parts that do not meet HONDA’s ‘design specifications may camage the motoroycle, 2. Use the special tools designed for this product. 3. use only metric tools when servicing this motoreyele. Metric belts, nurs, 1d serews are not interchangeable with English fasteners. The use o! incorrect tools and fasteners may damage the motorcycle. 4. Install nevr gaskets, Ovings, cotter gins, lock plates, etc. when reassembling 5. When tightening a series ot bolts or nuts, begin with the larger-clameter or inner bolts first, end tighten to the specified torque ciagonally, unless a particular sequence is specified. cate any sliding surfaces bafare razssombly. After reassombly, chec all parts for propor inctallation and operation. Clean parts in cleaning solvent upon disassembly. Lub 1-1GENERAL INFORMATION MODEL IDENTIFICATION "88: ABTER ‘28: ‘The frame serial number 's stamped on theright side af the “The vehicle identification number (VIN/ Is on the right side steering head. of the trame pipe. ULIDENTIFIGATION NUMBER ‘The engine serial number is stamped on the right erank- The cerburator icentification number is stamped on the case. carburetor body. 1-2 (iGENERAL INFORMATION SPECIFICATIONS <_>:Calfornia mocet DIMENSIONS — | Overall Iength 2,195 mm (86.4 in) ores meen Curd weight 168 kg (379.3 Ib} pressures 150 kPa (1.50 kgicm*, 22 psi? one passenger | Rear 200 kPa (2.00 kgicm®, 29 psi) | Displacement 844.0 cc (39.29 cu in) | Be |S an pes #5, ie, Main jet #155 1-3GENERAL INFORMATION TEM foRive TRAIN [Cuth Transmission ‘SPECIFICATIONS Wet, mati-plate speed constant mash 1 | Primary deiven 2,029 169/94) Final reduction 3.000 145/75) Gear ratio | 2,666 (82/12) | Gear ratio It 1.750 (28/16) Gear ratio Il 1.250 125/20) Goar ratio IV 1.000 123/23) Gew ratio V 0.840 121/25) Goar shift pattern Lett foot operated return system, 1-N—2—3—4—5 ELECTRICAL | Ignition Tpe-cor Ignition timing Inia | 8° BTDC at idle Full advance 28? BTDC at 4,000 rpm Alternator AC ganarater 0.18 kw/5,000 rpm Battery capacity 12v 8AH Spark plug NGK ND. Standard DPREEA 9 xzacPR U9 For extencied high OPRIEA—9 X27EPR—U apeed riding Spark phic aap 0.80.9 mm {0.031—0.036 in) Fuse Main 20a Sub TOA x 24158 Starting system Electical stater Headlight 12v 80/55W Tailibrake light 12V 32/3cp Front turn signalirunning fight 12V 32ep x2 | Flea: turn signel light BV B2ep x 2 | meter lights nav 1rwee | High beam indicator 12v1.7W Turn signal indicator 52v 3.4W x2 Noutral indicator sav a4wGENERAL INFORMATION TORQUE VALUES ENGINE | rem cry | THREAD | ponaue hom tem, fib newares Crentcase dain lua ie 265 18) titer cor bat 8 3108 7 ave aducingseow ock net 4B 228 10) Cyne hed bt oO} 230 201 pny ot the tend Cam spose et 2) 3 o\z0, 1a bey aching agar ote Rocke sm sat 2) 4 2328 201 ‘heats Suc am shat NI 2] 2828 20 tbo 2] 1 aias 17 cyte bead cover but Bini | ot] 8 ales 17 om| 1 | 8 tonon | (6mm SH | 11 6 12(1.2, 8) | spar ps i] 2 aire 13 neo b] te 0180 se psy ot tho shsede Cine 2] 'e ro110. ten ook nut i] as Homie 8 Primary dvs gar mut i | te toini.9, 80) Gearshift cam bolt 1 6 1211.2, Sb | Apply @ locking agent to the eeese stepper rm bol 8 25125 18) Rigrtcrmessecoverseunt | 8 wine Starter clutch bolt | 8 3013.0, 221 Apply a locking agent to the tora Tyee! ble 1) ow 125.425,00) | Apply MoSe poste othe teeeus Let crartoase cover bl >| 6 ware Steer gar cover 8 atta 8 trance oh ufos Bua 8 oer ek bot if 3 tee FRAME wrew ary | THREAD | ronaue wm ign, ri earns Down tke drain 7] 10 wae Oi seamer ma | te ors, 21 Otece fore nc 2] te ‘ole, 2 Fuel vaive cup 1 — 4 (0.4, 3) Spoke 2) = flag 3 ame hangernut rome) | 5 | 10 coven 23 (& mm) 8 8 2413.4, 25) | sk late to 3] 8 ono, Ope ae ut i} oa fols0 28 Waebar wove olde: i's e206. 18) fanaa over hole ar) zelz6 18 Beate dae tot s 8 sola 27 Fron nt no too e508 «7 fret ante her ut 2 wine a Fork slider socket bolt 2 8 2012.0, 14) Apoly a locking agent to the eas Lower lok inch bot +8 (3.9, 24) ron cap bo 2) ates 17 Uppe tore nich bo 48 wiles 20) ara calbr bracket to 28 22. 20 Stconng aise ut ae Boe 0 Steering stem nut ba 24 100 (10.0, 72) 1-5ENERAL INFORMATION rem aw | THREAD] ronaue ean. ewanKs Beer oe mt +) de 359.3691 Bes aster sin ck mat | 4 3019.9, 65) Seca ee | wera, eH Sr Seater eer net ber 1! 4 ess. 90 Becomtoatucctinknn =) 1 | 8 sous 2) se evans emmt | 4 |r was sal eh emo ware nr 1) 3 Sass | Sieger vet 1 | ot “pitt. 8 Beane coer brocat pot) 2 | 8 29129201 Fnae 9 >| 6 ae) eo saw >| 4 230025, 18 Broke hows ut trees on 1 | % 3838, 25 Bee noc int mt ilo Bie io bree pe mr tf iat 10) Brake hase boit | a | 10 35125, 25) | roots alps tact in bl 1) 8 nae Tre acta open oo cue pe font nt s|e 2202.18 tte bond bl 2| 8 202.9,18) ue urna ble 3) el 18) Sue send pet bot 2) Bo 80,28) ppv abekin agent io Ne one (arren 88) | es STANDARD TORQUE VALUES: tem T Torque Values T tem Torque Values. Sram bat ard Sones | Samwew 104.3 @ blared net wna Smmacen | 3883 | Sint om re a man bl ar vt 22.22,19 | @mmfange oe ana ene 10mm bolt and nut 35 25. 25) Srmflengebottand nut | 27127. 201 [12mm bet aa mt 2G 20)___| so mm feng ble andr foro. 20TOOLS D SPECIAL GENERAL INFORMA‘ DESCRIPTION Dd Needle bearing remover Compression gauge attachment | 07931-A70000 ‘TOOL NUMBER (07908 —KK60000 a1 equivalem commercially avcilabel in U.S.A, 07973 M3002 or 07873—MG30003 (07884551 0000 or 07984—€57010C (U.S.A. orly| 07631—0010000 07931—MK20100 | or oquivatont commercially 07939-MK50100 Favatable in U.S.A. 07836—KC10100 07741 —0010201 076MC—MKé0100 (077480060100 (07831 ~ME40000 or 07931 —mE4000A 07831 —KFOO100 07831 -KF00200 07GAD—sp40 191 07847—KA5O100, 0784?—KF00160 07816—KA80100 07846 — 4300101 or 07245 —MB00000 07853 —MJ10000 (07653—MJ00100 (07953—MJo0z00 07248—MJ001 00 Net available in U.S.A. 07914—3230001 97GMJ— 0010000 Me 1012/2 077020020001 GNHTS4 |US.A. only) 07936—3710800 07936 3710100 07936-3710200 REFER TO SECTION 1-7GENERAL INFORMATION COMMON DESCRIPTION. TOOL NUMBER REFER TO SECTION Spoke wrench C, 6.8.x 6.1 mm Float level gauge \Valve spring compressor Valve quice remover, 6.6 mm. Clutch center holder Geer howder Flywheel holder Rotor puller Tore bit (40) Driver Pilot, 36 men Attachment, 52 x 55 mm Pilot, 25 mm Attachment, 42 x 47 mm Pilot, 40 mm Attachment, 32% 36 mm Attachment, 62 x 88 mm ‘attachment I.D., 35 mm Bearing remover head, 15 mm Bearing remover shait Attachment, 72 376 mm Pilot, 20 mr Pilot, 15 mm Lock nut wrench, 30 x 32 mm Extension bar Bosring remover head, 17 mm Attachment, 97 x 40 mm Filet, 17 mm Attachment, 24x 26 mm Filot, 20 mm Pilot, 22 mm 977010020300 (07401 -0010000 07757—0010000 077420010200 077240050001 077240010100 0725 -0040000 077330020001 07933 — 3290001 97703-0010100 07749~0010000 07748—0040800 077480010400 07746 - 0040800 07746—0010300 07746 —0040800 077460010190 077460010800 077400030400 07746— 0050400 077480050100 077480010800 077460040500 077460040300 07716—0020400 07716—0020500- 07746—0050500 077460010200 07748~0040400 0748—0010700 07748—0040500 07746—0041000 ‘or equivalent commercially available in U.S.A. or 07984—6570100 fr equivalent commercially available in U.S.A Not availble in U.S.A. ‘or equivalent commercially avalable in U.S.A. (U.S.A. only) oF equivatant commercially available in U.S.A. \_ oF equivalent commercially available in U.S.A. 10, 12, 10 10 10, 12, 10 10.12, 10 10 10 10,13 10 10 2 2 2 13 13 13 VALVE SEAT CUTTER [ DESCAIPTION I TOOL NUMBER | REFER TO SECTION F Cutter holder, 6.6 mm (97781—-0010201 Float cutter. IN/EX 98.5 mm {32*) | 077800012400 | Not available in U.S.A. Interior cuttor IN/EX 37.5 mm (60°) | 07780—0014100. | Equivalent commercially 9 Seat cutter IN 40.0 mm (45°) | 07780—0019500 | available in U.S.A. Seat cuttor EX 38.0 mm (45°) | 97780-9019400— TESTERS DESCRIPTION TOOL NUMBER REFER TO SECTION Digital mult-tester (KOWA) CCiroult vester (SANWA) oF Circuit tester (KOWAL 1074110020000 KS AHM. 22-0 973080020000 TH-5H 02 U.S.A. only! 16, 17,18, 19 1-8CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: © Aloose wire, hemes or cable can be a salety hazard, After clamping, check each wire to ba sure it ic secure, © Do not squeeze wires against a weld or the end of @ clamp. © Secure wires and wire harnesses 1 the frame with bands at the designated locations. Tightan the bands to that only the ineulated surfaces contact the wires ot wire harnesses, © Route hamesses so they are not pulled taut ar have no ex- cessive slack © Protect wires and harnesses with electrical tape or tubing whee they contact a sharp edge or comer, # Do not use wires or harnesses with damaged insulation. Repair by wrapsing thom with protective tape or replace them. © Route wire harnesses to avoid sharo edges or corners. © Alco avoid the projected onde of bolte end sorows. © Keep wire harnesses away trom the exhaust pipes and other hot parts. © Be cure grommets are seated in their grooves properly. After clamping, check each harness to be certain thet it is not interfering with any moving or sliding perts, © Aftor routing, check hat the wire hamosses are not twisted or kinked Wire harnesses routed a long the handlebar should not be pulled taut, have excessive slack, or interfera with edjacert or currounding parte in all steering positions, © Do not bend or twist control cables. Damaged contre! cables will not operate smoothly and may stick or bind GENERAL INFORMATION (0: CORRECT >! INCORRECT 1-9GENERAL INFORMATION (1) FRONT BRAKE (2) CLUTCH HOSE CABLE 14 THROTTLE CABLES (3) TURN SIGNAL LIGHT RELAY (2) HEADLIGHT: CONNECTOR «) cb UNIT. (4) SPEEDOMETER CONNECTOR (BLACK) (5) SPEEDOMETER CABLE 1-10GENERAL INFORMATION (2) FUSE BOX i om 13) IGNITION (4) CARBURETOR CHOKE Com CABLE (6) PURGE CONTROL VALVE (California medel 11) FRONT BRAKE, only! HOSE 46) CLUTCH CABLE (8) PULSE GENERATOR (7) AIR INTAKE HOSE CONNECTOR "88: (3) REAR BRAKE LIGHT SWITCH (2) VACUUM TUBE CONNECTOR (1) PURGE CONTROL VALVE (California model ~~ ontys (4) AIR CLEANER CASE DRAIN TUBE (7) CARBURETOR (6) SEPARATOR (5) REAR SHOCK ABSORBER OVERFLOW TUBE DRAIN TUBE DRAIN TUBE 1-11GENERAL INFORMATION (2) CYLINDER HEAD COVER BREATHER TUBE (2) THROTTLE CABLES (1) REAR @RAKE LIGHT SWITCH WIFE 14) TURN SIGNAL LIGHT RELAY (5) SPEEDOMETER CABLE (6) CANISTER (California model only) (8) IGNITION SWITCH Wine (7) ENGINE STOP SWITCH CONNECTOR (WHITE) WIRE CONNECTOR (RED) (1) BATTERY POSITIVE (2) AIR INTAKE (3) BATTERY NEGATIVE WIRE HQSE WIRE CONNECTORGENERAL INFORMATION (2) REAR RIGHT TURN SIGNAL Rt (2) CLAMPS. LIGHT WIRE ) we (4) REAR LEFT TURN SIGNAL UGHT WIREGENERAL INFORMATION AFTER ‘88: (1) PURGE CONTROL VALVE (California medel onty) —™ (3) REAR BRAKE UGHT SWITCH CONNECTOR (4) AIR CLEANER E cas DRAIN TUBE 2) AIR INTAKE HOSE ‘ (6) SEPARATOR (5) SHOCK ABSORBER DRAIN TUBE (2) TAILIBRAKE LIGHT (6) CLAMPS WIRE U1) REAR RIGHT TURN SIGNAL LIGHT WIRE (4) REAR LEFT TURN SIGNAL LIGHT WIREGENERAL INFORMATION » Le exon \ NZ a= a L (2) SPEEDOMETER (3) SPEEDOMETER CONNECTOR =GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency and Califomia Air Resources Board (CARE) require manutacturers to certify that ‘their motorcycles comply with applicable axhcust emissions standards during their useful life. whan operated and maintained according to the instructions provided, and that motorsyoles built after January 1, 1983 comply with applicable noise omic. sion standerds fer one year oF 6,000 km (2,730 miles} after the sime of sale to the ultimate purchaser, when operated and ‘maintained according o the instructions provided. Compliance with the terms of the Distributor's Limled Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions systam warranty in effect. SOURCE OF EMISSIONS. ‘The combustion process produces carbon monoxide and hydrocarbons. Control of nydracarbons is very Important because, Under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic Honda Motor Co., Ltd. uilizes lean cerburetor settings as well as other systems, to reduce carbon monoxide and hydro- carbons. EXHAUST EMISSION CONTROL SYSTEM Except for California: ‘The exhaust emission control system is composed of a lean carburetor setting, end no acjustments should be made except icle speed adjustment with the throttle stop screw. The exhaust emission control system is separate fiom the crenkcase emission control system. California only: ‘The exhaust emission control system consists of a secondary air supply system which intraduces fitered air into the exhaust ‘gases in the exheust port. No adjustments to this system should be made, although periodic inspection of the components is recommended. The sacordary air supply systam helps improve emission performance. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with « closed crankcase system which routes crankcase emissions through the air cleaner into the ‘combustion chamber (1) BREATHER (2) AIR CLEANER "38: SEPARATOR, SS Frosh air = Blow by gee (4) AIR SUCTION VALVE (3) DRAIN PLUGS,GENERAL INFORMATION AFTER ‘88: a SepanaTon (2) AIR CLEANER 4) ainEuction SS Fresh air VALVE {31 DRAIN PLUG. > Bowby gas EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) Tha model complies with California Alr Resources Board evaporative emission requirements. Fuel vapor from the tuel tank and carburator is directed into the chareoal canister where itis adsorbed and storad while the {engine is stopped. When the engine is running and the purge control diaphragm velve is open, fuel vaporin the charcoal sanie- ter is drawn into the engine through the carburetor (1) FUEL TANK (2) CARBURETOR |9) AIR CLEANER, (6) CANISTER (4) PURGE CONTROL VALVE Revs 1-17GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS (U.S.A. only) [An Emission Control Information Label Is located on the inside of the right side cover as shown. It contains basic tune-up specifications. (1) EMISSION CONTROL: INFORMATION LABEL EMISSION CONTROL INFORMATION UPDATE LABEL [After making a high altitude carburetor edjustment (page 4-17), attach an update label on the right side frame down pips. In structions for obtaining the update label ere given in Sarvioe Letter No. 132. [1] EMISSION CONTROL INFORMATION UPDATE LABEL, VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) ‘The Vacuurn Hose Routing Diagram Label is on the inside of the lett side cover. Route the vacuum hhoses 2s shown on this label "BB: SHOWN, AFTER ‘88: Similar (1) VACUUM HOSE ROUTING DIAGRAM LABELGENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair oF raplace: ‘mont, of any device or clement of design incorporated into any new vehicle for the purpose of noise control pir to its sele oF delivery to the ultimate purchaser or wile itis in use; or (2) the use of the vehicle after such deviee or element of design has been removed or rendered inoperative by any person, D TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROH/BITED: Federal law prohibits the following acts ro the causing AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal cf, or puncturing of the muffler, baffles, header pipes or eny other component which conducts exhaust gases. 2. Removal of, of puncturing of any aart of the intake system. 3. Lack of proper maintenance. D 4, Replacing ary moving parts of the vehicle, of parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 1-19