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1. GENERAL INFORM ATION
SERVICE RULES ············································ 1-2 REAR WHEEL/ BRAKE/ SUSPENSION

SPECIFICATIONS············································1-8
M ODEL IDENTIFICATION······························ 1-2
HYDRAULIC BRAKE SPECIFICATIONS·········1-8
GENERAL SPECIFICATIONS························· 1-4
BATTERY/ CHARGING SYSTEM
LUBRICATION SYSTEM SPECIFICATIONS · 1-5 SPECIFICATIONS············································1-9
FUEL SYSTEM SPECIFICATIONS················· 1-5 IGNITION SYSTEM SPECIFICATIONS ··········1-9
CYLINDER HEAD/ VALVES LIGHTS/ M ETER/ SWITCHES

SPECIFICATIONS··········································· 1-5 SPECIFICATIONS············································1-9
CYLINDER/ PISTON SPECIFICATIONS ········· 1-6 STANDARD TORQUE VALUES ···················1-10
CLUTCH/ GEARSHIFT LINKAGE/ ENGINE & FRAM E TORQUE VALUES ········1-10

KICKSTARTER SPECIFICATIONS ················· 1-6
LUBRICATION & SEAL POINTS ··················1-14
CRANKSHAFT/ TRANSM ISSION
SPECIFICATIONS··········································· 1-7 CABLE & HARNESS ROUTING ···················1-17
FRONT WHEEL/ SUSPENSION/ EM ISSION CONTROL SYSTEM S ················1-25

STEERING SPECIFICATIONS························ 1-8
1-1
GENERAL INFORM ATION
SERVICE RULES
1. Use genuine Honda or Honda-recom m ended parts and lubricants or their equivalents. Parts that do not m eet Honda's
design specifications m ay cause dam age to the m otorcycle.
2. Use the special tools designed for this product to avoid dam age and incorrect assem bly.
3. Use only m etric tools w hen servicing the m otorcycle. M etric bolts, nuts and screw s are not interchangeable w ith
English fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates w hen reassem bling.
5. When tightening bolts or nuts, begin w ith the larger diam eter or inner bolt first. Then tighten to the specified torque
diagonally in increm ental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassem bly. Lubricate any sliding surfaces before reassem bly.
7. After reassem bly, check all parts for proper installation and operation.
8. Route all electrical w ires as show n on pages 1-17 through 1-24, Cable and Harness Routing.
M ODEL IDENTIFICATION
1-2
The fram e serial num ber is stam ped on the right side of the steering
head.
FRAM E SERIAL NUM BER

The engine serial num ber is stam ped on the low er left side of the
crankcase. ENGINE SERIAL NUM BER
The carburetor identification num ber is stam ped on the left side of the
carburetor body.
CARBURETOR IDENTIFICATION NUM BER

The color label is attached as show n. When ordering color-coded
parts, alw ays specify the designated color code.
COLOR LABEL
1-3
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
DIM ENSIONS Overall length 2,090 m m (82.3 in)
Overall w idth 750 m m (29.5 in)
Overall height 1,095 m m (43.1 in)
Wheelbase 1,340 m m (52.7 in)
Seat height 790 m m (31.1 in)
Footpeg height 567 m m (22.3 in)
Ground clearance 168 m m (6.6 in)
Dry w eight 126 kg (278 lbs)
Curb w eight 139 kg (306 lbs)
M axim um w eight capacity 170 kg (375 lbs)
FRAM E Fram e type Diam ond type
Front suspension Telescopic fork
Front w heel travel 130 m m (5.1 in)
Rear suspension Sw ingarm
Rear w heel travel 101 m m (4.0 in)
Rear dam per One side operation
Front tire size 2.75-18 42P
Rear tire size 3.00-18 52P
Front tire brand M RF NYLOGRIP ZAPPER - FS
Rear tire brand M RF NYLOGRIP ZAPPER
Front brake Hydraulic single disc
Rear brake M echanical drum (leading-trailing)
Caster angle 26° 00’
Trail length 97 m m (3.8 in)
Fuel tank capacity 13.0 liter (3.43 US gal, 2.86 lm p gal)
Fuel tank reserve capacity 1.0 liter (0.26 US gal, 0.22 lm p gal)
ENGINE Cylinder arrangem ent Single cylinder inclined 17° from vertical
Bore and stroke 57.3 x 57.8 m m (2.26 x 2.28 in)
Displacem ent 149.2 cm 3 (9.10 cu-in)
Com pression ratio 9.1:1
Valve train Chain driven OHC w ith rocker arm
Intake valve opens at 1 mm (0.04 in) lift 7° BTDC
closes at 1 mm (0.04 in) lift 28° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 27° BBDC
closes at 1 mm (0.04 in) lift 3° ATDC
Lubrication system Forced pressure and w et pum p
Oil pum p type Trochoid
Cooling system Air cooled
Air filtration Paper filter
Engine dry w eight 27.2 kg (60.0 lbs)
CARBURETOR Carburetor type Horizontal changable venturi
Throttle bore 26 m m (1.02 in)
DRIVE TRAIN Clutch system M ulti-plate, w et
Clutch operation system Cable operating
Transm ission 5 speeds
Prim ary reduction 3.350 (67/20)
Final reduction 2.800 (42/15)
Gear ratio 1st 3.076 (40/13)
2nd 1.789 (34/19)
3rd 1.304 (30/23)
4th 1.090 (24/22)
5th 0.937 (30/32)
Gearshift pattern Left foot operated return system
1-N-2-3-4-5
ELECTRICAL Ignition system DC – CDI
Starting system Kickstarter
Charging system Single phase output alternator
Regulator/rectifier SCR shorted, single phase half-w ave recti-
fication
1-4
LUBRICATION SYSTEM SPECIFICATIONS
Unit: m m (in)
ITEM STANDARD SERVICE LIM IT
Engine oil After draining 1.0 liter (1.1 US qt, 0.9 lm p qt) –
capacity After disassem bly 1.2 liter (1.3 US qt, 1.1 lm p qt) –
Recom m ended engine oil Honda 4-stroke oil or equivalent m otor –
oil
API service classification: SJ
Viscosity: SAE 20W40
Oil pum p Tip clearance 0.15 (0.006) 0.20 (0.008)
rotor Body clearance 0.15 – 0.20 (0.006 – 0.008) 0.25 (0.010)
Side clearance 0.05 – 0.11 (0.002 – 0.004) 0.15 (0.006)
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Carburetor identification num ber VK4FA
M ain jet #115
Slow jet #38
Pilot screw initial/final opening See page 5-19
Float level 13.0 m m (0.51 in)
Idle speed 1,400 ± 100 m in -1 (rpm )
Throttle grip free play 2 – 6 m m (0.08 – 0.24 in)
PAIR control valve specified vacuum 58.7 kPa (440 m m Hg)
CYLINDER HEAD/ VALVES SPECIFICATIONS

Unit: m m (in)
Cylinder com pression at 1,000 m in -1 (rpm ) 1,152 kPa (11.8 kgf/cm 2, 167 psi) –
Valve clearance IN 0.08 (0.003) –
EX 0.12 (0.005) –
Valve, Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.92 (0.194)
valve guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.04 (0.198)
Stem -to-guide clear- IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
ance EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)
Valve guide height IN/EX 16.8 – 17.0 (0.66 – 0.67) –
Valve seat w idth IN/EX 0.9 – 1.1 (0.035 – 0.043) 1.5 (0.06)
Valve spring Free length INNER 38.76 (1.526) 37.89 (1.492)
OUTER 35.95 (1.415) 35.14 (1.383)
Rocker arm Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm -to-shaft clear- IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
ance
Cam shaft Cam lobe height IN 32.994 – 33.234 (1.2990 – 1.3084) 32.96 (1.298)
EX 32.880 – 33.120 (1.2945 – 1.3039) 32.85 (1.293)
Cylinder head w arpage – 0.05 (0.002)
1-5
CYLINDER/ PISTON SPECIFICATIONS
Unit: m m (in)
Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Piston, Piston O.D. at 10 (0.4) from bottom 57.280 – 57.295 (2.2551 – 2.2557) 57.20 (2.252)
piston pin, Piston pin hole I.D. 14.002 – 14.008 (0.5513 – 0.5515) 14.04 (0.553)
piston ring Piston pin O.D. 13.994 – 14.000 (0.5509 – 0.5512) 13.96 (0.550)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Second 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.85 (0.033)
Piston ring-to-ring Top 0.030 – 0.060 (0.0012 – 0.0024) 0.10 (0.004)
groove clearance Second 0.030 – 0.060 (0.0012 – 0.0024) 0.10 (0.004)
Cylinder-to-piston clearance 0.005 – 0.030 (0.0002 – 0.0012) 0.09 (0.004)
Connecting rod sm all end I.D. 14.010 – 14.028 (0.5516 – 0.5523) 14.06 (0.554)
Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.10 (0.004)
CLUTCH/ GEARSHIFT LINKAGE/ KICKSTARTER SPECIFICATIONS

Unit: m m (in)
Clutch lever free play 10 – 20 (0.4 – 0.8) –
Clutch Spring free length 40.5 (1.59) 39.6 (1.56)
Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.6 (0.10)
Plate w arpage – 0.20 (0.008)
Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909)
Clutch outer guide O.D. 22.959 – 22.980 (0.9039 – 0.9047) 22.93 (0.903)
I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)
M ainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
Kickstarter idle gear I.D. 20.500 – 20.521 (0.8071 – 0.8079) 20.58 (0.810)
Kickstarter idle gear guide O.D. 20.459 – 20.480 (0.8055 – 0.8063) 20.43 (0.804)
I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
Countershaft O.D. at Kickstarter idle gear guide 16.966 – 16.984 (0.6680 – 0.6687) 16.94 (0.667)
Kickstarter drive gear I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.06 (0.632)
Kickstarter spindle O.D. at kickstarter drive gear 15.966 – 15.984 (0.6286 – 0.6293) 15.94 (0.628)
1-6
CRANKSHAFT/ TRANSM ISSION SPECIFICATIONS
Unit: m m (in)
Crankshaft Runout – 0.03 (0.001)
Connecting rod big end radial clear- 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
ance
Connecting rod big end side clear- 0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032)
ance
Transm ission Gear I.D. M 4, M 5 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)
C2 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C3 23.025 – 23.046 (0.9065 – 0.9073) 23.07 (0.908)
Bushing O.D. M 4, M 5 19.959 – 19.980 (0.7858 – 0.7866) 19.91 (0.784)
C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)
C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)
Gear-to-bushing M 4, M 5, C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance C2 0.015 – 0.057 (0.0006 –0.0022) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Bushing I.D. M 4, C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
M ainshaft / coun- M 4, C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667)
tershaft O.D. C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785)
C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785)
Bushing-to-shaft M 4, C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Shift fork, Shift fork shaft O.D. 9.986 – 9.995 (0.3931 – 0.3935) 9.93 (0.391)
shift fork Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)
shaft Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)
1-7
FRONT WHEEL/ SUSPENSION/ STEERING SPECIFICATIONS
Unit: m m (in)
M inim um tire thread depth – 1.5 (0.06)
Cold tire Driver only 175 kPa (1.75 kgf/cm 2, 25 psi) –
pressure Driver and passenger 175 kPa (1.75 kgf/cm 2, 25 psi) –
Axle runout – 0.2 (0.01)
Wheel rim Radial – 1.0 (0.04)
runout Axial – 1.0 (0.04)
Wheel hub-to-rim distance 8.8 ± 1 (0.35 ± 0.04) –
Fork Spring free length 468.5 (18.45) 458 (18.0)
Pipe runout – 0.20 (0.008)
Recom m ended fluid Fork fluid –
Fluid level 165 (6.50) –
Fluid capacity 150 ± 1.0 cm 3 (5.06 ± 0.03 US oz, 5.26 ± –
0.04 lm p oz)
Steering head bearing pre-load 0.7 – 1.3 kgf (1.64 – 2.81 lbf) –
REAR WHEEL/ BRAKE/ SUSPENSION SPECIFICATIONS

Unit: m m (in)
Cold tire pressure Driver only 225 kPa (2.25 kgf/cm 2, 33 psi) –
Driver and passenger 280 kPa (2.80 kgf/cm 2, 41 psi) –
Wheel rim runout Radial – 1.0 (0.04)
Axial – 1.0 (0.04)
Wheel hub-to-rim distance 3 ± 1 (0.12 ± 0.04) –
Drive chain Size/link 428/126 –
Slack 20 – 30 (0.8 – 1.2) –
Brake Pedal free play 20 – 30 (0.8 – 1.2) –
Drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)
HYDRAULIC BRAKE SPECIFICATIONS

Unit: m m (in)
Specified brake fluid DOT 3 or DOT 4 –
Brake disc thickness 3.8 – 4.2 (0.15 – 0.17) 3.5 (0.14)
Brake disc runout – 0.10 (0.004)
M aster cylinder I.D. 12.000 – 12.043 (0.4724 – 0.4741) 12.055 (0.4746)
M aster piston O.D. 11.957 – 11.984 (0.4707 – 0.4718) 11.945 (0.4703)
Caliper cylinder I.D. 26.000 – 26.050 (1.0236 – 1.0256) 26.060 (1.0260)
Caliper piston O.D. 25.918 – 25.968 (1.0204 – 1.0224) 25.91 (1.020)
1-8
BATTERY/ CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 2.5 Ah
Current leakage 0.1 m A m ax.
Specific grav- Fully charged 1.270 – 1.290
ity (20°C/68°F) Needs charging Below 1.230
Voltage Fully charged 12.7 – 12.9 V
Needs charging Below 12.3 V
Charging current Norm al 0.25 A/5 – 10 h
Quick 2.5 A/0.5 h
Alternator Capacity 0.125 kW/5,000 m in -1 (rpm )
Charging coil resistance (20°C/68°F) 0.2 – 1.0 Ω
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATION
Spark plug Standard CPR8EA-9 (NGK) or RG6YC (CHAM PION)
For extended high speed riding CPR9EA-9 (NGK)
Spark plug gap 0.8 – 0.9 m m (0.03 – 0.04 in)
Ignition coil prim ary peak voltage 100 V m inim um
Ignition pulse generator peak voltage 0.7 V m inim um
Ignition tim ing (“ F” m ark) 8° BTDC at idle
Throttle posi- Input voltage 4.75 – 5.25 V
tion sensor Resistance (20°C/68°F) 4.0 – 6.0 Ω
LIGHTS/ M ETER/ SWITCHES SPECIFICATIONS

ITEM SPECIFICATION
Bulbs Headlight (Hi/low beam ) 12 V - 35/35 W
Brake/tail light 12 V - 21/5 W
Turn signal light 12 V - 21 W x 4
Instrum ent light 12 V - 1.7 W x 3
Turn signal indicator 12 V - 1.7 W
High-beam indicator 12 V - 1.7 W
Neutral indicator 12 V - 1.7 W
Fuse M ain 15 A
Sub 10A
Fuel level sensor resistance Full 4 - 10 Ω
(20°C/68°F) Em pty 90 - 100 Ω
1-9
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 m m bolt and nut 5 (0.5, 3.6) 5 m m screw 4 (0.4, 2.9)
6 m m bolt and nut 10 (1.0, 7) 6 m m screw 9 (0.9, 6.5)
(Include SH flange bolt) 6 m m flange bolt 12 (1.2, 9)
8 m m bolt and nut 22 (2.2, 16) (Include NSHF) and nut
10 m m bolt and nut 34 (3.5, 25) 8 m m flange bolt and nut 26 (2.7, 20)
12 m m bolt and nut 54 (5.5, 40) 10 m m flange bolt and nut 39 (4.0, 29)
ENGINE & FRAM E TORQUE VALUES

• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
1. Apply engine oil to the threads and seating surface.

2. Apply locking agent to the threads.
3. U-nut
4. Apply grease to the threads.
ENGINE
M AINTENANCE
THREAD TORQUE
ITEM QTY REM ARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Spark plug 1 10 16 (1.6, 12)
Valve adjusting lock nut 2 6 14 (1.4, 10) NOTE 1
Tim ing hole cap 1 14 10 (1.0, 7)
Crankshaft hole cap 1 32 15 (1.5, 11) NOTE 4
Oil drain bolt 1 12 30 (3.1, 22)
Oil filter rotor cover screw 3 5 4 (0.4, 3.0)
LUBRICATION
THREAD TORQUE
ITEM QTY REM ARKS
Oil pum p plate screw 1 4 3 (0.3, 2.2)
FUEL SYSTEM
THREAD TORQUE
ITEM QTY REM ARKS
SE valve lock nut 1 10 2.3 (0.2, 1.7)
Carburetor drain screw 1 6 1.5 (0.2, 1.1)
Slow jet 1 5 1.5 (0.2, 1.1)
Needle jet holder 1 7 2.5 (0.3, 1.8)
M ain jet 1 5 2.1 (0.2, 1.6)
Float cham ber screw 3 4 2.1 (0.2, 1.6)
SE valve cover screw 2 5 3.4 (0.4, 2.5)
Vacuum cham ber cover screw 2 4 2.1 (0.2, 1.6)
Throttle cable stay screw 2 5 3.4 (0.4, 2.5)
Insulator band screw 1 5 1 (0.1, 0.7) page 1-12
1-10
CYLINDER HEAD/ VALVES
THREAD TORQUE
ITEM QTY REM ARKS
Cylinder head cover bolt 2 6 10 (1.0, 7)
Rocker arm shaft bolt 2 5 5 (0.5, 3.7)
Cam sprocket bolt 2 5 9 (0.9, 6.6)
Cam shaft holder bolt 4 8 32 (3.3, 24) NOTE 1
Carburetor insulator bolt 2 6 12 (1.2, 9)
Cam chain tensioner lifter plug 1 6 4 (0.4, 3.0)
CYLINDER/ PISTON
THREAD TORQUE
ITEM QTY REM ARKS
Cylinder stud bolt 4 8 11 (1.1, 8) page 1-12
CLUTCH/ GEARSHIFT LINKAGE/ KICKSTARTER
THREAD TORQUE
ITEM QTY REM ARKS
Clutch center lock nut 1 14 74 (7.5, 55) NOTE 1
Clutch lifter plate bolt 4 6 12 (1.2, 9)
Oil filter rotor lock nut 1 14 64 (6.5, 47) NOTE 1
Gear shift cam bolt 1 6 12 (1.2, 9) NOTE 2
Shift drum stopper arm bolt 1 6 12 (1.2, 9) NOTE 2
ALTERNATOR
THREAD TORQUE
ITEM QTY REM ARKS
Flyw heel lock nut 1 14 74 (7.5, 55) NOTE 1
Ignition pulse generator m ounting bolt 2 6 12 (1.2, 9) NOTE 2
Wire guide bolt 1 6 12 (1.2, 9) NOTE 2
THREAD TORQUE
ITEM QTY REM ARKS
M ainshaft bearing setting plate bolt 2 6 12 (1.2, 9) NOTE 2
Crankshaft bearing retainer plate bolt 3 6 12 (1.2, 9)
Push plug bolt 1 6 10 (1.0, 7) NOTE 2
OTHERS
THREAD TORQUE
ITEM QTY REM ARKS
Clutch lever pivot bolt 1 6 1 (0.1, 0.7)
Clutch lever pivot nut 1 6 5.9 (0.6, 4.4)
1-11
EXHAUST PIPE STUD BOLT:
20.5 – 22.5 m m
(0.81 – 0.89 in)
Em bed to incom plete thread

INSULATOR BAND SCREW:
7 – 9 mm
(0.3 – 0.4 in)
CYLINDER STUD BOLT:
113.4 – 115.4 m m
(4.46 – 4.54 in)
Em bed to incom plete thread
1-12
FRAM E
FRAM E/ BODY PANELS/ EXHAUST SYSTEM
THREAD TORQUE
ITEM QTY REM ARKS
Exhaust pipe stud bolt 2 8 11 (1.1, 8) page 1-12
ENGINE REM OVAL/ INSTALLATION
THREAD TORQUE
ITEM QTY REM ARKS
Front engine hanger nut 2 8 26 (2.7, 19)
Rear engine hanger nut 2 10 54 (5.5, 40)
Fixing plate bolt 2 6 12 (1.2, 9)
FRONT WHEEL/ BRAKE/ SUSPENSION/ STEERING

THREAD TORQUE
ITEM QTY REM ARKS
Spoke 36 BC3.5 3.7 (0.4, 2.7)
Front brake disc bolt 5 6 24 (2.5, 18) NOTE 2
Front axle nut 1 12 59 (6.0, 44) NOTE 3
Handlebar low er holder nut 2 8 26 (2.7, 19) NOTE 3
Handlebar upper holder bolt 4 8 26 (2.7, 19)
M aster cylinder holder bolt 2 6 9 (0.9,7)
Fork socket bolt 2 8 20 (2.0, 15) NOTE 2
Fork cap 2 26 22 (2.2, 16)
Bottom bridge pinch bolt 2 8 32 (3.3, 24)
Top bridge bolt 2 10 44 (4.5, 33)
Steering bearing adjustm ent nut 1 26 – page 12-29
Steering stem nut 1 24 74 (7.5, 55)
REAR WHEEL/ BRAKE/ SUSPENSION
THREAD TORQUE
ITEM QTY REM ARKS
Spoke 36 BC3.5 3.7 (0.4, 2.7)
Driven flange sleeve nut 1 22 59 (6.0, 44)
Driven sprocket nut 4 10 64 (6.5, 47) NOTE 3
Rear axle nut 1 14 68 (6.9, 50) NOTE 3
Rear brake arm nut 1 6 10 (1.0, 7) NOTE 3
Shock absorber m ounting nut 2 10 44 (4.5, 33) NOTE 3
Brake panel stopper arm joint nut 2 8 22 (2.2, 16)
Sw ingarm pivot nut 1 14 54 (5.5, 40) NOTE 3
HYDRAULIC BRAKE
THREAD TORQUE
ITEM QTY REM ARKS
Caliper bleeder valve 1 10 14 (1.4, 10)
M aster cylinder reservoir cap screw 2 4 1.2 (0.1, 0.9)
Brake caliper m ounting bolt 2 8 30 (3.1, 22)
Front brake light sw itch screw 1 4 1.2 (0.1, 0.9)
Brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Brake lever pivot nut 1 6 6.0 (0.6, 4.4)
Brake hose oil bolt 2 10 34 (3.5, 25)
Brake caliper slide pin 2 8 14 (1.4, 10) NOTE 2
IGNITION SYSTEM
THREAD TORQUE
ITEM QTY REM ARKS
Throttle position sensor screw 1 5 3.4 (0.4, 2.5)
LIGHTS/ M ETER/ SWITCHES

THREAD TORQUE
ITEM QTY REM ARKS
Fuel level sensor m ounting nut 4 6 10 (1.0, 7)
1-13
LUBRICATION & SEAL POINTS
ENGINE
LOCATION M ATERIAL REM ARKS
Crankcase m ating area Liquid sealant
Alternator w ire grom m et seating surface

Oil pum p rotors Engine oil
Oil through sliding area
Oil pum p drive gear teeth
Rocker arm shaft entire surface
Rocker arm inner surface and roller surface
Cam shaft lobes
Cam chain entire surface
Cylinder inner surface
Piston outer surface and piston rings
Clutch disc entire surface
Prim ary drive gear teeth
Prim ary driven gear teeth
Kickstarter driven gear teeth
Clutch lifter rod sliding surface
Gearshift spindle journal rotating area
Transm ission gear teeth
Shift fork shaft sliding area
Shift drum journal rotating area
Each bearing rotating area
Each O-ring
Each dust seal lip M ulti-purpose grease
Each oil seal lip
Crankshaft hole cap threads
Valve stem sliding surface M olybdenum oil solution
Piston pin entire surface (a m ixture of engine oil
Clutch outer guide entire surface and m olybdenum disul-
Clutch outer rotating area fide grease in a ratio of
Kickstarter drive gear teeth 1:1)
Kickstarter idle gear teeth and inner surface
Kickstarter idle gear bushing entire surface
Crankshaft connecting rod big end needle bearing
Crankshaft connecting rod sm all end inner surface
Crankshaft bearing push plug entire surface
M 4, M 5, C1, C2, C3 gear rotating surface
M 4, M 5, C1, C2, C3 gear bushing entire surface
M 3, C4, C5 gear shift fork grooves
1-14
Shift drum stopper arm bolt threads Locking agent Coating w idth:
6.5 ± 1.0 m m from tip
Gear shift cam bolt threads Coating w idth:
Ignition pulse generator m ounting bolt threads Coating w idth:
M ainshaft bearing setting plate bolt threads Coating w idth:
Alternator stator w ire guide bolt threads Coating w idth:
Crankshaft bearing push plug bolt threads Coating w idth:
1-15
FRAM E
Steering head bearings M ulti-purpose grease
Steering head cone race w ith extrem e pressure
Steering head bearing dust seal lips (SHELL ALVANIA EP2 or
EXCELIGHT EP2 or equiv-
alent)
Axle bolt surface M ulti-purpose grease
Wheel distance collar surface
Front w heel dust seal lips
Driven flange dust seal lip
Rear w heel hub O-ring
Rear brake cam rotating surface and shoe contacting
area
Rear brake panel anchor pin
Sw ingarm needle bearings
Sw ingarm pivot collar surface
Sw ingarm pivot dust seal cap lips
Center stand pivot
Speedom eter cable case inside
Speedom eter gear inner surface and teeth
Rear brake pedal pivot rotating area
Throttle grip pipe rotating area
Clutch lever pivot
Brake lever pivot
Brake m aster cylinder push rod contacting area
Brake caliper pin boot inner surface
Brake caliper pin sliding surface
Each dust seal lips
Each O-ring
Rear brake cam felt seal Gear oil
(IDEM ITSU AUTOLUB 30
or M ECHANIC OIL 44 or
equivalent)
Drive chain Gear oil
(SAE #80 – 90)
Throttle cable boot inside and connecting area Silicone grease
Clutch cable boot inside and connecting area
Brake m aster cylinder piston cups DOT3 or DOT4 brake fluid
Throttle cable case inside M olybdenum oil solution
Clutch cable case inside (a m ixture of engine oil
and m olybdenum disul-
fide grease in a ratio of
1:1)
Fork socket bolt threads Locking agent
Ignition sw itch m ounting bolt threads
Fork cap O-ring Fork fluid
Fork oil seal lips
Handlebar grip inner surface Honda Bond A or equiva-
lent
1-16
CABLE & HARNESS ROUTING
RIGHT FRONT TURN

SIGNAL LIGHT WIRE
LEFT FRONT TURN
SIGNAL LIGHT WIRE
Clam p the w hite

locating tape.
HEADLIGHT/FRONT TURN
SIGNAL LIGHT WIRE
1-17
LEFT HANDLEBAR
SWITCH WIRE
BRAKE HOSE
CLUTCH CABLE
THROTTLE
CABLE
CHOKE CABLE
RIGHT HANDLEBAR
SWITCH WIRE
IGNITION
SWITCH WIRE
SPPEEDOM ETER
CABLE
LEFT HANDLEBAR
COM BINATION M ETER SWITCH 9P (BLACK)
9P CONNECTOR CONNECTOR
TACHOM ETER WIRE

CONNECTOR
RIGHT HANDLEBAR HEADLIGHT/FRONT TURN

SWITCH 6P CONNECTOR SIGNAL LIGHT 6P (BLACK)
CONNECTOR
1-18
FRAM E
IGNITION
COIL WIRE
CLUTCH CABLE
HORN WIRE
CHOKE CABLE
CHOKE CABLE
SPPEEDOM ETER
CABLE
THROTTLE POSITION
SENSOR WIRE
1-19
RIGHT HANDLEBAR
FRAM E BRAKE HOSE
SWITCH WIRE
M AIN WIRE
HARNESS
THROTTLE
CABLE
THROTTLE
CABLE
M AIN WIRE THROTTLE

HARNESS CABLE
SPARK PLUG
WIRE
BRAKE HOSE
CLUTCH CABLE
1-20
FUEL LEVEL
SENSOR WIRE
AIR RESONATOR
SUPPLY AIR SUCTION AIR CHAM BER
IGNITION HOSE HOSE
COIL WIRE
AIR VENT
HOSE
VACUUM HOSE
50 m m (1.97 in)
CRANKCASE
BREATHER HOSE
ALTERNATOR/
IGNITION PULSE
GENERATOR WIRE
AIR CLEANER HOUSING

NEUTRAL SWITCH DRAIN HOSE
WIRE Drain hose shall be
installed along fram e sub
tube in 50 m m (1.97 in)
area.
1-21
Slant cut open

area facing CHOKE SPARK PLUG
M AIN WIRE THROTTLE
dow nw ard. CABLE WIRE
HARNESS CABLE
AIR VENT
HOSE
BATTERY
CLUTCH
BREATHER
CABLE
HOSE
CRANKCASE
BREATHER HOSE
REAR BRAKE CARBURETOR
LIGHT SWITCH DRAIN HOSE
WIRE
1-22
IGNITION
CONTROL
M ODULE
(ICM )
REGULATOR/
RIGHT REAR TURN
RECTIFIER
SIGNAL LIGHT WIRE
SUB FUSE (10A)
M AIN WIRE HARNESS
M AIN FUSE (15A)
TURN SIGNAL BATTERY (-) WIRE BATTERY (+) WIRE

RELAY
1-23
BRAKE/TAIL LIGHT
3P CONNECTOR/
REAR TURN SIGNAL
LIGHT WIRE
CONNECTOR
PASSING RELAY
LEFT REAR TURN

SIGNAL LIGHT WIRE
1-24
EM ISSION CONTROL SYSTEM S
SOURCE OF EM ISSIONS
The com bustion process produces carbon m onoxide, oxides of nitrogen and hydrocarbons. Control of hydrocarbons and
oxides nitrogen is very im portant because, under certain conditions, they react to form photochem ical sm og w hen sub-
jected to sunlight. Carbon m onoxide does not react in the sam e w ay, but it is toxic.
Honda M otor Co., Ltd. utilizes lean carburetor settings as w ell as other system s, to reduce carbon m onoxide, oxides of
nitrogen and hydrocarbons.
CRANKCASE EM ISSION CONTROL SYSTEM
The engine is equipped w ith a closed crankcase system to prevent discharging crankcase em issions into the atm osphere.
Blow -by gas is returned to the com bustion cham ber through the air cleaner and carburetor.
AIR CLEANER
HOUSING
CARBURETOR
CRANKCASE
BREATHER FRESH AIR
HOSE
BLOW-BY GAS
1-25
EXHAUST EM ISSION CONTROL SYSTEM
The exhaust em ission control system is com posed of a pulse secondary air injection system and lean carburetor settings,
no adjustm ent should be m ade except idle speed adjustm ent w ith the throttle stop screw .
PULSE SECONDARY AIR INJECTION SYSTEM
The pulse secondary air injection (PAIR) system introduces filtered air into the exhaust gases in the exhaust port. Fresh air
is draw n into the exhaust port by the function of the PAIR (Pulse Secondary Air Injection) control valve.
The reed valve prevents reverse air flow through the system . The PAIR control valve reacts to high intake m anifold vacuum
and w ill cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system .
No adjustm ents to the secondary air supply system should be m ade, although periodic inspection of the com ponents is
recom m ended.
PAIR CONTROL RESONATOR

VALVE AIR CHAM BER
AIR CLEANER
PAIR CHECK HOUSING
VALVE
EXHAUST PORT
CARBURETOR
FRESH AIR
EXHAUST GAS
1-26
2. FRAM E/ BODY PANELS/ EXHAUST SYSTEM
SERVICE INFORM ATION ······························ 2-2 FUEL TANK·····················································2-4
TROUBLESHOOTING ···································· 2-2 FRONT FENDER··············································2-5
FRONT COWL ················································ 2-3 REAR GRIP······················································2-6
WIND SCREEN ··············································· 2-3 REAR COWL····················································2-6
SEAT······························································· 2-3 REAR FENDER ················································2-8
RIGHT SIDE COVER······································· 2-4 SAREE GUARD ···············································2-8
LEFT SIDE COVER ········································· 2-4 EXHAUST PIPE/ M UFFLER·····························2-9
2-1
SERVICE INFORM ATION
GENERAL
• This section covers rem oval and installation of the body panels, fuel tank and exhaust system .
• Alw ays replace the exhaust pipe gaskets after rem oving the exhaust pipe from the engine.
• When installing the exhaust system , loosely install all fasteners, tighten the exhaust pipe joint nuts first, tighten the
m uffler band bolt, then tighten the m uffler m ounting bolts.
• Alw ays inspect the exhaust system for leaks after installation.
TORQUE VALUES
Exhaust pipe stud bolt 11 N·m (1.1 kgf·m , 8 lbf·ft) See page 2-10
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deform ed exhaust system
• Exhaust gas leak
• Clogged m uffler
2-2
FRONT COWL
REM OVAL/ INSTALLATION
Rem ove the front cow l m ounting screw s and bolt.
Rem ove the front cow l and disconnect the head- FRONT
light/turn signal light 6P (Black) connector. COWL SCREWS
Rem ove the bolts and num ber stay from the front
cow l.
Installation is in the reverse order of rem oval.
STAY
6P CONNECTOR
BOLTS
BOLT
WIND SCREEN
Rem ove the front cow l (page 2-3).
SCREWS
Do not damage the Rem ove the screw s and w ind screen.
w ind screen.
WIND
SCREEN
SEAT
Insert the ignition key into the seat lock and turn it
clockw ise. SEAT
Pull the seat lock lever dow nw ard.
Slide and rem ove the seat to the backw ard.
Install the seat, w hile aligning its hook w ith the
bracket on the fram e.
Turn the ignition key counterclockw ise and rem ove
the key.
LEVER
2-3
RIGHT SIDE COVER
Rem ove the seat (page 2-3).
Rem ove the right side cover m ounting screw s.
SCREW B
Be careful not to Release the side cover bosses from the fuel tank.
damage the side Rem ove the right side cover. SCREW A
cover bosses.
Installation is in the reverse order of rem oval. B
A
BOSSES
RIGHT SIDE COVER SCREW
LEFT SIDE COVER

Rem ove the left side cover m ounting screw s.
Be careful not to Release the side cover bosses from the fuel tank.
damage the side Rem ove the left side cover. LEFT SIDE A B
cover bosses. COVER
SCREW B
BOSSES SCREW A
SCREW
FUEL TANK
Rem ove the follow ing:
FUEL VALVE
– left side cover (page 2-4)
– right side cover (page 2-4)
Wipe the spilled Turn the fuel valve "OFF" and disconnect the fuel
gasoline off at hose.
once.
FUEL HOSE
2-4
Rem ove the fuel tank m ounting bolt and w asher.
While raising the fuel tank disconnect the fuel unit FUEL TANK BOLT/WASHER
2P (Brow n) connector.
Pull back and rem ove the fuel tank.
After installation, Installation is in the reverse order of rem oval.
turn the fuel valve
"ON" and make sure
that there are no
fuel leaks.
2P CONNECTOR
FRONT FENDER
Rem ove the front w heel (page 12-12).
– cable guide
– four bolts and brake hose clam p
– front fender and stay BRAKE HOSE
CLAM P
BOLTS
GUIDE
STAY
FRONT FENDER
2-5
REAR GRIP
BOLTS REAR GRIP
Rem ove the m ounting bolts and rear grip.
REAR COWL
– rear grip (page 2-6)
Rem ove the tw o rear cow l m ounting screw s, bolt
and w asher. BOLT
Raise the rear cow l assem bly and disconnect the WASHER
brake/tail light 3P connector.
3P
Rem ove the rear cow l assem bly. REAR COWL CONNECTOR
While installing the Installation is in the reverse order of rem oval. ASSEM BLY
rear cow l, route the
w ire harness prop-
erly page 1-17.
SCREWS
2-6
DISASSEM BLY/ ASSEM BLY
Rem ove the tw o screw s and center rear cow l.
SCREWS CENTER REAR COWL
Rem ove the nuts, w ashers and brake/tail light unit.

Rem ove the screw s and separate the right/left rear
cow l from the stay.
Assem bly is in the reverse order of disassem bly.
LEFT REAR
COWL
NUTS/
WASHERS
RIGHT REAR SCREWS

COWL
BRAKE/TAIL
LIGHT UNIT
2-7
REAR FENDER
Rem ove the rear cow l (page 2-6).
Disconnect the turn signal light w ire connectors.
Rem ove the bolts, collars and rear fender.
While installing the Installation is in the reverse order of rem oval.
rear fender, route CONNECTORS
the w ire harness
properly page 1-17.
REAR
FENDER
COLLARS BOLTS
SAREE GUARD
Rem ove the m ounting bolts and saree guard. SAREE
Installation is in the reverse order of rem oval. GUARD
BOLTS
2-8
EXHAUST PIPE/ M UFFLER
REM OVAL
– exhaust pipe joint nuts
– m uffler m ounting bolt, w asher and nut
– exhaust pipe/m uffler
– gasket
M OUNTING WASHER
BOLT
GASKET
NUT
JOINT
EXHAUST PIPE/ NUTS
M UFFLER
INSTALLATION
Install a new gasket into the exhaust port.
Alw ays replace the Install the exhaust pipe/m uffler.
exhaust pipe gasket Loosely install the m uffler m ounting bolt, w asher
w ith a new one and nut.
w hen remove the Install the exhaust pipe joint then install and tighten M OUNTING WASHER
exhaust pipe from the exhaust pipe joint nuts. BOLT
the engine. GASKET
Alw ays inspect the Tighten the m uffler m ounting bolt.

exhaust system for
leaks after installa-
tion.
NUT
JOINT
EXHAUST PIPE/ NUTS
M UFFLER
2-9
DISASSEM BLY/ ASSEM BLY
Rem ove the tw o bolts, m uffler protector, collars and
rubber m ounts.
Rem ove the tw o bolts, front cover, collar and rubber
m ount.
BOLTS
Rem ove the rear cover from the m uffler.
Assem bly is in the reverse order of disassem bly.
PROTECTOR
REAR COVER
FRONT
COVER
COLLAR/
RUBBER
M OUNT
STUD BOLT REPLACEM ENT

Rem ove the exhaust pipe stud bolts from the cylin-
der head. 20.5 – 22.5 m m
(0.81 – 0.89 in)
Install a new stud bolts into the cylinder head
em bed to incom plete threads.
TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft)
After installing the stud bolts, check that the length
from the bolt head to the cylinder head surface is
w ithin specification.
STUD BOLT
(Em bed to incom plete thread)
2-10
3. M AINTENANCE
SERVICE INFORM ATION ······························ 3-2 DRIVE CHAIN ················································3-15
M AINTENANCE SCHEDULE························· 3-4 BATTERY·······················································3-19
FUEL LINE ······················································ 3-5 BRAKE FLUID················································3-20
FUEL STRAINER SCREEN ····························· 3-5 BRAKE SHOES/ PADS WEAR ······················3-20
THROTTLE OPERATION································ 3-6 BRAKE SYSTEM ···········································3-21
CHOKE OPERATION ······································ 3-6 BRAKE LIGHT SWITCHES····························3-22
AIR CLEANER················································· 3-7 HEADLIGHT AIM ··········································3-22
CRANKCASE BREATHER······························ 3-8 CLUTCH SYSTEM ·········································3-22
SPARK PLUG ················································· 3-8 SIDE STAND ·················································3-23
VALVE CLEARANCE······································ 3-9 SUSPENSION ···············································3-23
ENGINE OIL·················································· 3-11 NUTS, BOLTS, FASTENERS························3-24
ENGINE OIL CENTRIFUGAL FILTER··········· 3-13 WHEELS/ TIRES ············································3-24
ENGINE IDLE SPEED ··································· 3-14 STEERING HEAD BEARINGS ······················3-25
SECONDARY AIR SUPPLY SYSTEM ·········· 3-15
3-1
M AINTENANCE
M AINTENANCE
GENERAL
• Place the m otorcycle on a level surface before starting any w ork.
• The exhaust contains poisonous carbon m onoxide gas that m ay cause loss of consciousness and m ay lead to death.
Run the engine in an open area or w ith an exhaust evacuation system in an enclosed area.
SPECIFICATIONS
ITEM SPECIFICATIONS
Valve clearance Intake 0.08 m m (0.003 in)
Exhaust 0.12 m m (0.005 in)
Engine oil capacity After draining 1.0 liter (1.1 US qt, 0.9 lm p qt)
After disassem bly 1.2 liter (1.3 US qt, 1.1 lm p qt)
Recom m ended engine oil Honda 4-stroke oil or equivalent m otor oil
Viscosity: SAE 10W-30
Engine idle speed 1,400 ± 100 m in -1 (rpm )
Drive chain slack 20 – 30 m m (0.8 – 1.2 in)
Drive chain size/link 428/126
Recom m ended brake fluid DOT 3 or DOT 4
Brake pedal free play 20 – 30 m m (0.8 – 1.2 in)
Clutch lever free play 10 – 20 m m (0.4 – 0.8 in)
Cold tire pressure Front Driver only 175 kPa (1.75 kgf/cm 2, 25 psi)
Driver and passenger 175 kPa (1.75 kgf/cm 2, 25 psi)
Rear Driver only 225 kPa (2.25 kgf/cm 2, 33 psi)
Driver and passenger 280 kPa (2.80 kgf/cm 2, 41 psi)
Tire size Front 2.75-18 42P
Rear 3.00-18 52P
M inim um tire tread depth Front 1.5 m m (0.06 in)
Rear 2.0 m m (0.08 in)
TORQUE VALUES
Spark plug 16 N·m (1.6 kgf·m , 12 lbf·ft)
Valve adjusting lock nut 14 N·m (1.4 kgf·m , 10 lbf·ft) Apply engine oil to the threads and seating
surface
Tim ing hole cap 10 N·m (1.0 kgf·m , 7 lbf·ft)
Crankshaft hole cap 15 N·m (1.5 kgf·m , 11 lbf·ft) Apply grease to the threads
Oil drain bolt 30 N·m (3.1 kgf·m , 22 lbf·ft)
Oil filter rotor cover screw 4 N·m (0.4 kgf·m , 3.0 lbf·ft)
Driven flange sleeve nut 59 N·m (6.0 kgf·m , 44 lbf·ft) U-nut
Rear axle nut 68 N·m (6.9 kgf·m , 50 lbf·ft) U-nut
Spoke 3.7 N·m (0.4 kgf·m , 2.7 lbf·ft)
3-2
M AINTENANCE
TOOLS
Spoke w rench, 5.8 x 6.1 m m Wrench tappet adjustm ent

07701-0020300 070M A-001I110
3-3
M AINTENANCE
M AINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Ow ner's M anual at each scheduled m aintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary.
C: Clean. R: Replace. A: Adjust. L: Lubricate.
The follow ing item s require som e m echanical know ledge. Certain item s (particularly those m arked * and * * ) m ay require
m ore technical inform ation and tools. Consult their authorized Honda dealer.
FREQUENCY WHICHEVER
COM ES ODOMETER READING (NOTE 1)
FIRST REFER TO
ITEM S
* FUEL LINE
PLEASE REFER NOTE
x 1,000 m i
x 1,000 km
M ONTHS
0.6
1
2.5
4
6
I
5
8
12
I
7.5
12
18
I
PAGE
3-5
* FUEL STRAINER SCREEN
* THROTTLE OPERATION
* CHOKE OPERATION
PAGEM AKER 6.5 C
I
I
C
I
I
C
I
I
3-5
3-6
3-6
FILE
AIR CLEANER NOTE 2 C C R 3-7
CRANKCASE BREATHER NOTE 4 C C C 3-8
SPARK PLUG I R I 3-8
* VALVE CLEARANCE I I I I 3-9
ENGINE OIL R R R R 3-11
* * ENGINE OIL CENTRIFUGAL FILTER C 3-13
* ENGINE IDLE SPEED I I I I 3-14
* SECONDARY AIR SUPPLY SYSTEM I 3-15
DRIVE CHAIN EVERY 1,000 km (600 m i) I, L 3-15
BATTERY I I I 3-19
BRAKE FLUID NOTE 3 I I I 3-20
BRAKE SHOES/PADS WEAR I I I 3-20
BRAKE SYSTEM I I I I 3-21
* BRAKE LIGHT SWITCH I I I 3-22
* HEADLIGHT AIM I I I 3-22
CLUTCH SYSTEM I I I I 3-22
SIDE STAND I I I 3-23
* SUSPENSION I I I 3-23
* NUTS, BOLTS, FASTENERS I I 3-24
* * WHEELS/TIRES I I I I 3-24
* * STEERING HEAD BEARINGS I I 3-25
* Should be serviced by an authorized Honda dealer, unless the ow ner has proper tools and service data and is
m echanically qualified.
* * In the interest of safety, w e recom m ended these item s be serviced only by an authorized Honda dealer.
NOTES:
1. At higher odom eter readings, repeat at the frequency interval established here.
2. Service m ore frequently w hen riding in unusually w et or dusty areas.
3. Replace every 2 years. Replacem ent requires m echanical skill.
4. Service m ore frequently w hen riding in rain or at full throttle.
3-4
M AINTENANCE
FUEL LINE
Replace the fuel line if it is cracked, dam aged or
leaking. If the fuel flow is restricted, inspect the fuel
line and fuel strainer for blockage.
FUEL LINE
FUEL STRAINER SCREEN

Turn the fuel valve "OFF".
Rem ove the fuel strainer cup and drain the contents FUEL VALVE
of the cup into a suitable container.
FUEL STRAINER CUP
Rem ove the O-ring and strainer screen.

STRAINER SCREEN
Wash the strainer screen and cup in clean non-flam -
m able high flash point solvent.
Install the strainer, new O-ring and fuel strainer cup
in the fuel valve body, m aking sure that the O-ring is
in place.
FUEL STRAINER CUP O-RING
Tighten the fuel strainer cup.

FUEL VALVE
Turn the fuel valve "ON" and be sure there are no
fuel leaks.
FUEL STRAINER CUP
3-5
M AINTENANCE
THROTTLE OPERATION
Check for sm ooth throttle grip full opening and
autom atic full closing in all steering positions. 2 – 6 m m (0.08 – 0.24 in)
Check the throttle cable and replace it if it is deterio-
rated, kinked or dam aged.
Lubricate the throttle cable, if throttle operation is
not sm ooth.
M easure the free play at the throttle grip flange.
FREE PLAY: 2 – 6 mm (0.08 – 0.24 in)
Throttle grip free play can be adjusted at either end

of the throttle cable. DUST COVER
M inor adjustm ents are m ade w ith the upper
adjuster at throttle housing adjuster.
Slide the dust cover from the adjuster.
Adjust the free play by loosening the lock nut and
turning the adjuster.
After adjustm ent, tighten the lock nut and reposition
the dust cover properly on the adjuster.
Recheck the throttle operation.
M ake m ajor adjustm ents as described below .
LOCK NUT ADJUSTER
M ajor adjustm ents can be m ade w ith the low er

LOCK NUT
adjusting nut at the carburetor.
– throttle cable drum cover (page 5-8)
Loosen the lock nut and turn the adjusting nut.
After adjustm ent is com plete, tighten the lock nut
w hile holding the adjusting nut. ADJUSTING
Recheck the throttle operation. NUT
CHOKE OPERATION
• This m otorcycle is equipped w ith a fuel enriching
circuit controlled by a starting enrichm ent (SE)
valve. CHOKE LEVER
• The SE valve opens the enriching circuit via a
choke cable w hen the choke lever is pulled back.
Check for sm ooth operation of the choke lever.
Lubricate the choke cable if the operation is not
sm ooth.
Inspect the cable for cracks w hich could allow m ois-
ture to enter.
Replace the cable if necessary.
3-6
M AINTENANCE
AIR CLEANER
AIR CLEANER ELEM ENT
Rem ove the screw s.
Rem ove the air cleaner cover as show n w hile
releasing the boss from the rear fender. SCREWS
AIR CLEANER
COVER
BOSS
Rem ove the air cleaner elem ent.

ELEM ENT
Clean the air cleaner elem ent in accordance w ith the
m aintenance schedule (page 3-4).
Also replace the air cleaner elem ent any tim e it is
excessively dirty or dam age.
Clean the air cleaner elem ent using com pressed air
from the carburetor side from 30 m m distance.
Blow com pressed air also from air intake side w ith
45° angle from 50 m m distance along the fold line.
Install the rem oved parts in the reverse order of
rem oval.
ELEM ENT
3-7
M AINTENANCE
CRANKCASE BREATHER
• Service m ore frequently w hen ridden in rain, at
full throttle, or after the m otorcycle is w ashed or
overturned.
Check the crankcase breather hose for deterioration,
dam age or loose connection. M ake sure that the
hoses are not kinked, pinched or cracked.
BREATHER HOSE
Rem ove the drain plug from the air cleaner housing
drain hose and drain deposits into a suitable con-
tainer.
Reinstall the drain plug.
DRAIN PLUG
SPARK PLUG
REM OVAL
Disconnect the spark plug cap.
PLUG CAP
Clean around the Rem ove the spark plug using a equipped spark plug
SPARK PLUG
spark plug bases w rench or an equivalent.
w ith compressed
Inspect or replace the spark plug as described in the
air before remov-
m aintenance schedule (page 3-4).
ing the plug, and be
sure that no debris
is allow ed to enter
into the combustion
chamber.
3-8
M AINTENANCE
INSPECTION
Check the follow ing and replace if necessary (rec-
om m ended spark plug:page 3-2) CENTER ELECTRODE
• Insulator for dam age

• Electrodes for w ear
• Burning condition, coloration;
– dark to light brow n indicates good condition
– excessive lightness indicates m alfunctioning
ignition system or lean m ixture
– w et or black sooty deposit indicates over-rich
m ixture
INSULATOR SIDE ELECTRODE
Clean the spark plug electrodes w ith a w ire brush or

special plug cleaner.
Check the gap betw een the center and side elec- 0.8 – 0.9 m m
trodes w ith a w ire-type feeler gauge. (0.03 – 0.04 in)
If necessary, adjust the gap by bending the side
electrode carefully.
SPARK PLUG GAP: 0.8 – 0.9 mm (0.03 – 0.04 in)
INSTALLATION
Install and hand tighten the spark plug to the cylin-
der head, then tighten the spark plug to the speci-
fied torque using a spark plug w rench. SPARK PLUG

Connect the spark plug cap.
PLUG CAP
VALVE CLEARANCE
INSPECTION
Inspect and adjust Rem ove the cylinder head cover (page 7-6).
the valve clearance TIM ING HOLE CAP
Rem ove the tim ing hole cap and crankshaft hole
w hile the engine is
cap.
cold (below 35°C/
95°F).
CRANKSHAFT
HOLE CAP
3-9
M AINTENANCE
Rotate the crankshaft counterclockw ise and align
the “ T” m ark on the flyw heel w ith the index notch INDEX NOTCH
on the left crankcase cover.
M ake sure the piston is at TDC (Top Dead Center) on
the com pression stroke.
This position can be obtained by confirm ing that
there is slack in the rocker arm . If there is no slack, it
is because the piston is m oving through the exhaust
stroke to TDC. Rotate the crankshaft one full turn
and m atch up the “ T” m ark again.
“ T” M ARK
Check the valve clearance by inserting a feeler

gauge betw een the adjusting screw and valve stem . ADJUSTING SCREW
VALVE CLEARANCE:
IN: 0.08 mm (0.003 in)
EX: 0.12 mm (0.005 in)
FEELER GAUGE
Adjust by loosening the valve adjusting screw lock

nut and turning the adjusting screw until there is ADJUSTING WRENCH
LOCK NUT
slight drag on the feeler gauge.
Apply clean engine oil to the lock nut.
Hold the adjusting screw and tighten the lock nut to
the specified torque.
TOOL:
Wrench, tappet adjustment 070M A-001I110

Recheck the valve clearances.
Install the cylinder head cover (page 7-7).

Apply clean engine oil to the tim ing hole cap and
crankshaft hole cap new O-rings and install them .
Apply grease to crankshaft hole cap threads.
O–RINGS
3-10
M AINTENANCE
Install and tighten the tim ing hole cap to the speci-
fied torque. TIM ING HOLE CAP

Install and tighten the crankshaft hole cap to the
specified torque.
CRANKSHAFT
HOLE CAP
ENGINE OIL
OIL LEVEL INSPECTION
Support the m otorcycle on its center stand on a
level ground. FILLER CAP/DIPSTICK
Start the engine and let it idle for 3 – 5 m inutes.

Stop the engine and w ait 2 – 3 m inutes.
Rem ove the oil filler cap/dipstick and w ipe it clean.
Reinstall the oil filler cap/dipstick, but do not screw
it.
Rem ove the oil filler cap/dipstick and check the oil
level.
If the level is below the low er m ark on the dipstick,

fill the crankcase w ith recom m ended oil.
UPPER
LOWER
Other viscosities
show n in the chart RECOM M ENDED ENGINE OIL:
may be used w hen Honda 4-stroke oil or equivalent motor oil
the average tem- API service classification: SJ
perature in your Viscosity: SAE 20W40
riding area is w ithin
the indicated range.
3-11
M AINTENANCE
Apply clean engine oil to a new O-ring and install it.
Reinstall the oil filler cap/dipstick. O–RING
FILLER CAP/DIPSTICK
ENGINE OIL CHANGE

Drain the oil w hile Warm up the engine.
the engine is w arm Stop the engine and rem ove the oil filler cap/dip- FILLER CAP/DIPSTICK
and the motorcycle stick.
is on its center
stand.
Rem ove the drain bolt/sealing w asher.

Drain the engine oil com pletely.
Install a new sealing w asher on to the drain bolt.
Install and tighten the drain bolt/sealing w asher to
the specified torque.
BOLT/ SEALING WASHER
Fill the crankcase w ith the recom m ended engine oil.

ENGINE OIL CAPACITY:
1.0 liters (1.1 US qt, 0.9 Imp qt) at draining
1.2 liters (1.3 US qt, 1.1 Imp qt) at disassembly
Install the oil filler cap/dipstick.
Check the oil level (page 3-11).
Be sure there are no oil leaks.
FILLER CAP/DIPSTICK
3-12
M AINTENANCE
ENGINE OIL CENTRIFUGAL FILTER
Rem ove the right crankcase cover (page 9-5).
COVER/GASKET
Rem ove the three screw s, oil filter rotor cover and
gasket.
SCREWS
Do not allow dust Clean the oil filter rotor cover and inside of the oil
and dirt to enter the filter rotor using a clean lint-free cloth. FILTER ROTOR
oil passage in the
crankshaft. Never
use compressed air
for cleaning.
While pressing dow n the oil through from the

reverse side, rem ove the clip. OIL THROUGH
CLIP
Rem ove the oil through and spring.

Blow and clean the oil through w ith com pressed air. OIL THROUGH
Apply clean engine oil to the oil through surface and
install the spring and oil through.
SPRING
3-13
M AINTENANCE
While pressing dow n the oil through from the
reverse side, install the clip. OIL THROUGH
Check the oil through operates freely, w ithout bind-

ing.
CLIP
Install a new gasket on to the oil rotor cover.

Install and tighten the oil filter rotor cover. COVER/ GASKET
TORQUE: 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
Install the right crankcase cover (page 9-7).
SCREWS
ENGINE IDLE SPEED

• Inspect and adjust the idle speed after all other
engine m aintenance item s have been perform ed
and are w ithin specifications.
• The engine m ust be w arm for accurate adjust-
m ent. Ten m inutes of stop-and-go riding is suffi-
cient.
Warm up the engine, shift the transm ission into
neutral and place the vehicle on a level surface.
Connect a tachom eter.
Turn the throttle stop screw as required to obtain
the specified idle speed.
IDLE SPEED: 1,400 ± 100 min-1 (rpm)
THROTTLE STOP SCREW
3-14
M AINTENANCE
SECONDARY AIR SUPPLY SYSTEM
• The secondary air supply system introduces fil-
tered air into exhaust gases in the exhaust port.
The secondary air is draw n into the exhaust port
w henever there is negative pressure pulse in the
exhaust system . This charged secondary air pro-
m otes burning of the unburned exhaust gases
and changes a considerable am ount of hydrocar-
bons and carbon m onoxide into relatively harm -
less carbon dioxide and w ater.
If the hoses show Rem ove the left side cover (page 2-5). AIR SUCTION HOSE
any signs of heat
Check the air supply hose, air suction hose and vac-
damage, inspect
uum hose for deterioration, dam age or loose con-
the PAIR check
nections.
valve in the PAIR
reed valve cover for M ake sure that the hoses are not cracked.
damage.
AIR SUPPLY HOSE VACUUM HOSE

Rem ove the hose and resonator air cham ber.
RESONATOR AIR CHAM BER
Check the hose for deterioration, dam age or loose
connection. M ake sure that the hose is not cracked.
Check the resonator air cham ber for clogging, dam -
age or fatigue.
HOSE
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
Excessive chain slack, 50 m m (2.0 in) or m ore, m ay

dam age the fram e.
Never inspect and Turn off the ignition sw itch, place the m otorcycle on
adjust the drive its center stand on a level ground and shift the
chain w hile the transm ission into neutral.
engine is running.
Rem ove the chain slack inspection cover.
COVER
3-15
M AINTENANCE
Check the slack in the drive chain low er run m idw ay
betw een the sprockets.
CHAIN SLACK:20 – 30 mm (0.8 – 1.2 in)
20 – 30 m m
(0.8 – 1.2 in)
ADJUSTM ENT
Never inspect and Turn off the ignition sw itch, place the m otorcycle on
adjust the drive its center stand on a level ground and shift the AXLE NUT
chain w hile the transm ission into neutral.
engine is running.
Loosen the rear axle nut.
Loosen the rear sleeve nut.

SLEEVE NUT ADJUSTING NUT LOCK NUT
Loosen the both adjuster lock nuts.
Turn the both adjusting nuts an equal num ber of
turns until the correct drive chain slack is obtained.
Align the chain adjuster index m arks w ith the rear
edge of the adjusting slots.
INDEX M ARK REAR EDGE

Tighten the sleeve nut to the specified torque.
SLEEVE NUT
3-16
M AINTENANCE
Tighten the rear axle nut to the specified torque.
LOCK NUT AXLE NUT
Tighten the both sides of adjusting nuts and lock
nuts.
Recheck the drive chain slack and free w heel rota-
tion.
Check the rear brake pedal free play (page 3-21).
ADJUSTING NUT
CLEANING INSPECTION AND LUBRI-

CATION
Turn off the ignition sw itch, place the m otorcycle on
its center stand on a level ground and shift the DRIVE CHAIN CASES
transm ission into neutral.
Rem ove the bolts and drive chain cases.
BOLT
Lubricate the drive chain w ith #80–90 gear oil. Wipe

off the excess oil. DRIVE CHAIN
If the drive chain becom es extrem ely dirty, it should

be rem oved and cleaned prior to lubrication. RETAINING CLIP M ASTER
LINK
Rem ove the left crankcase rear cover (page 6-5).
Carefully rem ove the retaining clip w ith pliers.
Rem ove the m aster link, link plate and drive chain.
LINK
PLATE
3-17
M AINTENANCE
Clean the chain w ith non-flam m able or high flash
point solvent and w ipe it dry. NON-FLAM M ABLE
SOFT BRUSH
Be sure the chain has dried com pletely before lubri- OR HIGH FLASH
cating. POINT SOLVENT
Lubricate the drive chain w ith #80–90 gear oil.
Wipe off the excess gear oil. CLEANING
WIPE AND DRY
LUBRICATE
GEAR OIL
(SAE #80–90)
Inspect the drive chain for possible dam age or w ear.

Replace any chain that has dam aged rollers, loose
fitting links, or otherw ise appears unserviceable.
M easure the drive chain length w ith the chain held 41PINS/40LINKS
so that all links are straight.
DRIVE CHAIN LENGTH (41 pins/ 40 links)
STANDARD: 508 mm (20.0 in)
SERVICE LIM IT: 511 mm (20.1 in)
Installing a new chain on badly w orn sprockets w ill

cause a new chain to w ear quickly.
Inspect the drive and driven sprocket teeth for w ear WEAR
or dam age, replace if necessary.
Never use a new drive chain on w orn sprockets.
Both chain and sprockets m ust be in good condi-
tion, or the new replacem ent chain w ill w ear rap-
idly.
Check the attaching bolts and nuts on the drive and DAM AGE NORM AL
driven sprockets.
If any are loose, torque them .
Install the drive chain onto the sprockets.

Install the m aster link and link plate. M ASTER
Install the retaining clip w ith its open and opposite LINK
the direction of chain travel.
RETAINING LINK
CLIP PLATE
3-18
M AINTENANCE
Install the left crankcase rear cover (page 6-8).
DRIVE CHAIN CASE
Install the drive chain case w hile aligning the tabs
w ith grooves.
Install and tighten the bolts.
BOLTS
BATTERY
Rem ove the right side cover (page 2-4).
Add only distilled Inspect the electrolyte level. FILTER CAPS
w ater. Tap w ater
When the electrolyte level nears the low er level,
contains that w ill
rem ove the battery (page 15-6) and filler cap.
shorten the life of
Add distilled w ater to the upper level line.
the battery.
After filling, install each filler cap firm ly.
For the battery charging and specific gravity, see
page 15-7.
M ake sure that the battery breather hose is correctly

positioned, and not kinked, trapped or bent in such
aw ay as to obstruct the passage of the air.
• If the hose is blocked, the battery’s internal pres-
sure w ill not be relived, the breather m ay com e
off, or the battery crack as a result.
Install the battery (page 15-6).
3-19
M AINTENANCE
BRAKE FLUID
• Do not m ix different types of fluid, as they are
not com patible w ith each other.
• Do not allow foreign m aterial to enter the system
w hen filling the reservoir.
Spilled fluid can dam age painted, plastic or rubber

parts. Place a rag over these parts w henever the
system is serviced.
Turn the handlebar to the left until the reservoir is
parallel to the ground. SIGHT GLASS
Check the brake reservoir level through the sight
glass.
• When the fluid level is low , check the brake pads
for w ear (page 3-20). A low fluid level m ay be
due to w orn brake pads. If the brake pads are
w orn, the caliper pistons are pushed out, and
this causes a low reservoir level. If the brake
pads are not w orn and the fluid level is low ,
check entire system for leaks (page 3-21).
LOWER LEVEL LINE
BRAKE SHOES/ PADS WEAR

FRONT BRAKE PADS
Check the brake pad for w ear.
Replace the brake pads if either pad is w orn to the PADS
front of w ear lim it groove.
Refer to page 14-7 for brake pad replacem ent.
LIM IT GROOVE
REAR BRAKE SHOES

Check the w ear indicator position w hen the brake
pedal is applied. REFERENCE M ARK ARROW
If the arrow on the indicator plate aligns w ith the

reference m ark on the brake panel, inspect the brake
drum (page 13-17).
Replace the brake shoes (page 13-17) if the drum
I.D. is w ithin the service lim it.
3-20
M AINTENANCE
BRAKE SYSTEM
FRONT BRAKE
Inspect the brake hose and fittings for deterioration,
cracks and sings of leakage. FITTING
Tighten any loose fittings.
Replace hoses and fittings as required.
Firm ly apply the brake lever, and check that no air
has entered the system .
If the lever feels soft or spongy w hen operated,
bleed the air from the system .
Refer to page 14-5 for brake bleeding procedures.
FITTING
REAR BRAKE
Check the brake pedal and brake rod for loose con-
nections, excessive play, or other dam age.
Replace or repair if necessary.
M easure the rear brake pedal free play.
FREE PLAY: 20 – 30 mm (0.8 – 1.2 in)
20 – 30 m m
(0.8 – 1.2 in)
M ake sure the cut- Adjust the rear brake pedal free play by turning the
out of the adjusting adjusting nut.
nut is seated on the
Recheck the free play, then check and adjust the
brake arm pin.
brake light sw itch (page 3-22).
ADJUSTING NUT
3-21
M AINTENANCE
BRAKE LIGHT SWITCHES
• The front brake light sw itch does not require
adjustm ent.
• Adjust the rear brake light sw itch after adjusting
the brake pedal free play.
Adjust the brake light sw itch so that the brake light
com es on just prior to the brake actually being BRAKE LIGHT SWITCH BODY
engaged.
Hold the sw itch If the light fails to com e on, adjust the sw itch so that
body and turn the the light com es on at the proper tim e.
adjuster. Do not
turn the sw itch
body.
ADJUSTER
HEADLIGHT AIM
Place the m otorcycle on a level ground.
Adjust the headlight Adjust the headlight beam vertically by loosening
beam as specified the headlight adjusting bolt.
by local law s and
regulations.
BOLT
CLUTCH SYSTEM
Place the m otor cycle on its center stand.
Check the cable and clutch lever for loose connec-
tions, excessive play, or other dam age.
Replace or repair if necessary.
Inspect the clutch cable for kinks or dam age, and 10 – 20 m m
lubricate the cable. (0.4 – 0.8 in)
M easure the clutch lever free play at the tip of the
clutch lever.
FREE PLAY: 10 – 20 mm (0.4 – 0.8 in)
3-22
M AINTENANCE
Adjustm ents can be m ade w ith the adjusting nut at
the engine. LOCK NUT
Loosen the lock nut and turn the adjusting nut.
After adjustm ent is com plete, tighten the lock nut
w hile holding the adjusting nut.
Check the clutch operation.
If the free play cannot be obtained, or the clutch
slips during the test ride, disassem ble and inspect
the clutch (page 9-8).
ADJUSTING
NUT
SIDE STAND
Support the m otorcycle on its center stand.
SIDE STAND SPRING
Check the side stand spring for dam age or loss of
tension.
Check the side stand assem bly for freedom of
m ovem ent and lubricate the side stand pivot if nec-
essary.
M ake sure the side stand is not bent.
SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the forks by operating the front
brake and com pressing the front suspension several
tim es.
Check the entire assem bly for signs of leaks, dam -
age or loose fasteners.
Loose, w orn or Replace dam aged com ponents w hich cannot be
damaged suspen- repaired.
sion parts impair
Tighten all nuts and bolts.
motorcycle stability
and control. Refer to page 12-18 for fork service.
REAR SUSPENSION INSPECTION

Check the action of the rear shock absorber by com -
pressing the rear end several tim es.
Check the entire shock absorber assem bly for leaks
or dam age.
Loose, w orn or Replace dam aged com ponents w hich cannot be
damaged suspen- repaired.
sion parts impair
Tighten all nuts and bolts.
motorcycle stability
and control. Refer to page 13-23 for shock absorber service.
3-23
M AINTENANCE
Support the m otorcycle securely and raise the rear
w heel off the ground.
Check for w orn sw ingarm bearings by grabbing the
rear w heel and attem pting to m ove the w heel side
to side.
Replace the bearings if any looseness to noted.
Refer to page 13-24 for sw ingarm service.
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-10).
Check that all safety clips, hose clam ps and cable
stays are in place and properly secured.
WHEELS/ TIRES
Check for w orn w heel bearing by grabbing the front
w heel, and attem pting to m ove the w heel side to
side.
Replace the bearings if any looseness is noted
(page 12-14).
M aking sure the fork is not allow ed to m ove, raise
the front w heel and check for play. Turn the w heel
and check that it rotates sm oothly w ith no usual
noises.
If faults are found, inspect the w heel bearings.
Check for w orn w heel bearing by grabbing the rear

w heel, and attem pting to m ove the w heel side to
side.
As the sw ingarm Support the m otorcycle securely and raise the rear
pivot is included in w heel off the ground.
this check, be sure Check for play in either the w heel or the sw ingarm
to confirm the loca- pivot. Turn the w heel and check that it rotates
tion of the play; i.e. sm oothly w ith no unusual noises.
from the w heel
If abnorm al conditions are suspected, check the rear
bearings or the
w heel bearings.
sw ingarm pivot.
3-24
M AINTENANCE
Check the tire pressure w hen the tires are cold.
RECOM M ENDED TIRE PRESSURE AND TIRE SIZE:
FRONT REAR
175 225
Driver only
Tire pressure (1.75, 25) (2.25, 33)
kPa (kgf/cm 2, psi) Driver and 175 280
passenger (1.75, 25) (2.80, 41)
2.75-18 3.00-18
Tire size
42P 52P
TIRE PRESSURE GAUGE
Check the tires for cuts, em bedded nails, or other

dam age.
Check the front w heel (page 12-12) and rear w heel
(page 13-8) for trueness.
M easure the tread depth at the center of the tires.
Replace the tires w hen the tread depth reaches the
follow ing lim its.
M INIM UM TREAD DEPTH

FRONT: 1.5 mm (0.06 in)
REAR: 2.0 mm (0.08 in)
Retighten the w heel spokes periodically.

TOOL:
Spoke w rench, 5.8 x 6.1 mm 07701 – 0020300
TORQUE:
Front: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Rear: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
SPOKE WRENCH
STEERING HEAD BEARINGS

Check that the control cables do not interfere w ith
handlebar rotation.
Support the m otorcycle on its center stand and raise
the front w heel off the ground.
Check that the fork m oves freely from forw ard to
backw ard.
If the fork m oves unevenly, binds, or has vertical
m ovem ent, inspect the steering head bearings
(page 12-26).
3-25
M EM O
4. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM ············· 4-2 ENGINE OIL STRAINER SCREEN ··················4-4
SERVICE INFORM ATION ······························ 4-3 OIL PUM P························································4-4
TROUBLESHOOTING ···································· 4-3
4-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM
ROCKER ARM
CAM SHAFT
OIL FILTER ROTOR
CRANKSHAFT
OIL PUM P
OIL STRAINER SCREEN
M AINSHAFT
COUNTERSHAFT
4-2
LUBRICATION SYSTEM
GENERAL
Used engine oil m ay cause skin cancer if repeatedly left in contact w ith the skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly w ash your hands w ith soap and
w ater as soon as possible after handling used oil.
• The oil pum p can be serviced w ith the engine installed in the fram e.
• The service procedures in this section m ust be perform ed w ith the engine oil drained.
• When rem oving and installing the oil pum p, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pum p is w orn beyond the specified service lim it, replace the oil pum p as an assem bly.
• After the oil pum p has been installed, check that there are no oil leaks and that oil pressure is correct.
• Refer to the follow ing:
– engine oil level check (page 3-11)
– engine oil change (page 3-12)
– engine oil centrifugal filter cleaning (page 3-13)
SPECIFICATIONS
Unit: m m (in)
Engine oil After draining 1.0 liter (1.1 US qt, 0.9 lm p qt) –
capacity After disassem bly 1.2 liter (1.3 US qt, 1.1 lm p qt) –
Recom m ended engine oil Honda 4-stroke oil or equivalent m otor –
oil
Viscosity: SAE 20W40
Oil pum p Tip clearance 0.15 (0.006) 0.20 (0.008)
Side clearance 0.05 – 0.11 (0.002 – 0.004) 0.15 (0.006)
TORQUE VALUE
Oil pum p plate screw 3 N·m (0.3 kgf·m , 2.2 lbf·ft)
TROUBLESHOOTING
Engine oil level too low , high oil consumption
• External oil leaks
• Worn valve guide or seal
• Worn piston rings or incorrect piston ring installation
• Worn cylinder
Engine oil contamination
• Oil not changed often enough
• Clogged oil strainer
• Faulty cylinder head gasket
• Worn piston rings
4-3
LUBRICATION SYSTEM
ENGINE OIL STRAINER SCREEN
OIL STRAINER SCREEN
Rem ove oil strainer screen and record the direction.
Clean the oil strainer screen and check for dam age,
replace if necessary.
Coat the screen rubber w ith engine oil and install it

at original direction. OIL STRAINER SCREEN DIRECTION:
CRANKCASE
OIL PUM P
REM OVAL
Rem ove the oil pum p drive gear.
DRIVE GEAR
Rem ove the tw o m ounting bolts and the oil pum p.

OIL PUM P
M OUNTING BOLTS
4-4
LUBRICATION SYSTEM
Rem ove the tw o dow el pins.
DOWEL PINS
DISASSEM BLY
Rem ove the screw and oil pum p cover.
PUM P COVER
SCREW
Rem ove the rotor shaft and inner rotor.

INNER ROTOR
ROTOR SHAFT
Rem ove the outer rotor from the oil pum p body.
OUTER ROTOR
4-5
LUBRICATION SYSTEM
INSPECTION
• M easure at several places and use the largest
reading to com pare to the service lim it.
• If any portion of the oil pum p is w orn beyond the
specified service lim it, replace the oil pum p and
pum p cover as an assem bly.
Tem porarily install outer rotor, inner rotor and rotor
shaft into the oil pum p body. BODY CLEARANCE :
M easure the pum p body clearance.
SERVICE LIM IT: 0.25 mm (0.010 in)
M easure the rotor tip clearance.

TIP CLEARANCE :
Rem ove the rotor shaft.

SIDE CLEARANCE :
M easure the side clearance.
4-6
LUBRICATION SYSTEM
ASSEM BLY
PUM P BODY
ROTOR SHAFT
PUM P COVER
OUTER ROTOR
INNER ROTOR
3 N·m (0.3 kgf·m , 2.2 lbf·ft)
Apply clean engine oil to the outer rotor and install

it into the oil pum p body.
OUTER ROTOR
Apply clean engine oil to the inner rotor and rotor

shaft and install them . INNER ROTOR
ROTOR SHAFT
4-7
LUBRICATION SYSTEM
Install the oil pum p cover and tighten the screw .
PUM P COVER
SCREW
INSTALLATION
Install tw o dow el pins into the crankcase.
DOWEL PINS
Install the oil pum p and tighten the m ounting bolts.

OIL PUM P
M OUNTING BOLTS
Apply clean engine oil to the oil pum p drive gear

and install it.
DRIVE GEAR
4-8
5. FUEL SYSTEM
SYSTEM COM PONENTS ······························ 5-2 CARBURETOR ················································5-8
SERVICE INFORM ATION ······························ 5-3 PILOT SCREW ADJUSTM ENT·····················5-19
TROUBLESHOOTING ···································· 5-4 SECONDARY AIR SUPPLY SYSTEM ··········5-23
AIR CLEANER HOUSING ······························ 5-5 FUEL STRAINER···········································5-24
STARTING ENRICHM ENT (SE) VALVE········ 5-7
5-1
FUEL SYSTEM
SYSTEM COM PONENTS
FUEL SYSTEM
5-2
FUEL SYSTEM
GENERAL
• Bending or tw isting the control cable w ill im pair sm ooth operation and could cause the cable to stick or bind, resulting
in loss of vehicle control.
• Work in a w ell ventilated area. Sm oking or allow ing flam es or sparks in the w ork area or w here gasoline is stored can
cause a fire or explosion.
• When disassem bling the fuel system parts, note the locations of the O-rings. Replace them w ith new ones on reassem -
bly.
• Before rem oving the carburetor, place an approved gasoline container under the carburetor drain hose, loosen the
drain screw and drain the carburetor.
• After rem oving the carburetor, w rap the intake port of the engine w ith a shop tow el or cover it w ith pieces of tape to
prevent any foreign m aterial from dropping into the engine.
• If the vehicle is to be stored for m ore than one m onth, drain the float cham ber. Fuel left in the float cham ber m ay cause
clogged jets, resulting in hard starting or poor driveability.
SPECIFICATIONS
ITEM SPECIFICATIONS
Carburetor identification num ber VK4FA
M ain jet #115
Slow jet #38
Float level 13.0 m m (0.51 in)
Idle speed 1,400 ± 100 m in -1 (rpm )
PAIR control valve specified vacuum 58.7 kPa (440 m m Hg)
TORQUE VALUES
SE valve lock nut 2.3 N·m (0.2 kgf·m , 1.7 lbf·ft)
Carburetor drain screw 1.5 N·m (0.2 kgf·m , 1.1 lbf·ft)
Slow jet 1.5 N·m (0.2 kgf·m , 1.1 lbf·ft)
Needle jet holder 2.5 N·m (0.3 kgf·m , 1.8 lbf·ft)
M ain jet 2.1 N·m (0.2 kgf·m , 1.6 lbf·ft)
Float cham ber screw 2.1 N·m (0.2 kgf·m , 1.6 lbf·ft)
SE valve cover screw 3.4 N·m (0.4 kgf·m , 2.5 lbf·ft)
Vacuum cham ber cover screw 2.1 N·m (0.2 kgf·m , 1.6 lbf·ft)
Throttle cable stay screw 3.4 N·m (0.4 kgf·m , 2.5 lbf·ft)
Insulator band screw 1 N·m (0.1 kgf·m , 0.7 lbf·ft) see page 5-17
TOOL
Float level gauge

070M J-001I110
5-3
FUEL SYSTEM
TROUBLESHOOTING
Engine w on’t start
• Too m uch fuel getting to the engine
– Air cleaner clogged
– Flooded carburetor
• Intake air leak
• Fuel contam inated/deteriorated
• No fuel to carburetor
– Fuel strainer clogged
– Fuel hose clogged
– Fuel valve stuck
– Float level m isadjusted
Lean mixture
• Fuel jet clogged
• Float valve faulty
• Float level too low
• Fuel line restricted
• Intake air leak
• Throttle valve faulty
Rich mixture
• Choke valve in close position
• Float valve faulty
• Float level too high
• Air jets clogged
• Flooded carburetor
Engine stall, hard to start, rough idling
• Fuel line restricted
• Ignition system m alfunction
• Fuel m ixture too lean/rich (pilot screw adjustm ent)
• Fuel contam inated/deteriorated
• Intake air leak
• Idle speed m isadjusted
• Float level m isadjusted
Afterburn w hen engine braking is used
• Lean m ixture in slow circuit
• Faulty PAIR control valve
• Faulty PAIR check valve
• Clogged hose of the PAIR system
Backfiring or misfiring during acceleration
• Fuel m ixture too lean
Poor performance (driveability) and poor fuel economy
• Fuel system clogged
5-4
FUEL SYSTEM
AIR CLEANER HOUSING
REM OVAL
– right side cover (page 2-4) BREATHER HOSE
– air cleaner elem ent (page 3-7)
– battery (page 15-6)
Loosen the air cleaner connecting boot band screw .
Disconnect the crank case breather hose.
BAND SCREW
Disconnect the resonator air cham ber hose and air
cleaner housing drain hose. DRAIN HOSE
HOSE
Rem ove the m ounting bolts.

BOLTS
Disconnect the air vent hose (page 5-7) from the car-
buretor and rem ove the hose from the fram e CLAM PS AIR VENT HOSE
clam ps. 2P CONNECTOR
Disconnect the rear brake light sw itch 2P connector.
– battery breather hose
– m ain fuse (15A) M AIN
– turn signal relay (page 17-18) FUSE (15A)
Rem ove the m ounting bolt.
Rem ove the air cleaner housing from right side.
AIR CLEANER BREATHER

HOUSING BOLT HOSE
5-5
FUEL SYSTEM
INSTALLATION
Install the air cleaner housing to the fram e.
CLAM PS AIR VENT HOSE
Install and tighten the m ounting bolt.
2P CONNECTOR
Route all hoses as Install the follow ing:
show n on page 1- – battery breather hose
17. – m ain fuse (15A)
– turn signal relay (page 17-18)
Connect the air vent hose to the carburetor (page 5- M AIN
7) and clam p the hose to the fram e. FUSE (15A)
Connect the rear brake light sw itch 2P connector.
AIR CLEANER BREATHER

HOUSING BOLT HOSE
Install and tighten the m ounting bolts.
BOLT
While installing the Connect the resonator air cham ber hose and air
drain hose, route cleaner housing drain hose. DRAIN HOSE
the w ire harness
properly page 1-17.
HOSE
Carrying out as Connect the air cleaner connecting boot and tighten
show n that the the band screw . BAND SCREW
direction of the
BREATHER HOSE
Connect the crank case breather hose.
band screw .
Install the follow ing:
– battery (page 15-6)
– air cleaner elem ent (page 3-7)
30°
5-6
FUEL SYSTEM
STARTING ENRICHM ENT (SE) VALVE
Rem ove the fuel tank (page 2-4).
CARBURETOR AIR VENT HOSE
Disconnect the air vent hose.
Loosen the starting enrichm ent (SE) valve lock nut
and rem ove the SE valve from the carburetor body.
SE VALVE LOCK NUT/

SE VALVE
Check the SE valve for scoring, scratches or w ear.

Check the seat at the tip of the SE valve for stepped SE VALVE
w ear.
Replace the SE valve set if necessary.
When installing new SE valve, com press the spring

and release the choke cable and spring from the SE SPRING CHOKE CABLE
valve.
Install the SE valve to the choke cable.
SE VALVE
Handle the SE valve Install the SE valve to the carburetor body.

lock nut w ith care, Tighten the SE valve lock nut. CARBURETOR AIR VENT HOSE
that can easily be
damaged.
TORQUE: 2.3 N·m (0.2 kgf·m, 1.7 lbf·ft)
After the installation, check for the sm ooth opera-
tion of the choke lever (page 3-6).
Connect the air vent hose.
Install the fuel tank (page 2-4).
SE VALVE LOCK NUT/SE VALVE
5-7
FUEL SYSTEM
CARBURETOR
REM OVAL
Rem ove the SE valve (page 5-7).
AIR VENT HOSE
Turn the fuel valve “ OFF” and disconnect the fuel
hose from the carburetor.
Disconnect the air vent hose and throttle sensor 3P
connector from the carburetor.
THROTTLE SENSOR
3P CONNECTOR FUEL HOSE
Loosen the drain screw and drain the fuel from the
float cham ber into the approved gasoline container. DRAIN HOSE
Com pletely drain any residual fuel, tighten the drain
screw to the specified torque.
Disconnect the drain hose from the carburetor.
DRAIN SCREW

Rem ove the tw o screw s and throttle cable drum COVER
cover.
SCREWS
Loosen the throttle cable lock nut and disconnect

LOCK NUT
the throttle cable end from the throttle drum .
CABLE END THROTTLE DRUM
5-8
FUEL SYSTEM
Loosen the insulator band screw and air cleaner
connecting boot band screw .
Rem ove the carburetor.
SCREWS
DISASSEM BLY
THROTTLE CABLE STAY
Rem ove the tw o screw s and throttle cable stay.
THROTTLE CABLE STAY
SCREWS
VACUUM CHAM BER

As the compression Rem ove the tw o screw s and vacuum cham ber
spring is very long, cover. VACUUM CHAM BER COVER
it w ill jump out of
the carburetor
w hen the cover is
removed.
SCREWS
Rem ove the com pression spring and diaphragm /

vacuum piston from the carburetor body. DIAPHRAGM /
VACUUM PISTON
COM PRESSION
SPRING
5-9
FUEL SYSTEM
Turn the needle holder counterclockw ise and
rem ove it.
NEEDLE HOLDER
Be careful not to Rem ove the spring and jet needle from the vacuum
damage the dia- piston. JET NEEDLE
phragm. SPRING
Check the follow ing:
– jet needle for stepped w ear
– vacuum piston for w ear or dam age
– diaphragm for pin holes, deterioration or dam -
age
– spring for w ear or dam age
– needle holder for dam age
Replace the dam age parts, if necessary.
DIAPHRAGM /
VACUUM PISTON NEEDLE HOLDER
FLOAT
Rem ove the screw s and float cham ber.
FLOAT CHAM BER SCREWS
Pull out the float pin.
FLOAT PIN
5-10
FUEL SYSTEM
Rem ove the float and float valve.
FLOAT
FLOAT VALVE
JETS
NEEDLE JET M AIN JET
– m ain jet HOLDER
– slow jet
– needle jet holder
– needle jet
Damaged the pilot Before rem oving the pilot screw , record the num ber SPRING/
screw seat w ill of turns until it seats lightly, then rem ove the pilot WASHER/
occur if the screw screw , spring, w asher and O-ring. NEEDLE JET O-RING
is tightened against
the seat.
PILOT
SLOW JET SCREW
Check each jet for w ear or dam age.

Check the pilot screw , spring, w asher and O-ring for
w ear or dam age.
Replace the dam aged parts, if necessary. O-RING NEEDLE JET
HOLDER
SPRING
PILOT
SCREW
NEEDLE JET
WASHER SLOW JET M AIN JET

STARTING ENRICHM ENT (SE) VALVE COVER
Rem ove the tw o screw s/w ashers.
SE VALVE COVER
Rem ove the valve cover and O-ring.
Check the O-ring for deteriorated or dam age.
Check the starting enrichm ent (SE) valve cover and
SE valve air passage.
If air passage is clogged, blow open w ith com -
pressed air (page 5-12).
SCREWS/
WASHERS O-RING
5-11
FUEL SYSTEM
CARBURETOR CLEANING
Blow open the fuel passage from the valve seat side
w ith com pressed air and clean the strainer screen. STRAINER SCREEN
VALVE SEAT
Blow open each air and fuel passages in the carbu-

retor body w ith com pressed air. CARBURETOR BODY
Check each part for w ear or dam age and replace

them if necessary.
5-12
FUEL SYSTEM
ASSEM BLY
2.1 N·m (0.2 kgf·m ,

1.6 lbf·ft) VACUUM
SPRING CHAM BER
COVER
DIAPHRAGM / JET NEEDLE

VACUUM PISTON
STAY
SPRING
3.4 N·m (0.4 kgf·m ,

2.5 lbf·ft)
NEEDLE
FLOAT HOLDER
VALVE
O-RING
FLOAT
STARTING
O-RING ENRICHM ENT (SE)
VALVE COVER
FLOAT PIN
DRAIN
SCREW
O-RING
1.5 N·m
(0.2 kgf·m ,
SLOW JET 3.4 N·m (0.4 kgf·m ,
1.1 lbf·ft) WASHER
1.5 N·m (0.2 2.5 lbf·ft)
kgf·m , 1.1 SPRING
O-RING
NEEDLE JET PILOT
2.1 N·m (0.2 FLOAT NEEDLE JET SCREW
kgf·m , 1.6 lbf·ft) CHAM BER HOLDER
M AIN JET
2.5 N·m
(0.3 kgf·m , 2.1 N·m (0.2 kgf·m ,
1.8 lbf·ft) 1.6 lbf·ft)
JETS
Damage to the pilot Install the pilot screw w ith the spring, w asher and
screw seat w ill new O-ring, and return it to its original position as
occur if the pilot noted during rem oval.
screw is tightened
Perform the pilot screw adjustm ent if a new pilot O-RING
against the seat.
screw is installed (page 5-19).
SPRING
PILOT
SCREW
WASHER
5-13
FUEL SYSTEM
Handle the jets w ith Install the follow ing:
care, they can eas-
– needle jet
ily be scored or
– needle jet holder
scratched. NEEDLE JET
– m ain jet
– slow jet HOLDER
TORQUES:
Needle jet holder: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
M ain jet: 2.1 N·m (0.2 kgf·m, 1.6 lbf·ft)
Slow jet: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
NEEDLE JET
SLOW JET M AIN JET
FLOAT
Check the tip of the float valve w here it contacts the
valve seat for stepped w ear or contam ination. FLOAT VALVE VALVE SEAT
Replace the valve if the tip is w orn or contam inated.
Check the operation of the float valve.
Inspect the float valve seat for scores, scratches,
clogging and dam age.
If the seat is dam aged, replace the carburetor body.
Install the float valve to the float.

FLOAT
Install the float to the carburetor body.
FLOAT VALVE
Install the float pin through the body and float.

FLOAT PIN
5-14
FUEL SYSTEM
With the float valve seated and the float arm just
touching the valve, m easure the float level w ith the FLOAT LEVEL GAUGE
special tool as show n.
FLOAT LEVEL: 13.0 mm (0.51 in)
TOOL:
Float level gauge 070M J-001I110
The float cannot be adjusted.
Replace the float assem bly if it the float level is out
of specification.
Install a new O-ring into the float cham ber groove.

FLOAT CHAM BER
Install the float cham ber.
O-RING
Install and tighten the float cham ber screw s to the

specified torque. FLOAT CHAM BER SCREWS
TORQUE: 2.1 N·m (0.2 kgf·m, 1.6 lbf·f)
STARTING ENRICHM ENT (SE) VALVE COVER

Install the SE valve cover and new O-ring.
SE VALVE COVER
Install the tw o screw s/w ashers.
Tighten the screw s.
SCREWS/
O-RING WASHERS
5-15
FUEL SYSTEM
VACUUM CHAM BER
Install the jet needle into the diaphragm /vacuum
piston. JET NEEDLE
SPRING
Install the spring onto the needle holder and set the
needle holder into the vacuum piston.
DIAPHRAGM /
VACUUM PISTON NEEDLE HOLDER
Turn the needle holder clockw ise w hile pressing it

until it locks. Align
Holder flanges and piston grooves should be fitted
after turning.
DIAPHRAGM / NEEDLE
VACUUM PISTON HOLDER
Be careful not to Install the diaphragm /vacuum piston into the carbu-
damage the jet nee- retor body by aligning the tab of the diaphragm VACUUM
dle. w ith the groove of carburetor body. CHAM BER COVER
Lift the bottom of the piston w ith your finger to set

COM PRESSION
the diaphragm rib into the groove in the carburetor
SPRING
body.
Be careful not to Install the com pression spring and vacuum cham -
pinch the dia- ber cover w hile lifting the piston in place.
phragm under the Install the tw o screw s and vacuum cham ber cover
chamber cover, and before releasing the vacuum piston.
to keep the spring
straight w hen com-
pressing the spring.
TAB
Check that the spring installed correctly by pushing

the bottom of the piston w ith your finger and m ake COM PRESSION
sure that the piston returns back in place sm oothly. SPRING
VACUUM PISTON
5-16
FUEL SYSTEM
Tighten the tw o screw s.
SCREWS
THROTTLE CABLE STAY

Install the tw o screw s and throttle cable stay.
Tighten the tw o screw s. THROTTLE CABLE STAY
SCREWS
INSTALLATION
Install the carburetor to the connecting hose and
insulator. CARBURETOR SCREWS
Tighten the insulator band screw so that the band
ends clearance is 7 – 9 m m (0.3 – 0.4 in).
Carrying out as Tighten the connecting boot band screw .

show n that the
direction of the 7 – 9 mm
band screw . (0.3 – 0.4 in) 30°
BAND SCREW SE VALVE
Connect the throttle cable end to the throttle drum

and tighten the lock nut. LOCK NUT
CABLE END THROTTLE DRUM
5-17
FUEL SYSTEM
Install the throttle cable drum cover and tw o screw s.
Tighten the tw o screw s. COVER
Check the throttle operation (page 3-6).
SCREWS
Connect the drain hose to the carburetor.

DRAIN HOSE
Connect the air vent hose and throttle sensor 3P

connector to the carburetor. AIR VENT HOSE
After installation, Connect the fuel hose to the carburetor.
turn the fuel valve
Install the SE valve (page 5-7).
"ON" and make sure
these are no fuel
leaks.
THROTTLE SENSOR
3P CONNECTOR FUEL HOSE
5-18
FUEL SYSTEM
PILOT SCREW ADJUSTM ENT
• The pilot screw is correctly adjusted at the fac-
tory. As the adjustm ent of the pilot screw is very
critical for the em ission of CO and HC gases,
such an adjustm ent shall be carried out very
carefully.
• Place the m otorcycle on its center stand on a
level surface.
• Use a tachom eter w ith graduations of 50 m in -1
(rpm ) or sm aller that w ill accurately indicate a 50
m in -1 (rpm ) change.
• If the CO m easurem ent tool is available, perform
the adjustm ent by co concentration m easure-
m ent procedure.
ADJUSTM ENT BY CO CONCENTRA-

TION M EASUREM ENT
• Check the follow ing item s before inspection.
– air cleaner (page 3-7)
– spark plug (page 3-8)
– crankcase breather (page 3-8)
– secondary air supply system (page 5-23)
– ignition tim ing (page 16-7)
1. Connect an appropriate pipe or hose (heat-resis-
tant, chem ical-resistant) to the m uffler so that the PROBE PIPE
probe can be inserted by m ore than 60 cm (0.24
in).
2. Connect a tachom eter according to the tachom e-
ter m anufacturer’s instructions.
60 cm
(0.24 in)
Damage to the pilot 3. Rem ove the left side cover (page 2-4).
screw seat w ill PILOT SCREW WRENCH
Turn the pilot screw clockw ise until it seats
occur if the pilot
lightly, and then back it out to the specification
screw is tightened
given.
against the seat.
INITIAL OPENING: 1-1/ 2 turns out
PILOT SCREW
5-19
FUEL SYSTEM
4. Warm up the engine for 10 m inutes at idle speed.
• Do not w arm up the engine by running the
m otorcycle. The catalytic converter w ill act and
affect the m easurem ent.
Be careful if using M easure the engine oil drain bolt tem perature.
w ater thermome-
ter, the measure- DRAIN BOLT TEM PERATURE: 60 – 65 °C
ment may be
affected by the
atmospheric tem-
perature.
DRAIN BOLT
5. Adjust the idle speed w ith the throttle stop

screw .
THROTTLE
STOP SCREW
6. Insert the probe into the m uffler and m easure the

carbon-m ono-oxide (CO,%) concentration. CO M EASUREM ENT TOOL
CO measurement at idle: 0.7 – 0.8 %

If the CO concentration is exist, adjust the pilot
screw as follow ing.
5-20
FUEL SYSTEM
7. Disconnect the vacuum hose of PAIR control
valve, then it connect the vacuum pum p and VACUUM PUM P
plug the vacuum port.
Apply the specified vacuum to the PAIR control VACUUM HOSE
valve vacuum hose m ore than 58.7 kPa PLUG
(440m m Hg) (m ake sure the secondary air does
not supply).
When PAIR sys- 8. Start the engine and check the idle speed.
tem stop, idle
speed w ill change. IDLE SPEED: 1,350 ± 100 min-1 (rpm)
If the idle speed is out of specification, adjust the
idle speed by turning the throttle stop screw w ith
the PAIR system stopped.
THROTTLE
STOP SCREW
9. Turn the pilot screw and adjust the CO concen-

tration. CO M EASUREM ENT TOOL
CO measurement at idle:
(secondary air does not supply) 3.5 – 4.5 %
10.Disconnect the plug from the vacuum port, then
rem ove the vacuum pum p and connect the vac-
uum hose of PAIR control valve.
Start the engine.
Adjust the idle speed w ith the throttle stop screw
if necessary.
M easure the CO concentration again.
CO measurement at idle: 0.7 – 0.8 %
If the CO concentration is exist, check the sec-
ondary air supply system (page 5-23).
5-21
FUEL SYSTEM
IDLE DROP PROCEDURE
Damage to the pilot 1. Rem ove the left side cover (page 2-4).
screw seat w ill
Turn the pilot screw until it seats lightly, then
occur if the screw
back it out to the specification given.
is tightened against
This is an initial setting prior to the final pilot
the seat.
screw adjustm ent.
INITIAL OPENING: 1 – 1/ 2 turns out
Reference engine 2. Warm up the engine to norm al operating tem -
oil temperature: 60 perature.
– 65°C.
3. Stop the engine and connect the tachom eter,
according to the m anufacturer’s instructions.
PILOT SCREW
4. Disconnect the vacuum hose of PAIR control

valve, then it connect the vacuum pum p and
plug the vacuum port. VACUUM PUM P
Apply the specified vacuum to the PAIR control
valve vacuum hose m ore than 58.7 kPa VACUUM HOSE
(440m m Hg) (m ake sure the secondary air does PLUG
not supply).
5. Start the engine and adjust the idle speed w ith

the throttle stop screw .

6. Turn the pilot screw in or out slow ly to obtain the
highest engine speed.
7. Lightly open the throttle 2–3 tim es, then adjust
the idle speed w ith the throttle stop screw .
8. Turn the pilot screw in gradually until the engine
speed drops by 100 m in -1 (rpm ).
9. Turn the pilot screw outw ard to final opening. THROTTLE
STOP SCREW
FINAL OPENING: 1/ 2 turns out from the position
obtained in step 8
10.Disconnect the plug from the vacuum port, then
rem ove the vacuum pum p and connect the vac-
uum hose of PAIR control valve.
11.Readjust the idle speed w ith the throttle stop
screw .
5-22
FUEL SYSTEM
SECONDARY AIR SUPPLY SYSTEM
SYSTEM INSPECTION
Warm up to the engine to norm al operating tem per-
ature.
PORT
Rem ove the air cleaner elem ent (page 3-7) and fuel
tank (page 2-4).
Disconnect the air suction hose from the air cleaner
housing.
Check the air suction hose port is clean and free car-
bon deposits.
If the port is carbon fouled, check the PAIR control
valve.
HOSE
Disconnect the air suction hose from the resonator

air cham ber.
Then check the air suction hose is clean and free of
carbon deposits.
Disconnect the vacuum hose of PAIR control valve,
then it connect the vacuum pum p and plug the vac- AIR SUCTION HOSE VACUUM PUM P
uum port.
VACUUM HOSE
Tem porary install the fuel tank (page 2-4).
Start the engine and open the throttle slightly to be
certain that air is sucked in through the air suction
hose.
If the air is not draw n in, check the air suction hose
for clogging.
With the engine running, gradually apply vacuum to
the PAIR control valve vacuum hose.
Check that the air suction hoses stop draw ing air,
and that the vacuum dose not bleed.
SPECIFIED VAC-
UUM : 58.7 kPa (440mmHg)
PLUG
If the air is draw n in or if the specified vacuum is not
m aintained, install a new PAIR control valve.
PAIR CHECK VALVE INSPECTION

VALVE COVER
– fuel tank (page 2-4)
– PAIR control valve (page 5-24)
– tw o screw s
– valve cover
– PAIR check valve
Check the valve reed for fatigue or dam age, replace
the PAIR control valve if necessary.
Replace the PAIR control valve if the seat rubber is
cracked, deteriorated or dam aged, or if there is
clearance betw een the reed and seat.
SCREWS CHECK VALVE
5-23
FUEL SYSTEM
PAIR CONTROL VALVE
AIR SUPPLY HOSE VACUUM HOSE
Disconnect the PAIR control valve vacuum hose and
air supply hose.
Disconnect the air suction hose.

Rem ove the bolts, nuts and PAIR control valve. BOLT/NUTS
AIR SUCTION HOSE
FUEL STRAINER
REM OVAL
Drain the fuel from the fuel tank into the approved
gasoline container. SCREW
Rem ove the left side cover (page 2-4).
Rem ove the screw and fuel valve knob.
KNOB

Loosen the fuel valve lock nut.
LOCK NUT
5-24
FUEL SYSTEM
Rem ove the fuel strainer and fuel valve assem bly
O-RING FUEL VALVE
from the fuel tank.
Rem ove the fuel strainer and O-ring from the fuel
valve.
FUEL STRAINER
CLEANING
Clean the fuel strainer w ith com pressed air.
FUEL STRAINER
INSTALLATION
Install a new O-ring onto the fuel strainer, and
install the fuel strainer into the fuel valve. FUEL VALVE
O-RING
Install the fuel strainer and fuel valve assem bly into
the fuel tank.
FUEL STRAINER
Tighten the fuel valve lock nut.

LOCK NUT
5-25
FUEL SYSTEM
Install the fuel valve knob w hile aligning the fuel FUEL
valve tab w ith the knob hole.
VALVE
KNOB
ALIGN
Install and tighten the screw .

SCREW
Install the left side cover (page 2-4).
KNOB
5-26
6. ENGINE REM OVAL/ INSTALLATION
SYSTEM COM PONENTS ······························ 6-2 ENGINE REM OVAL ········································6-4
SERVICE INFORM ATION ······························ 6-3 ENGINE INSTALLATION ································6-6
6-1
SYSTEM COM PONENTS
54 N·m (5.5 kgf·m ,

40 lbf·ft)
12 N·m (1.2 kgf·m , 9 lbf·ft)
26 N·m (2.7 kgf·m ,

19 lbf·ft)
6-2
GENERAL
• When rem oving/installing the engine, tape the fram e around the engine beforehand for fram e protection.
• The follow ing com ponents can be serviced w ith the engine installed in the fram e.
– oil pum p (page 4-4)
– cylinder head/valves (page 7-14)
– cylinder/piston (page 8-4)
– clutch/gearshift linkage/kickstarter (page 9-5)
– alternator (page 10-4)
• The follow ing com ponents require engine rem oval for service.
– crankshaft/transm ission (page 11-6)
SPECIFICATIONS
ITEM SPECIFICATIONS
Engine oil capacity After draining 1.0 liter (1.1 US qt, 0.9 lm p qt)
After disassem bly 1.2 liter (1.3 US qt, 1.1 lm p qt)
Engine dry w eight 27.2 kg (60.0 lbs)
TORQUE VALUES
Front engine hanger nut 26 N·m (2.7 kgf·m , 19 lbf·ft)
Rear engine hanger nut 54 N·m (5.5 kgf·m , 40 lbf·ft)
Fixing plate bolt 12 N·m (1.2 kgf·m , 9 lbf·ft)
TOOL
Sprocket holder
070SRTKSP009
6-3
ENGINE REM OVAL
Support the m otor cycle on its center stand.
CRANK CASE NEUTRAL SWITCH
Drain the engine oil (page 3-12). BREATHER HOSE WIRE CONNECTOR
– spark plug cap (page 3-8)
– clutch cable (page 9-5)
– carburetor (page 5-8)
– exhaust pipe/m uffler (page 2-9)
– PAIR air supply hose (page 5-24)
Disconnect the alternator 2P connector, ignition
pulse generator w ire connector and neutral sw itch
w ire connector. IGNITION PULSE
Disconnect the crank case breather hose. ALTERNATOR 2P GENERATOR WIRE
CONNECTOR CONNECTOR
Loosen the rear axle nut.

AXLE NUT
Loosen the sleeve nut, both side drive chain adjust-

ing lock nuts and adjusting nuts. SLEEVE NUT LOCK NUT
Push the rear w heel forw ard and m ake a drive chain
slack fully.
ADJUSTING NUT
Rem ove the kickstarter pedal pinch bolt and kick-
starter pedal.
KICKSTARTER
BOLT PEDAL
6-4
Rem ove the gear shift pedal pinch bolt and gear
shift pedal. PEDAL
PINCH BOLT
Rem ove the m ain step m ounting bolts and m ain

step. BOLTS
M AIN STEP
Rem ove the tw o bolts.
BOLTS
Rem ove the left crankcase rear cover and bracket.

LEFT CRANK CASE
REAR COVER
BRACKET
6-5
Rem ove the fixing plate bolts, fixing plate and drive
CHAIN BOLTS
sprocket w ith chain.
FIXING PLATE SPROCKET
The jack height Support the engine using a jack or other adjustable
must be continu- support to ease of engine hanger bolts rem oval. BOLTS/
ally adjusted to NUTS
relieve stress for
– front engine hanger bolts and nuts
ease of bolt
– plate bolts and nuts
removal.
– front engine hanger plate
PLATE
Rem ove the rear engine hanger bolts and nuts.

During engine Rem ove the engine from the fram e.
removal, hold the
engine securely and
be careful not to
damage the frame
and engine. BOLTS/
NUTS
ENGINE INSTALLATION
• Place the jack or other adjustable support under
the engine.
• The jack height m ust be continually adjusted to
relieve stress for ease bolt installation.
• Carefully align the m ounting points w ith the jack
to prevent dam age to engine, fram e, w ires and
cables.
• All the engine m ounting bolts and nuts loosely
install, then tighten the bolts and nuts to the
specified torque.
6-6
During engine Place the engine in the fram e.
installation, hold the
Install the rear engine hanger bolts and nuts, but do
engine securely and
not tighten it yet.
be careful not to
damage the frame
and engine. REAR
ENGINE
HANGER
BOLT/
NUTS
Install the plate, plate bolts and nuts.

FRONT
Install the front engine hanger bolts and nuts. ENGINE
Tighten the front and rear engine hanger nuts to the HANGER
specified torque. BOLT/
NUTS PLATE
TORQUES: BOLT/
Front engine hanger nut: 26 N·m (2.7 kgf·m, 19 NUTS
lbf·ft)
Rear engine hanger nut: 54 N·m (5.5 kgf·m, 40
lbf·ft)
PLATE
Install the drive chain onto the drive sprocket.

Install the drive sprocket to the counter shaft. CHAIN Align FIXING PLATE
Install the fixing plate.

Rotate the fixing plate and align the hole in the plate
w ith the bolt hole in the drive sprocket.
SPROCKET
Tighten the fixing plate bolts to the specified torque.

BOLTS
6-7
Install the left crankcase rear cover and bracket.
LEFT CRANK CASE
REAR COVER
BRACKET
Install and tighten the tw o bolts.
BOLTS
Install the m ain step and tighten the m ounting bolts.

BOLTS
M AIN STEP
Install the gear shift pedal and tighten the pinch

bolt. PEDAL
PINCH BOLT
6-8
Install the kickstarter pedal so the distance betw een
the left crankcase cover and kickstarter pedal is 4 –
18 m m (0.16 – 0.71 in).
Install and tighten the pinch bolt.
4 – 18 m m
(0.16 – 0.71 in)
KICKSTARTER
BOLT PEDAL
Connect the crank case breather hose. NEUTRAL SWITCH

CRANK CASE
Connect the alternator 2P connector, ignition pulse BREATHER HOSE WIRE CONNECTOR
generator w ire connector and neutral sw itch w ire
connector.
– PAIR air supply hose (page 5-24)
– clutch cable (page 9-7)
– spark plug cap (page 3-9)
Inspect the follow ing: IGNITION PULSE
– drive chain slack (page 3-15) ALTERNATOR 2P GENERATOR WIRE
– brake pedal free play (page 3-21) CONNECTOR CONNECTOR
– clutch lever free play (page 3-22)
Fill the crankcase w ith recom m ended engine oil to
the proper level (page 3-12).
6-9
M EM O
7. CYLINDER HEAD/ VALVES
SYSTEM COM PONENTS ······························ 7-2 CAM SHAFT HOLDER 7

DISSASSEM BLY/ ASSEM BLY ·····················7-11
SERVICE INFORM ATION ······························ 7-3
CYLINDER HEAD
TROUBLESHOOTING ···································· 7-5 DISSASSEM BLY/ ASSEM BLY ·····················7-14
CYLINDER COM PRESSION··························· 7-6 CAM SHAFT HOLDER/

CYLINDER HEAD INSTALLATION ···············7-23
CYLINDER HEAD COVER······························ 7-6
CAM CHAIN TENSIONER LIFTER················7-25
CAM SHAFT HOLDER/
CYLINDER HEAD REM OVAL ························ 7-9
7-1
SYSTEM COM PONENTS
10 N·m (1.0 kgf·m , 7 lbf·ft)
32 N·m (3.3 kgf·m , 24 lbf·ft)
12 N·m (1.2 kgf·m , 9 lbf·ft)
9 N·m (0.9 kgf·m , 6.6 lbf·ft)
7-2
GENERAL
• This section covers service of the cylinder head, valves, rocker arm s and cam shaft.
• The cylinder head and valves services can be done w ith the engine installed in the fram e.
• Be careful not to dam age the m ating surfaces w hen rem oving the cylinder head cover and cylinder head. Do not strike
the cylinder head cover and cylinder head too hard during rem oval.
• When disassem bling, m ark and store the disassem bled parts to ensure that they are reinstalled in their original loca-
tions.
• Clean all disassem bled parts w ith cleaning solvent and dry them by blow ing them off w ith com pressed air before
inspection.
• Cam shaft and rocker arm lubricating oil is fed through oil passage in the cylinder head. Clean the oil passage before
assem bling cylinder head.
SPECIFICATIONS
Unit: m m (in)
Cylinder com pression at 1,000 m in -1 (rpm ) 1,152 kPa (11.8 kgf/cm 2, 167 psi) –
EX 0.12 (0.005) –
valve guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Stem -to-guide clear- IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
ance EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)
Valve seat w idth IN/EX 0.9 – 1.1 (0.035 – 0.043) 1.5 (0.06)
OUTER 35.95 (1.415) 35.14 (1.383)
Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm -to-shaft clear- IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
ance
Cam shaft Cam lobe height IN 32.994 – 33.234 (1.2990 – 1.3084) 32.96 (1.298)
EX 32.880 – 33.120 (1.2945 – 1.3039) 32.85 (1.293)
Cylinder head w arpage – 0.05 (0.002)
TORQUE VALUES
Cylinder head cover bolt 10 N·m (1.0 kgf·m , 7 lbf·ft)
Rocker arm shaft bolt 5 N·m (0.5 kgf·m , 3.7 lbf·ft)
Cam shaft holder bolt 32 N·m (3.3 kgf·m , 24 lbf·ft) Apply engine oil to the threads and
seating surface.
Cam sprocket bolt 9 N·m (0.9 kgf·m , 6.6 lbf·ft)
Carburetor insulator bolt 12 N·m (1.2 kgf·m , 9 lbf·ft)
Cam chain tensioner lifter plug 4 N·m (0.4 kgf·m , 3.0 lbf·ft)
7-3
TOOLS
Valve guide driver Valve spring com pressor Valve seat cutter, 27.5 m m (45° EX)
070GD-006I150 070GE-001I100 070GH-003I180
Valve seat cutter, 29 m m (45° IN) Flat cutter, 27 m m (32° EX) Flat cutter, 30 m m (32° IN)
07780-0010300 07780-0013300 07780-0012200
Interior cutter, 26 m m (60° EX) Interior cutter, 30 m m (60° IN) Cutter holder
07780-0014500 07780-0014000 070GH-005I150
Valve guide ream er

070GH-001I160
7-4
TROUBLESHOOTING
• Engine top-end problem s usually affect engine perform ance. These problem s can be diagnosed by a com pression test,
or by tracing top-end noise w ith a sounding rod or stethoscope.
• If the perform ance is poor at low speeds, check for w hite sm oke in the crankcase breather hose. If the hose is sm oky,
check for a seized piston ring (page 8-5).
Compression too low , hard starting or poor performance al low speed
• Valves
– Incorrect valve adjustm ent
– Burned or bent valve
– Incorrect valve tim ing
– Weak valve spring
– Uneven valve seating
– Valve stuck open
• Cylinder head
– Leaking or dam aged cylinder head gasket
– Warped or cracked cylinder head
– Loose spark plug
• Cylinder/piston problem (page 8-4).
Compression too high
• Excessive carbon build-up on piston head or com bustion cham ber
Excessive smoke
• Worn valve stem or valve guide
• Dam aged stem seal
Excessive noise
• Incorrect valve adjustm ent
• Sticking valve or broken valve spring
• Excessive w orn valve seat
• Worn or dam aged cam shaft
• Worn rocker arm and/or shaft
• Worn rocker arm follow er and valve stem end
• Worn cam sprocket teeth
• Worn cam chain
• Worn or dam aged cam chain tensioner
Rough idle
• Low cylinder com pression
7-5
CYLINDER COM PRESSION
Warm up the engine to norm al operating tem pera-
ture. SPARK PLUG
Stop the engine, disconnect the spark plug cap.

Rem ove the spark plug.
SPARK PLUG CAP
Install the com pression gauge into the spark plug

hole.
Shift the transm ission in neutral.
Open the throttle all the w ay and crank the engine
w ith the kickstarter until the gauge reading stops
rising.
COM PRESSION PRESSURE:
1,152 kPa (11.8 kgf/ cm 2, 167 psi) at 1,000 min-1(rpm)
If com pression is high, it indicates that carbon
deposits have accum ulated on the com bustion
cham ber and/or the piston crow n.
COM PRESSION
If com pression is low , pour 3 – 5 cc (0.1 – 0.2 oz) of GAUGE
clean engine oil into the cylinder through the spark
plug hole and recheck the com pression.
If the com pression increases from the previous
value, check the cylinder, piston and piston rings.
• Leaking cylinder head gasket
• Worn piston ring
• Worn cylinder and piston
If com pression is the sam e as the previous value,
check the valves for leakage.
CYLINDER HEAD COVER

REM OVAL
Disconnect the air supply hose.
BOLTS/RUBBER WASHERS
Rem ove the tw o bolts and rubber w ashers.
AIR SUPPLY HOSE
7-6
Rem ove the cylinder head cover and cover packing.
HEAD COVER
Rem ove the PAIR passage O-ring from the cylinder
head cover.
O-RING PACKING
Rem ove the oil through and O-ring from the cam -
shaft holder. OIL THROUGH O-RING
Rem ove the tw o bolts.

AIR SUPPLY PIPE
Rem ove the air supply pipe and O-ring.
BOLTS O-RING
INSTALLATION
Apply clean engine oil to a new O-ring.
AIR SUPPLY PIPE
Install a new O-ring to the air supply pipe.
Install the air supply pipe to the cylinder head cover.
Install and tighten the tw o bolts.
BOLTS
O-RING
7-7
Install the oil through and O-ring to the cam shaft OIL THROUGH O-RING
holder.

HEAD COVER
Install the PAIR passage O-ring to the cylinder head
cover.
Install a new cover packing into the cylinder head
cover groove.
Install the cylinder head cover onto the cylinder
head.
O-RING PACKING
Install the rubber w ashers to the cylinder head

cover w ith their “ UP” m ark facing up. "UP" M ARK
Install and tighten the head cover bolts to the speci-

fied torque. BOLTS/RUBBER WASHERS
7-8
CAM SHAFT HOLDER/
CYLINDER HEAD REM OVAL
PLUG
– plug cap (page 3-8)
– cylinder head cover (page 7-6).
M ake sure the piston is at TDC (Top Dead Center) on
the com pression stroke (page 3-9).
Rem ove the tensioner lifter plug and O-ring.
O-RING
M ake a tensioner shaft stopper tool out of a thin

piece of steel (0.8 m m thickness) using the diagram .
16.5 m m
6.5 m m
9.5 m m 4.5 m m
M ATERIAL THICKNESS: 0.8 m m
Turn the tensioner shaft clockw ise w ith the stopper

tool to retract the tensioner, then insert the stopper STOPPER TOOL
fully to hold the tensioner in the fully retracted posi-
tion.
Be careful not to let Rem ove the cam sprocket bolts.

the sprocket bolts BOLTS
fall into the crank-
case.
7-9
Rem ove the cam sprocket off the cam shaft flange.
Rem ove the sprocket from the cam chain. CAM CHAIN
Attach a piece of w ire to the cam chain to prevent it
from falling into the crankcase.
CAM SHAFT FLANGE SPROCKET

Rem ove the tw o cylinder head bolts.
BOLTS/WASHERS
Rem ove the four bolts, w ashers and cam shaft
holder.
BOLTS
CAM SHAFT HOLDER

Rem ove the cylinder head.
CYLINDER HEAD
Rem ove the gasket and dow el pins. GASKET
DOWEL PINS
7-10
CAM SHAFT HOLDER
DISSASSEM BLY/ ASSEM BLY
DISASSEM BLY
Rem ove the bolt and cam shaft retainer plate.
Rem ove the cam shaft from the cam shaft holder. BOLT
PLATE CAM SHAFT
Rem ove the rocker arm shaft bolts.

BOLTS
Rem ove the rocker arm shafts and rocker arm s from
the holder. ROCKER ARM
SHAFT
INSPECTION
CAM SHAFT BEARING
Turn the outer race of each bearing w ith your finger.
The bearings should turn sm oothly and quietly. BEARING
Also check that the bearing inner race fits tightly on
the cam shaft.
7-11
CAM LOBE
M easure the height of each cam lobe.
SERVICE LIM IT: IN: 32.96 mm (1.298 in)
EX: 32.85 mm (1.293 in)
Inspect the cam lobe for dam age or excessively
w orn.
Inspect the oil passages and rocker arm s for w ear or
dam age if necessary.
ROCKER ARM SHAFT

M easure the rocker arm shaft O.D.
ROCKER ARM
Turn the rocker arm roller w ith your finger.
The roller should turn sm oothly and quietly. ROLLER
M easure the rocker arm I.D.
Calculate the rocker arm -to-shaft clearance.
ASSEM BLY
Clean the threads of each rocker arm shaft thor-
oughly. ROCKER ARM
SHAFT
Apply clean engine oil to the rocker arm s, rollers
and shafts rolling surfaces.
7-12
Carrying out as Set the rocker arm in the cam shaft holder, then
show n that the install the rocker arm shaft into the cam shaft holder
ROCKER ARM
direction of a rocker through the rocker arm .
arm shafts.
SHAFT
Align the hole of the rocker arm shaft w ith the hole
of the cam shaft holder. BOLT
Install the rocker arm shaft bolts.
Tighten the rocker arm shaft bolts to the specified

torque. BOLTS
Lubricate the cam shaft bearings w ith clean engine

oil. BEARINGS
Apply clean engine oil to the cam lobes.
CAM LOBES
7-13
M ake sure the tab of cam shaft is turning the
upw ard. TAB
Install the cam shaft into the cam shaft holder.
CAM SHAFT
Install the cam shaft retainer plate and tighten the

bolt. BOLT
PLATE
CYLINDER HEAD
DISSASSEM BLY/ ASSEM BLY
DISASSEM BLY
Rem ove the spark plug (page 3-8).
Rem ove the tw o bolt and carburetor insulator.
BOLTS INSULATOR
To prevent loss of While com pressing the valve spring w ith a valve
tension, do not spring com pressor, rem ove the valve cotters. COTTERS
compress the valve
spring more than
TOOL:
necessary to
remove the cotters.
Valve spring compressor 070GE-001I100
VALVE SPRING
COM PRESSOR
7-14
M ark all disassem- Loosen the valve spring com pressor and rem ove
VALVE STEM SEAL
bled parts to ensure the follow ing:
correct reassembly.
– spring retainers
– valve springs
– inlet and exhaust valve
– stem seals
– spring seats SPRING
RETAINER
SPRING SEAT VALVE SPRINGS

Rem ove the carbon deposits from the com bustion
cham ber. CYLINDER
Clean off any gasket m aterials from the cylinder HEAD SURFACE
head surface.
COM BUSTION
CHAM BER
INSPECTION
VALVE SPRING
M easure the valve spring free length.
SERVICE LIM IT:

INNER: 37.89 mm (1.492 in)
OUTER: 35.14 mm (1.383 in)
CYLINDER HEAD
Be careful not to Check the spark plug hole and valve area for cracks.
damage the gasket Check the cylinder head for w arpage w ith a straight
surface. edge and a feeler gauge.
7-15
VALVE
Inspect the valve for trueness, burning, scratches or
abnorm al stem w ear. VALVE
M easure the valve stem O.D.
EX: 4.90 mm (0.193 in)
Insert each valve into the valve guide and check the
valve m ovem ent in the guide.
VALVE GUIDE
Alw ays rotate the Ream the valve guide to rem ove the carbon build-
reamer clockw ise, up before checking the valve guide. VALVE GUIDE REAM ER
never counterclock-
w ise w hen install- TOOL:
ing, removing and Valve guide reamer 070GH-001I160
reaming.
M easure and record each valve guide I.D. w ith a ball

gauge or inside m icrom eter. VALVE GUIDE
SERVICE LIM IT: IN/ EX: 5.04 mm (0.198 in)

Calculate the stem -to-guide clearance.
EX: 0.09 mm (0.004 in)
• If the stem -to-guide clearance exceeds the ser-
vice lim it, determ ine if a new guide w ith stan-
dard dim ensions w ould bring the clearance
w ithin tolerance. If so replace the guides as nec-
essary and ream to fit.
• If the stem -to-guide clearance still exceeds the
service lim it w ith new guides, replace the valve
and guide.
• Reface the valve seat w henever new valve
guides are installed.
7-16
VALVE GUIDE REPLACEM ENT
Chill the replacem ent valve guides in the freezer
section of a refrigerator for about an hour.
Heat the cylinder head to 130°C – 140°C (275°F –
290°F) w ith a hot plate or oven. Do not heat the cyl-
inder head beyond 150°C (300°F). Use tem perature
indicator sticks, available from w elding supply
stores, to be sure the cylinder head is heated to the
proper tem perature.
• Wear insulated gloves to avoid burns w hen han-
dling the heated cylinder head.
• Using a torch to heat the cylinder head m ay
cause w arping.
• Be careful not to dam age the m ating surface.
Support the cylinder head and drive the valve

guides and clips out of the cylinder head from the VALVE GUIDE DRIVER
com bustion cham ber side.
TOOL:
Valve guide driver 070GD-006I150
While the cylinder head is still heated, take off the

new valve guides from the freezer and install the VALVE GUIDE DRIVER
new clips to the new guides.
Drive new guides in the cylinder head from the cam -
shaft side.
TOOL:
Valve guide driver 070GD-006I150
After installing the valve guides, m easure the valve
guide height from the cylinder head.
SPECIFIED HEIGHT:16.8 – 17.0 mm (0.66 – 0.67 in)
Let the cylinder head cool to room tem perature.
VALVE GUIDE CLIP
Ream the new valve guides.
VALVE GUIDE REAM ER
TOOL:
Valve guide reamer 070GH-001I160
• Take care not to tilt or lean the ream er in the
guide w hile ream ing. Otherw ise, the valve is
installed slanted, that causes oil leaks from the
stem seal and im proper valve seat contact and
results in the valve seat refacing not able to be
perform ed.
• Insert the ream er from the com bustion cham ber
side of the head and alw ays rotate the ream er
clockw ise.
• Use cutting oil on the ream er during this opera-
tion.
Clean the cylinder head thoroughly to rem ove any
m etal particles after ream ing and reface the valve
seat.
7-17
VALVE SEAT INSPECTION
Clean the intake and exhaust valves thoroughly to
rem ove the carbon deposits. HAND
LAPPING TOOL
Apply light coating of Prussian Blue to the valve
seats.
Tap the valves and seats using a rubber hose or
other hand lapping tool.
Rem ove the valve and inspect the w idth of each

valve seat.
The valve seat contact should be w ithin the speci-
fied w idth and even all around the circum ference.
STANDARD: 0.9 – 1.1 mm (0.035 – 0.043 in)
Valve seat w idth is not w ithin specification, reface
the valve seat (page 7-19).
SEAT WIDTH
Inspect the valve seat face for:

• Dam aged face:
– Replace the valve and reface the valve seat.
• Uneven seat w idth:
– Bent or collapsed valve stem ;
Replace the valve and reface the valve seat.
DAM AGED FACE UNEVEN SEAT WIDTH
The valve cannot be • Contact area (too high or too low area)
grounded. If the – Reface the valve seat.
valve face is burned
or badly w orn or if it
contacts the seat
unevenly, replace
the valve.
TOO LOW TOO HIGH
7-18
VALVE SEAT REFACING
Follow the refacing Valve Seat Cutters, a grinder or equivalent valve
manufacture’s seat refacing equipm ent are recom m ended to cor-
operating instruc- rect a w orn valve seat.
tions.
45°
60°
32°
If the contact area is too high on the valve, the seat

m ust be low ered using a 32 degree flat cutter. CONTACT TOO HIGH
OLD SEAT
If the contact area is too low on the valve, the seat WIDTH
m ust be raised using a 60 degree inner cutter.
32°
CONTACT TOO LOW
OLD SEAT
WIDTH
60°
Reface the valve Use a 45 degree cutter to rem ove the roughness or
seat w ith a 45 irregularities from the seat. ROUGHNESS
degree cutter w hen
a valve guide is
TOOLS:
replaced.
Seat cutter, 27.5 mm (EX) 070GH-003I180
Seat cutter, 29 mm (IN) 07780-0010300
Cutter holder 070GH-005I150
VALVE SEAT CUTTER
Using 32 degree cutter, rem ove top 1/4 of the exist-

ing valve seat m aterial.
TOOLS: OLD SEAT WIDTH

Flat cutter, 27 mm (EX) 07780-0013300
Flat cutter, 30 mm (IN) 07780-0012200
32°
7-19
Using 60 degree cutter, rem ove the bottom 1/4 of
the old seat.
Rem ove the cutter and inspect the area you have
just rem oved. OLD SEAT WIDTH
TOOLS:
Interior cutter, 26 mm (EX) 07780-0014500
Interior cutter, 30 mm (IN) 07780-0014000
60°
Install a 45 degree finish cutter and cut the seat to

proper w idth.
M ake sure that all pitting and irregularities are
rem oved. SEAT WIDTH
Refinish if necessary.
STANDARD SEAT WIDTH:

0.9 – 1.1 mm (0.035 – 0.043 in)
45°
After cutting the seat, apply lapping com pound to

the valve face and lap the valve using light pressure. HAND
LAPPING TOOL
• Excessive lapping pressure m ay deform or dam -
age the seat.
• Change the angle of lapping tool frequently to
prevent uneven seat w ear.
• Lapping com pound can cause dam age if it enters
betw een the valve stem and guide.
After lapping, w ash any residual com pound off the
cylinder head and valve.
Recheck the seat contact after lapping.
7-20
ASSEM BLY
VALVE COTTERS
RETAINER
VALVE SPRING
SPRING SEAT
STEM SEAL
VALVE GUIDE
CLIP
INTAKE VALVE EXHAUST VALVE
Clean the cylinder head assem bly w ith solvent and

blow through all oil passages w ith com pressed air.
VALVE STEM SEAL
Install the valve seats and new valve stem seals.
Lubricate each valve stem w ith m olybdenum oil
solution.
To avoid damage to Insert the intake and exhaust valve into the valve SPRING
the seal, turn the guides. RETAINER
valve slow ly w hen
inserting.
SPRING SEAT VALVE SPRINGS

Install the valve springs and retainers. The springs
tightly w ound coils should face tow ard the com bus-
tion cham ber.
Com bustion cham ber side
7-21
Grease the cotters Com press the valve spring and install the valve cot-
to ease installation. ters. COTTERS
To prevent loss of
tension, do not
TOOL:
compress the valve
spring more than
Valve spring compressor 070GE-001I100
necessary.
VALVE SPRING
COM PRESSOR
Support the cylin- Tap the stem s gently w ith tw o plastic ham m er to
der head above the firm ly seat the cotters. COTTERS
w ork bench sur-
face to prevent
valve damage.
Install a new O-ring to the carburetor insulator.

O-RING
Carrying out as Install the carburetor insulator to the cylinder head

INSULATOR TAB
show n that the and tighten the bolts to the specified torque.
direction of the
insulator tab. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the spark plug (page 3-8).
BOLTS
7-22
CANSHAFT HOLDER/
CYLINDER HEAD INSTALLATION
Do not allow dust Clean any gasket m aterial from the cylinder m ating
and dirt to enter the surfaces.
engine.
GASKET
Install the dow el pins and new gasket.
DOWEL PINS
Route the cam chain through the cylinder head and
install the cylinder head onto the cylinder.
CYLINDER HEAD CAM CHAIN

Install the cam shaft holder to the cylinder head,
w hile aligning the holes in the cylinder head w ith CAM SHAFT HOLDER
dow el pins in the cam shaft holder.
Align
Apply clean engine oil to the threads and seating

surfaces of the cam shaft holder bolts.
Install the w ashers onto the cam shaft holder bolts.
Install and tighten the bolts to the specified torque.
Install and tighten the cylinder head bolts.
BOLTS
BOLTS/WASHERS
7-23
Rem ove the tim ing hole cap and crankshaft hole cap
(page 3-9). INDEX NOTCH
Rotate the crankshaft counterclockw ise and align
the “ T” m ark on the flyw heel w ith the index notch
on the left crankcase cover.
M ake sure the piston is at TDC (Top Dead Center). “ T” M ARK
Apply clean engine oil to the cam chain.

SPROCKET
Attach the cam sprocket to the cam chain w ith the CAM CHAIN
index line facing outside.
Tem porarily align the index line on the sprocket
w ith the upper surface of the cylinder head w ithout
m oving the cam chain.
INDEX LINE
Install the cam sprocket onto the cam shaft flange.
"o" M ARK BOLTS
Be sure that the index lines on the cam sprocket
align w ith the upper surface of the cylinder head
w hen the index line of the “ T” m ark on the flyw heel
is aligned w ith the index notch on the crankcase
cover.
Apply locking agent to the cam sprocket bolt
threads.
"o" mark side is fas- Install and tighten the cam sprocket bolts.
tened previously.
INDEX LINE
Rem ove the stopper tool from the cam chain ten-
sioner lifter. STOPPER TOOL
7-24
Apply clean engine oil to a new O-ring and install it
to the lifter. PLUG
Install the plug and tighten it.
– cylinder head cover (page 7-7)
– plug cap (page 3-8)
O-RING
CAM CHAIN TENSIONER LIFTER

REM OVAL
Rem ove the tensioner lifter plug and O-ring.
PLUG
O-RING
Rem ove the tw o m ounting bolts.
Rem ove the cam chain tensioner lifter and gasket. TENSIONER LIFTER BOLTS
GASKET
INSPECTION
Check the lifter operation:
– The tensioner shaft should not go into the body
w hen it is pushed.
– When it is turned clockw ise w ith a stopper tool
(page 7-9), the tensioner lifter shaft should be
pulled into the body. The shaft spring out of the
body as soon as the stopper tool is released.
TENSIONER LIFTER
7-25
INSTALLATION
Turn the tensioner lifter shaft clockw ise w ith the
stopper tool to retract the tensioner lifter, then TENSIONER LIFTER
insert the stopper fully to hold the tensioner lifter in
the fully retracted position.
STOPPER TOOL
Install a new gasket on the cam chain tensioner

lifter.
GASKET
Install the cam chain tensioner lifter.

Install the tw o m ounting bolts and tighten them . TENSIONER LIFTER BOLTS
Rem ove the stopper tool from the tensioner lifter.

to the lifter. PLUG
Install the tensioner lifter plug and tighten it.
O-RING
7-26
8. CYLINDER/ PISTON
SYSTEM COM PONENTS ······························ 8-2 TROUBLESHOOTING·····································8-3

8
SERVICE INFORM ATION ······························ 8-3 CYLINDER/ PISTON ········································8-4
8-1
CYLINDER/ PISTON
SYSTEM COM PONENTS
CYLINDER/ PISTON
8-2
CYLINDER/ PISTON
GENERAL
• The cylinder and piston services can be done w ith the engine installed in the fram e.
• Take care not to dam age the cylinder w all and piston.
• Be careful not to dam age the m ating surfaces w hen rem oving the cylinder. Do not strike the cylinder too hard during
rem oval.
• Cam shaft and rocker arm lubricating oil is fed through an oil passage in the cylinder. Clean the oil passage before
installing cylinder.
SPECIFICATIONS
Unit: m m (in)
Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Second 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.85 (0.033)
Connecting rod sm all end I.D. 14.010 – 14.028 (0.5516 – 0.5523) 14.06 (0.554)
TORQUE VALUES
Cylinder stud bolt 11 N·m (1.1 kgf·m , 8 lbf·ft) See page 8-4
TROUBLESHOOTING
Compression too low , hard starting or poor performance at low speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or dam aged cylinder and piston
Compression too high, overheating or knocking
• Excessive carbon built-up on piston or com bustion cham ber
Excessive smoke
• Worn cylinder, piston or piston rings
• Im proper installation of piston rings
• Scored or scratched piston or cylinder w all
Abnormal noise (piston)
• Worn piston pin or piston pin hole
• Worn cylinder, piston or piston ring
• Worn connecting rod sm all end
Slider base piston

070SRTKSP008
8-3
CYLINDER/ PISTON
CYLINDER/ PISTON
CYLINDER REM OVAL
Rem ove the cylinder head (page 7-9).
CAM CHAIN GUIDE
Rem ove the cam chain guide.
Avoid damaging the Lift the cylinder and rem ove it, being careful not to
gasket surfaces. dam age the piston w ith the stud bolts. CYLINDER
Clean the top of the cylinder thoroughly.
Rem ove the dow el pins and gasket.

GASKET
DOWEL PINS
STUD BOLT REPLACEM ENT

Rem ove the stud bolts from the crankcase.
Install the new stud bolts into the crankcase em bed
to incom plete threads.
TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft) 113.4 – 115.4 m m
(4.46 – 4.54 in)
After installing the stud bolts, check that the length
from the bolt head to the crankcase surface is w ithin
specification.
STUD BOLT
(Em bed to incom plete thread)
8-4
CYLINDER/ PISTON
CYLINDER INSPECTION
Inspect the cylinder w all for scratches and w ear.
CYLINDER
M easure and record the cylinder I.D. at three levels
in both the X and Y axes. Take the m axim um read-
ing to determ ine the cylinder w ear.
Calculate the cylinder-to-piston clearance (page 8-
6).
Calculate the cylinder for taper and out of round at

three levels in an X and Y axis. Take the m axim um
reading to determ ine the out of round.
SERVICE LIM IT: TOP
Taper: 0.10 mm (0.004 in)
Out of round: 0.10 mm (0.004 in)
M IDDLE
The cylinder m ust be rebored and an oversize pis-
ton fitted if the service lim it is exceeded.
The follow ing oversize pistons are available:
BOTTOM
0.25 mm (0.0098 in) – 1.00 mm (0.0394 in)
The cylinder m ust be rebored so that the clearance
for an oversize piston is 0.005 – 0.030 m m (0.0002 –
0.0012 in).
Check the cylinder for w arpage by placing a straight
edge and a feeler gauge across the studs and bolt
holes as show n.
PISTON REM OVAL

Place a clean shop Rem ove the piston pin clip using the pair of pliers.
tow el over the
crankcase to pre-
vent the possibility
of the clip falling
into the crankcase.
PISTON PIN CLIP
8-5
CYLINDER/ PISTON
Rem ove the piston pin out and rem ove the piston.
PISTON
Inspect the piston rings for m ovem ent by pressing
the rings. The rings should be able to m ove in its
groove w ithout catching.
PISTON PIN
Spread each piston ring and rem ove it by lifting it
up at a point just opposite the gap. PISTON RING
• Do not dam age the piston ring by spreading the

ends too far.
• Be careful not to dam age the piston w hen the
piston ring rem oval.
Never use a w ire Clean carbon deposits from the piston ring grooves
brush; it w ill scratch w ith a ring that w ill be discarded. PISTON
the grooves.
PISTON RING
PISTON INSPECTION
Inspect the piston for cracks or other dam age.
Inspect the ring grooves for excessive w ear and car-
bon build-up.
M easure each piston O.D. at 10 m m (0.4 in) from the
bottom , and 90° to the piston pin hole.
10 m m (0.4 in)
Calculate the cylinder-to-piston clearance. Take the
m axim um reading to determ ine the clearance (Cyl-
inder I.D.:page 8-5).
8-6
CYLINDER/ PISTON
M easure each piston pin hole I.D. in an X and Y axis.
Take the m axim um reading to determ ine I.D. PISTON
M easure the piston pin O.D. at three points.

Calculate the piston-to-piston pin clearance.
PISTON PIN
M easure the connecting rod sm all end I.D.

CONNECTING ROD
Calculate the connecting rod sm all end-to-piston pin
clearance.
Using a piston, push the ring securely into the cylin-

PISTON RING
der and m easure the end gap using a feeler gauge.
SERVICE LIM IT:

Top: 0.40 mm (0.016 in)
Second: 0.40 mm (0.016 in)
Oil: 0.85 mm (0.033 in)
8-7
CYLINDER/ PISTON
Alw ays replace the Inspect the piston rings, and replace them if they
piston rings as a are w orn.
set.
Reinstall the piston rings (page 8-8) into the piston
grooves.
Push in the ring until the outer surface of the piston
ring is nearly flush w ith the piston and m easure the
clearance using a feeler gauge.
SERVICE LIM IT:

Top: 0.10 mm (0.004 in)
Second: 0.10 mm (0.004 in)
PISTON RING
PISTON INSTALLATION
Clean the piston heads, ring lands and skirts.
Carefully install the piston rings onto the piston w ith
their m arkings facing up.
• Do not dam age the piston ring by spreading the
ends too far.
• Be careful not to dam age the piston w hen the
piston ring installation.
• Do not confuse the top and second rings.
• After installing the rings they should rotate
freely, w ithout sticking.
• Space the ring end gaps 120 degrees apart.
TOP RING
(“ R” M ARK)
SECOND RING
(“ RN” M ARK)
120°
120° TOP RING

120°
SECOND RING
SPACER
A SIDE RAILS
A A: 20 m m (0.8 in) or m ore
TOP RING
SECOND RING
OIL RING
8-8
CYLINDER/ PISTON
When cleaning the Clean any gasket m aterial from the cylinder m ating
cylinder mating sur- surface of the crankcase.
face, place a shop
tow el over the cyl-
inder opening to
prevent dust or dirt
enter the engine.
M ATING SURFACE
Apply m olybdenum oil solution to the piston pin
"IN" M ARK PISTON
outer surfaces.
Install the piston w ith its “ IN” m ark facing the intake
side.
Install the piston pin.
PISTON PIN
Install the new piston pin clips.
• Place a shop tow el over the crankcase opening to
prevent piston pin clips from falling into the
crankcase.
• Alw ays use new piston pin clips. Reinstalling
used piston pin clips m ay lead to serious engine
dam age.
• Set the piston pin clip in the groove properly.
• Do not align the clip’s end gap w ith the piston
cut-out.
PISTON PIN CLIP
CYLINDER INSTALLATION
Do not reuse the Install the dow el pins and new gasket.
gasket, replace
GASKET
w ith a new one.
DOWEL PINS
8-9
CYLINDER/ PISTON
Be careful not to Apply clean engine oil to the cylinder w all, piston
damage the piston outer surface and piston rings. CYLINDER
rings and cylinder
Route the cam chain through the cylinder and install
w all.
the cylinder over the piston w hile com pressing the
piston rings w ith your fingers.
TOOL:
Slider base piston 070SRTKSP008
PISTON/
PISTON RINGS SLIDER BASE PISON
Insert the cam chain guide into the cylinder and

crankcase groove. CAM CHAIN GUIDE
Install the cylinder head (page 7-23).
GROOVE
8-10
9. CLUTCH/ GEARSHIFT LINKAGE/ KICKSTARTER
SYSTEM COM PONENTS ······························ 9-2 GEARSHIFT LINKAGE··································9-15
SERVICE INFORM ATION ······························ 9-3 KICKSTARTER IDLE GEAR ··························9-17

9
TROUBLESHOOTING ···································· 9-4 KICKSTARTER ··············································9-18
RIGHT CRANKCASE COVER························· 9-5 PRIM ARY DRIVE GEAR/

CRANKSHAFT COLLAR ·······························9-21
CLUTCH·························································· 9-8
9-1
SYSTEM COM PONENTS
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER
12 N·m (1.2 kgf·m ,

9 lbf·ft)
12 N·m (1.2 kgf·m , 9 lbf·ft)
74 N·m (7.5 kgf·m , 55 lbf·ft)
64 N·m (6.5 kgf·m , 47 lbf·ft)
12 N·m (1.2 kgf·m ,

9 lbf·ft)
9-2
GENERAL
• This section covers service of the clutch, gearshift linkage, kickstarter. All services can be done w ith the engine installed
in the fram e.
• Transm ission oil viscosity and level have an effect on clutch disengagem ent. w hen the clutch does not disengage or
m otorcycle creeps w ith clutch disengaged, inspect the transm ission oil level before servicing the clutch system .
SPECIFICATIONS
Unit: m m (in)
Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.6 (0.10)
Plate w arpage – 0.20 (0.008)
Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909)
I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)
M ainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
TORQUE VALUES
Clutch center lock nut 74 N·m (7.5 kgf·m , 55 lbf·ft) Apply engine oil to the threads and seating surface.
Clutch lifter plate bolt 12 N·m (1.2 kgf·m , 9 lbf·ft)
Oil filter rotor lock nut 64 N·m (6.5 kgf·m , 47 lbf·ft) Apply engine oil to the threads and seating surface.
Shift drum stopper arm bolt 12 N·m (1.2 kgf·m , 9 lbf·ft) Apply a locking agent to the threads.
Gear shift cam bolt 12 N·m (1.2 kgf·m , 9 lbf·ft) Apply a locking agent to the threads.
9-3
TOOLS
Lock nut w rench Pin driver Clutch center holder
0701-KRB-T7900 07744-0010200 070SRTKSP011
Gear holder Holder gear drum stopper arm

0706-KRB-T7900 070SRTKSP010
9-4
TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the free play.
Clutch lever difficult to pull in
• Dam aged, kinked or dirty clutch cable
• Im properly routed clutch cable
• Dam aged clutch lifter m echanism
• Faulty clutch lifter plate bearing
Clutch w ill not disengage or motorcycle creeps w ith clutch disengaged
• Excessive clutch lever free play
• Clutch plate w arped
• Oil level too high, im proper oil viscosity, or additive used
• Check for oil additive
Clutch slips
• Clutch lifter sticking
• Worn clutch discs
• Weak clutch springs
• No clutch lever free play
• Check for oil additive
Hard to shift
• M isadjusted clutch cable
• Dam aged or bent shift fork
• Bent shift fork shaft
• Incorrect engine oil viscosity
• Incorrect gearshift spindle assem bly
• Dam aged shift drum guide grooves
Transmission jumps out of gear
• Worn shift drum stopper arm
• Worn or broken gearshift spindle return spring
• Dam aged shift drum guide grooves
• Worn gear dogs or dog holes
Gearshift pedal w ill not return
• Weak or broken gearshift spindle return spring
• Bent gearshift spindle
9-5
RIGHT CRANKCASE COVER
REM OVAL
Drain the engine oil (page 3-12).
LIFTER ARM CLUTCH CABLE
– kickstarter pedal (page 6-4)
– m ain step (page 6-5)
Loosen the lock nut and adjusting nut, then discon-
nect the clutch cable from the clutch lifter arm .
ADJUSTING
NUT LOCK NUT
Loosen the right crankcase cover bolts in a criss-

cross pattern in 2 or 3 steps, and rem ove the bolts, HOLDER COVER
clutch cable holder and right crankcase cover.
BOLTS
Rem ove the gasket and dow el pins.
GASKET
DOWEL PINS
DISASSEM BLY
Rem ove the lifter piece.
LIFTER PIECE
Unhook the return spring from right crankcase
cover.
Unhook
RETURN SPRING
9-6
M easure and record the length of drive pin protru-
sion. PIN DRIVER
Drive the spring pin into the clutch lifter arm until
the pin end is flush w ith the lifter arm surface, using
the pin driver.
TOOL:
Pin driver 07744-0010200
CLUTCH
Pulling the clutch lifter arm out and rem ove the LIFTER ARM
return spring.
RETURN
SPRING
SPRING PIN
Rem ove the kickstarter spindle dust seal.

DUST SEAL
Rem ove the clutch lifter arm and dust seal.
Check the lifter piece and arm for w ear or dam age.
Check the return spring for fatigue or dam age.
Replace them if necessary.
DUST SEAL
CLUTCH LIFTER ARM
ASSEM BLY
Apply grease to a new kickstarter spindle dust seal
lip and install it into the right crankcase cover.
Apply grease to a new clutch lifter arm dust seal lip DUST SEAL
and install it into the right crankcase cover.
Apply clean engine oil to the clutch lifter arm rod
sliding surface and install it into the right crankcase
cover.
CLUTCH LIFTER ARM DUST SEAL
Install the return spring onto the lifter arm end.

PIN DRIVER
From the opposite side, drive the spring pin until it
projects the sam e am ount as recorded at disassem -
bly, using the pin driver.
TOOL:
Pin driver 07744-0010200
CLUTCH
LIFTER ARM
RETURN SPRING SPRING PIN
9-7
Hook the return spring ends as show n.
CLUTCH LIFTER ARM
Install the lifter piece into the lifter arm groove w hile
aligning the groove w ith the lifter piece hole.
Hooks
RETURN SPRING LIFTER PIECE
INSTALLATION
Be careful not to Clean off any gasket m aterial from the m ating sur-
damage the mating faces of the right crankcase and cover. GASKET
surfaces.
Install the dow el pins and new gasket.
DOWEL PINS
Install the right crankcase cover, clutch cable holder
and cover bolts. HOLDER COVER
Tighten the bolts in a crisscross pattern in 2 or 3
steps.
BOLTS
Connect the clutch cable to the clutch lifter arm .
LIFTER ARM CLUTCH CABLE
Adjust the clutch lever free play (page 3-22).
– m ain step (page 6-8)
– kickstarter pedal (page 6-9)
Fill the crankcase w ith the recom m ended engine oil
(page 3-12).
9-8
CLUTCH
DISASSEM BLY
LOCK NUT WRENCH GEAR HOLDER
– right crankcase cover (page 9-6)
– oil filter rotor cover (page 3-13)
– oil pum p drive gear (page 4-4)
Install the gear holder betw een the prim ary drive
and driven gears as show n, and loosen the oil filter
rotor lock nut.
TOOLS:
Gear holder 0706-KRB-T7900
Lock nut w rench 0701-KRB-T7900
LOCK NUT
Rem ove the lock nut, lock w asher and oil filter rotor.
OIL FILTER ROTOR
LOCK NUT WASHER
Loosen the clutch lifter plate bolts in a crisscross

pattern in several steps. LIFTER PLATE
Rem ove the bolts, lifter plate and clutch springs.
BOLTS / SPRINGS
Attach the clutch center holder to the pressure plate
CLUTCH CENTER HOLDER LOCK NUT
using four clutch lifter plate bolts to hold the clutch
center, then loosen the clutch center lock nut using
the special tool.
TOOL:
Clutch center holder 070SRTKSP011
9-9
Rem ove the special tools, lock nut and lock w asher.
WASHER
LOCK NUT
PRESSURE PLATE
– clutch center
– clutch disc A CLUTCH CENTER
– clutch plates and discs B
– pressure plate
DISC A DISCS B / PLATES DISC A

CLUTCH OUTER
– w asher
– clutch outer
WASHER
Rem ove the clutch outer guide.
CLUTCH OUTER GUIDE
9-10
INSPECTION
CLUTCH LIFTER BEARING
Turn the inner race of the lifter bearing w ith your
finger. LIFTER PLATE BEARING
The bearing should turn sm oothly and quietly.
Also check that the outer race of the bearing fits
tightly in the lifter plate.
Replace the bearing if the inner race does not turn
sm oothly, quietly, or if the outer race fits loosely in
the lifter plate.
CLUTCH SPRING
Replace the clutch Check the clutch spring for fatigue or dam age.
springs as a set.
M easure the clutch spring free length.
CLUTCH CENTER
Check the grooves of the clutch center for dam age
or w ear caused by the clutch plates. CLUTCH CENTER
GROOVE
CLUTCH DISC
Check the clutch discs for signs of scoring or discol-
oration. DISC A DISC B
A>B
9-11
Replace the clutch M easure the thickness of each disc.
discs and plates as CLUTCH DISC
a set. SERVICE LIM IT:
Disc A, B: 2.6 mm (0.10 in)
CLUTCH PLATE
Replace the clutch Check the plate for discoloration.
discs and plates as Check the clutch plate for w arpage on a surface CLUTCH PLATE
a set. plate using a feeler gauge.
Warped clutch plates prevent the clutch from disen-
gaging properly.
CLUTCH OUTER/ OUTER GUIDE

Check the slots in the clutch outer for nicks, cuts or
indentations m ade by the clutch discs. CLUTCH OUTER
Check the prim ary driven gear teeth for w ear or
dam age.
M easure the clutch outer I.D.
M easure the clutch outer guide I.D. and O.D.
SERVICE LIM IT:

I.D.: 17.04 mm (0.671 in)
O.D.: 22.93 mm (0.903 in)
OUTER GUIDE
M AINSHAFT
M easure the m ainshaft O.D. at the clutch outer
guide.
M AIN SHAFT
9-12
ASSEM BLY
Apply m olybdenum oil solution to the entire surface
of the clutch outer guide and install it onto the m ain-
CLUTCH OUTER GUIDE
shaft.
Apply clean engine oil to the prim ary driven gear

and kickstarter driven gear.
KICKSTARTER
DRIVEN GEAR
PRIM ARY
DRIVEN GEAR
Install the clutch outer and w asher.

CLUTCH OUTER
WASHER
9-13
Coat the clutch discs w ith clean engine oil.
Assem ble clutch discs A, B, clutch plates and pres- PRESSURE PLATE
sure plate onto clutch center, w hile aligning "o"
m ark of clutch center and pressure plate. DISCS B/PLATES
DISC A
DISC A
Align
CLUTCH CENTER
Install the tabs of Install the clutch center assem bly into the clutch
CLUTCH OUTER SHALLOW SLOT
clutch disc A (out outer.
side) into the shal-
low slots in the
clutch outer.
DISC A
CLUTCH CENTER ASSEM BLY (OUT SIDE)
Install the lock w asher.
Apply clean engine oil to the threads and seating LOCK NUT
surface of a lock nut and install it.
LOCK WASHER
9-14
Attach the clutch center holder to the pressure plate LOCK NUT
CLUTCH CENTER HOLDER
using four lifter plate bolts to hold the clutch center,
then tighten the clutch center lock nut using the spe-
cial tool.
TOOL:
Clutch center holder 070SRTKSP011
Install the clutch springs, lifter plate and bolts.

LIFTER PLATE
Tighten the lifter plate bolts in a crisscross pattern
in several steps.
BOLTS / SPRINGS
Install the oil filter rotor and lock w asher onto the
OIL FILTER ROTOR
crankshaft.
Apply clean engine oil to the threads and seating
surface of the lock nut and install it w ith the cham -
fered side facing in.
LOCK NUT WASHER
Install the gear holder betw een the prim ary drive
and driven gears as show n, and tighten the oil filter LOCK NUT WRENCH
rotor lock nut.
TOOLS:
Gear holder 0706-KRB-T7900
Lock nut w rench 0701-KRB-T7900

– oil pum p drive gear (page 4-8)
– oil filter rotor cover (page 3-13)
GEAR HOLDER LOCK NUT
9-15
GEARSHIFT LINKAGE
REM OVAL
GEARSHIFT SPINDLE WASHER
– gearshift pedal (page 6-5)
– clutch assem bly (page 9-9)
Pull the gearshift spindle out of the crankcase.
Rem ove the thrust w asher.

HOLDER GEAR
– gearshift cam bolt
DRUM STOPPER
– gearshift cam
ARM
TOOL:
Holder gear drum stopper arm 070SRTKSP010
BOLT

DOWEL PINS RETURN SPRING WASHER
– dow el pins from the shift drum
– stopper arm bolt
– stopper arm
– w asher
– return spring
STOPPER ARM BOLT

INSPECTION
Check the gearshift spindle for w ear or bend.
Check the spindle plate for w ear, dam age or defor- RETURN SPRING
m ation.
Check the return spring for fatigue or dam age.
GEARSHIFT SPINDLE PLATE
9-16
INSTALLATION
Apply a locking agent to the stopper arm bolt
threads. RETURN SPRING WASHER
Install the return spring, w asher, stopper arm and

bolt, and tighten the bolt.
Hook the return spring to the stopper arm groove.
BOLT
Hook
STOPPER ARM
Install the dow el pin into the shift drum hole.

Align
Hold the stopper arm using a special tool and install
the gearshift cam , w hile aligning the pins hole w ith
the dow el pins.
TOOL:
Holder gear drum stopper arm 070SRTKSP010
GEARSHIFT CAM STOPPER ARM

Apply a locking agent to the gearshift cam bolt
threads. GEARSHIFT CAM BOLT
Install the gearshift cam bolt and tighten it.
Apply clean engine oil to the gearshift spindle jour-

nal rotating area. GEARSHIFT SPINDLE WASHER
Install the thrust w asher onto the gearshift spindle

and insert the spindle into the crankcase.
9-17
Install the spindle, w hile aligning the return spring
ends w ith the stopper pin. Align
– clutch assem bly (page 9-13)
– gearshift pedal (page 6-8)
GEARSHIFT SPINDLE
KICKSTARTER IDLE GEAR

REM OVAL
Rem ove the clutch assem bly (page 9-9).
IDLE GEAR WASHER
Rem ove the snap ring, w asher and kickstarter idle
gear.
SNAP RING
Rem ove the bushing and w asher.

WASHER BUSHING
INSPECTION
M easure the kickstarter idle gear I.D.
M easure the bushing I.D. and O.D.
SERVICE LIM IT:

I.D.: 17.04 mm (0.671 in)
O.D.: 20.43 mm (0.804 in)
IDLE GEAR BUSHING
9-18
M easure the countershaft O.D. at the kickstarter idle
COUNTER SHAFT
gear.
INSTALLATION
Apply m olybdenum oil solution to the bushing.
WASHER
Install the w asher and bushing. BUSHING
Apply clean engine oil to the kickstarter idle gear

teeth. WASHER
IDLE GEAR
Install the idle gear, w asher and snap ring.
Install the clutch assem bly (page 9-13).
SNAP RING
KICKSTARTER
REM OVAL
Unhook the return spring from the crankcase.
RETURN SPRING
9-19
WASHER KICKSTARTER ASSEM BLY
– kickstarter assem bly
– ratchet spring
– w asher
RATCHET SPRING
DISASSEM BLY
RATCHET GEAR
– collar
– return spring
– starter ratchet gear
RETURN SPRING COLLAR

WASHER B DRIVE GEAR
– snap ring
– w asher A WASHER A
– kickstarter drive gear
– w asher B
WASHER A
WASHER B
SNAP RING
INSPECTION
DRIVE GEAR
– Ratchet gear and drive gear for excessive w ear
or dam age.
– Spindle for vent or dam age.
M easure the drive gear I.D. and spindle O.D. at the
drive gear.
SERVICE LIM IT:

Drive gear I.D.: 16.06 mm (0.632 in)
Spindle O.D.: 15.94 mm (0.628 in)
SPINDLE
9-20
ASSEM BLY
WASHER B DRIVE GEAR
– w asher B
– kickstarter drive gear
WASHER A
– w asher A
– snap ring
WASHER A
WASHER B
SNAP RING
Install the ratchet gear.
RATCHET GEAR
Hook the return spring to the hole of the spindle.

RETURN SPRING
Hook
Install the collar to the return spring, w hile aligning

the cut-out of the collar w ith the spring. Align
COLLAR
9-21
INSTALLATION
Apply clean engine oil to the kickstarter drive gear
WASHER KICKSTARTER
teeth.
ASSEM BLY
Install the ratchet spring and w asher to the spindle.
Install the kickstarter assem bly.
RATCHET SPRING
Hook the return spring to the crankcase.

RETURN SPRING
Hook
PRIM ARY DRIVE GEAR/

CRANKSHAFT COLLAR
REM OVAL
Rem ove the clutch assem bly (page 9-9).
PRIM ARY DRIVE GEAR
Rem ove the prim ary drive gear.
Rem ove the crankshaft collar and w oodruff key.

WOODRUFF KEY
CRANKSHAFT COLLAR
9-22
INSTALLATION
Install the w oodruff key onto the crankshaft.
Align
Install the crankshaft collar, w hile aligning the
groove w ith the w oodruff key.
CRAN SHAFT COLLAR

Apply clean engine oil to the prim ary drive gear.
Align
Install the prim ary drive gear, w hile aligning the
groove w ith the w oodruff key.
Install the clutch assem bly (page 9-13).
PRIM ARY DRIVE GEAR
9-23
9-24
10. ALTERNATOR/ STARTER CLUTCH
SYSTEM COM PONENTS ···························· 10-2 FLYWHEEL····················································10-6
SERVICE INFORM ATION ···························· 10-3 STATOR/ IGNITION PULSE GENERATOR ··10-7
LEFT CRANKCASE COVER ························· 10-4

10
10-1
ALTERNATOR/ STARTER CLUTCH
SYSTEM COM PONENTS
74 N·m (7.5 kgf·m , 55 lbf·ft)
10-2
GENERAL
• This section covers the rem oval and installation of the flyw heel and alternator stator. These services can be done w ith
the engine installed in the fram e.
• See page 15-9 for alternator stator inspection.
TORQUE VALUES
Flyw heel lock nut 74 N·m (7.5 kgf·m , 55 lbf·ft) Apply engine oil to the threads and seat-
ing surface.
Ignition pulse generator m ounting bolt 12 N·m (1.2 kgf·m , 9 lbf·ft) Apply a locking agent to the threads.
Wire guide bolt 12 N·m (1.2 kgf·m , 9 lbf·ft) Apply a locking agent to the threads.
TOOLS
Flyw heel holder Flyw heel puller
070SRTKSP013 070SRTKSP014
10-3
LEFT CRANKCASE COVER
REM OVAL
ALTERNATOR 2P
Disconnect the alternator 2P connector and ignition CONNECTOR
pulse generator w ire connector.
IGNITION PULSE
GENERATOR WIRE
CONNECTOR

Rem ove the neutral sw itch w ire from the left crank- NEUTRAL
case grooves. SWITCH WIRE
The left crankcase Loosen the left crankcase cover bolts in a crisscross
cover (stater) is pattern in several steps. LEFT CRANKCASE COVER
magnetically
Rem ove the left crankcase cover bolts and cover.
attached to the fly-
w heel, be careful to
remove.
BOLTS
Rem ove the dow el pins and gasket. GASKET
DOWEL PINS
10-4
INSTALLATION
Install the new gasket and dow el pins.
GASKET
DOWEL PINS
Install the left crankcase cover and tighten the bolts.

BOLTS
Route the neutral sw itch w ire to the left crankcase
grooves. NEUTRAL
Install the left crankcase rear cover (page 6-8). SWITCH WIRE
Connect the alternator 2P connector and ignition

pulse generator w ire connector. ALTERNATOR 2P
CONNECTOR
IGNITION PULSE
GENERATOR WIRE
CONNECTOR
10-5
FLYWHEEL
REM OVAL
Rem ove the left crankcase cover (page 10-4).
FLYWHEEL HOLDER NUT/ WASHER
Hold the flyw heel w ith the flyw heel holder and
rem ove the flyw heel lock nut and w asher.
TOOL:
Flyw heel holder 070SRTKSP013
Rem ove the flyw heel using the flyw heel puller.
FLYWHEEL PULLER
TOOL:
Flyw heel puller 070SRTKSP014
FLYWHEEL
When remove the Rem ove the w oodruff key.

w oodruff key, be
careful not to dam-
age the key groove
and crankshaft.
WOODRUFF KEY
INSTALLATION
When install the Clean any oil from the crankshaft taper.
w oodruff key, be
Install the w oodruff key.
careful not to dam-
age the key groove
and crankshaft.
WOODRUFF KEY
10-6
Install the flyw heel, w hile aligning the w oodruff key
on the crankshaft w ith flyw heel keyw ay. Align
FLYWHEEL
Apply clean engine oil to the flyw heel lock nut

FLYWHEEL HOLDER
threads and seating surface.
NUT/ WASHER
Install the w asher and lock nut.
Hold the flyw heel w ith the flyw heel holder, tighten
the lock nut to the specified torque.
TOOL:
Flyw heel holder 070SRTKSP013

Install the left crankcase cover (page 10-5).
STATOR/ IGNITION PULSE

GENERATOR
REM OVAL
Rem ove the left crankcase cover (page 10-4).
Rem ove the grom m et. SOCKET BOLTS
Rem ove the three socket bolts, w ire guide and igni- GROM M ET
tion pulse generator.
IGNITION PULSE
GUIDE GENERATOR
Rem ove the three socket bolts and stator from the
left crankcase cover. BOLTS
STATOR
10-7
INSTALLATION
Install the stator.
Install the three bolts and tighten it. BOLTS
STATOR
Apply liquid sealant to the w ire grom m et seating

surface and install the grom m et into the groove.
Install the w ire guide and ignition pulse generator. GROM M ET SOCKET BOLTS
Apply a locking agent to the three bolt threads.
Install the bolts and tighten it to the specified
torque.
IGNITION PULSE
GUIDE GENERATOR
10-8
11. CRANKSHAFT/ TRANSM ISSION
SYSTEM COM PONENTS ···························· 11-2 TRANSM ISSION ···········································11-7
SERVICE INFORM ATION ···························· 11-3 CRANKSHAFT·············································11-16
TROUBLESHOOTING ·································· 11-5 CRANKCASE ASSEM BLY ··························11-18
CRANKCASE SEPARATION ························ 11-6 11
11-1
SYSTEM COM PONENTS
CRANKSHA FT/TRANSM ISSION
12 N·m (1.2 kgf·m ,

9 lbf·ft)
12 N·m (1.2 kgf·m ,

9 lbf·ft)
10 N·m (1.0 kgf·m ,

7 lbf·ft)
11-2
GENERAL
• The follow ing com ponents m ust be rem oved before separating the crankcase:
– engine (page 6-4)
– flyw heel (page 10-6)
– cylinder head (page 7-6)
– cylinder/piston (page 8-4)
– oil pum p (page 4-4)
– clutch (page 9-8)
– gearshift linkage (page 9-15)
– kickstarter idle gear (page 9-17)
– kickstarter (page 9-18)
– prim ary drive gear/crankshaft collar (page 9-21)
– neutral sw itch (page 17-13)
• Be careful not to dam age the crankcase m ating surfaces w hen servicing.
SPECIFICATIONS
Unit: m m (in)
Crankshaft Runout – 0.03 (0.001)
ance
ance
Transm ission Gear I.D. M 4, M 5 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)
C2 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C3 23.025 – 23.046 (0.9065 – 0.9073) 23.07 (0.908)
Bushing O.D. M 4, M 5 19.959 – 19.980 (0.7858 – 0.7866) 19.91 (0.784)
C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)
C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)
Gear-to-bushing M 4, M 5, C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance C2 0.015 – 0.057 (0.0006 –0.0022) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Bushing I.D. M 4, C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
M ainshaft / coun- M 4, C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667)
tershaft O.D. C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785)
C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785)
Bushing-to-shaft M 4, C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
shift fork Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)
shaft Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)
TORQUE VALUE
M ainshaft bearing setting plate bolt 12 N·m (1.2 kgf·m , 9 lbf·ft) Apply locking agent to the threads.
Crankshaft bearing retainer plate bolt 12 N·m (1.2 kgf·m , 9 lbf·ft)
Push plug bolt 10 N·m (1.0 kgf·m , 7 lbf·ft) Apply locking agent to the threads.
11-3
TOOLS
Rem over head, 12 m m Rem over shaft, 12 m m Rem over w eight
070M C-KPLI410 070M C-KPLI420 070M C-KPLI300
Driver Pilot, 12 m m Pilot, 14 m m

070GD-001I100 070GD-004I130 07746-0041200
Pilot, 15 m m Pilot, 17 m m Pilot, 20 m m

07746-0040300 070GD-004I150 070GD-004I160
Pilot, 30 m m Attachm ent, 22 x 24 m m Attachm ent, 32 x 35 m m

07746-0040700 07746-0010800 070GD-002I140
11-4
Attachm ent, 37 x 40 m m Attachm ent, 42 x 47 m m Attachm ent, 52 x 55 m m
070GD-002I150 070GD-002I160 07NAD-P200100
Rem over shaft, 17 m m Rem over handle Attachm ent, 34 m m

07936-3710300 07936-3710100 07JAD-PL60100
TROUBLESHOOTING
Excessive noise
• Worn, sized or chipped transm ission gear
• Worn or dam aged transm ission bearing
• Worn or dam aged connecting rod bearing
• Worn crankshaft bearing
• Worn connecting rod sm all end
• Worn balancer bearing
Hard to shift
• Bent shift fork
• Dam aged shift drum guide groove
• Dam aged shift fork guide pin
Transmission jumps out of gear
• Worn gear dogs or slots
• Worn shift drum guide groove
• Worn shift fork guide pin
• Worn shift fork groove in gear
• Worn shift fork shaft
• Bent fork shaft
11-5
CRANKCASE SEPARATION
Refer to Service Inform ation (page 11-3) for rem oval PLATE
of necessary parts before disassem bling the crank- GUIDE
case.
Rem ove the tensioner guide plate bolts, plate and
tensioner guide.
Rem ove the cam chain.
CHAIN BOLTS
Rem ove the bolt and push plug plate.
BOLT PUSH PLUG PLATE
Rem ove the push plug and spring.

SPRING
PUSH PLUG
Rem ove the right crankcase bolt.
BOLT
11-6
Rem ove the three bolts and bearing retainer plates.
BOLTS/ BOLTS
Rem ove the left crankcase bolts. PLATES
Place the crankcase assem bly w ith the right side

dow n. LEFT CRANKCASE
Do not ply the Carefully separate the left crankcase from the right
crankcase halves. crankcase w hile tapping them at several locations
w ith a soft ham m er.
RIGHT CRANKCASE
Rem ove the dow el pins.
DOWEL PINS
TRANSM ISSION
REM OVAL
Separate the crankcase halves (page 11-6).
SHIFT FORK SHAFTS
Pull the shift fork shafts and rem ove it from the shift
forks.
11-7
Rem ove the shift forks and shift drum . SHIFT FORKS
SHIFT DRUM
Rem ove the m ainshaft and countershaft together.
M AINSHAFT
COUNTERSHAFT
Disassem ble the m ainshaft and countershaft.
M AINSHAFT
COUNTERSHAFT
INSPECTION
GEARS
Check the gear dogs, dog holes and teeth for dam -
age or excessive w ear.
M easure the I.D. of each gear.
SERVICE LIM IT:
M 4, M 5: 20.05 mm (0.789 in)
C1: 20.55 mm (0.809 in)
C2: 23.07 mm (0.908 in)
C3: 23.07 mm (0.908 in)
11-8
BUSHINGS
Check the bushings for w ear or dam age.
M easure O.D. of each bushing.
SERVICE LIM IT:
M 4, M 5: 19.91 mm (0.784 in)
C1: 20.41 mm (0.804 in)
C2, C3: 22.95 mm (0.904 in)
Calculate the gear-to-bushing clearance.
SERVICE LIM IT:
M 4, M 5, C1: 0.10 mm (0.004 in)
C2: 0.10 mm (0.004 in)
C3: 0.10 mm (0.004 in)
M easure I.D. of each bushing.
SERVICE LIM IT:

M 4, C1: 17.04 mm (06.71 in)
C2, C3: 20.07 mm (0.790 in)
M AINSHAFT/ COUNTERSHAFT
Check the spline grooves and sliding surfaces for
abnorm al w ear or dam age. M4
M easure the O.D. of the m ainshaft and countershaft
at the gear and bushing sliding areas.
SERVICE LIM IT:
M ainshaft (at M 4 gear bushing):
16.93 mm (0.667 in)
Countershaft (at C1 gear bushing):
16.93 mm (0.667 in)
(at C2 gear bushing):
19.94 mm (0.785 in)
(at C3 gear bushing): C2 C3 C1
19.94 mm (0.785 in)
Calculate the bushing-to-shaft clearance.
SERVICE LIM IT:
M 4, C1: 0.10 mm (0.004 in)
C2: 0.10 mm (0.004 in)
C3: 0.10 mm (0.004 in)
SHIFT DRUM
Inspect the shift drum end for scoring, scratches, or
SHIFT DRUM
evidence of sufficient lubrication.
Check the shift drum grooves for abnorm al w ear or
dam age.
11-9
SHIFT FORK
Check the shift forks for deform ation or abnorm al
w ear.
M easure each shift fork claw thickness.
M easure I.D. of each fork.
SHIFT FORK SHAFT

Check the shift fork shafts for dam age and straight-
ness.
M easure the shift fork shaft O.D.
BEARING REPLACEM ENT

INSPECTION
Turn the inner race of each bearing w ith your finger.
The bearings should turn sm oothly and quietly.
Also check that bearing outer races fit tightly in the
crankcases.
REM OVAL
Rem ove the bolts and m ainshaft bearing setting M AINSHAFT
BOLTS/SETTING PLATES
plates from the right crankcase.
BEARING
Drive out the m ainshaft bearing from the right
crankcase.
Drive out the countershaft bearing from the right
crankcase w ith follow ing tools.
TOOLS:
Remover shaft, 17 mm 07936-3710300
Remover handle 07936-3710100
Remover w eight 070M C-KPLI300
COUNTERSHAFT
BEARING
11-10
Rem ove the countershaft dust seal and gear shift COUNTERSHAFT
spindle dust seal from the left crankcase.
DUST SEAL
GEAR SHIFT
SPINDLE
DUST SEAL
Drive out the countershaft bearing from the left

COUNTERSHAFT
crankcase.
BEARING
Drive out the m ainshaft bearing from the left crank- M AINSHAFT
case w ith follow ing tools.
BEARING
TOOLS:
Remover head, 12 mm 070M C-KPLI410
Remover shaft, 12 mm 070M C-KPLI420
11-11
INSTALLATION
Lubricate the all bearings w ith engine oil.
DRIVER
Drive new bearings into the left crankcase w ith fol- ATTACHM ENT
low ing tools:
TOOLS:
RIGHT CRANKCASE
M ainshaft bearing:
Driver 070GD-001I100
Attachment, 37 x 40 mm 070GD-002I150
Pilot, 17 mm 070GD-004I150
Countershaft bearing:
Pilot, 17 mm 070GD-004I150 BEARING PILOT
LEFT CRANKCASE
M ainshaft bearing:
Pilot, 12 mm 070GD-004I130
Countershaft bearing:
Pilot, 20 mm 070GD-004I160
Apply grease to the new dust seal lips.

Drive to case 0.5 – 1.0 m m (0.02 – 0.04 in)
Install the countershaft and gearshift spindle dust end face
seals w ith follow ing tools as show n.
TOOLS:
Countershaft dust seal:
Attachment, 34 mm 07JAD-PL60100
Pilot, 20 mm 070GD-004I160
Gearshift spindle dust seal:
Driver 070GD-001I100 GEAR SHIFT
Attachment, 22 x 24 mm 07746-0010800 SPINDLE COUNTERSHAFT
Pilot, 14 mm 07746-0041200 DUST SEAL DUST SEAL
Apply locking agent to the threads of the setting

plate bolt. BOLTS/
Install the setting plates and bolts. SETTING PLATES
Tighten the bolts to the specified torque.
11-12
INSTALLATION
Clean all parts in solvent.
Apply clean engine oil to each gear teeth. CORRECT INCORRECT
Apply m olybdenum oil solution to the bushing slid-
ing surface to ensure initial lubrication.
Assem ble all parts into their original positions.
• Check the gears for freedom of m ovem ent or
rotation on the shaft.
• Install the w ashers and snap rings w ith the
cham fered side facing of the thrust load side.
Confirm the inner side of snap rings and w asher
w hen you detect the cham fered side.
• Do not reuse w orn snap ring w hich could easily
spin in the groove. SNAP RING
• Check that the snap rings are seated in the
grooves and align their end gaps w ith the
grooves of the spline.
M AINSHAFT
: Each gear teeth THRUST WASHER
SPLINE WASHER
: Bushing, spline w asher and spline collar
SPLINE COLLAR
SNAP RING
SPLINE
WASHER
M 4 BUSHING
M 2 GEAR
(19T)
M 5 GEAR
M 4 GEAR (32T)
(22T) M 3 GEAR
(23T)
Cham fered Side
M AINSHAFT/ M 1 GEAR
(13T)
Sharped
Cham fered Edge Cham fered
Side Side Side
11-13
COUNTERSHAFT
: Each gear teeth
: Bushing and spline w asher

C3 GEAR
SPLINE WASHER (30T) THRUST
C3 BUSHING WASHER
C4 GEAR
C1 GEAR (24T)
(40T)
SNAP
THRUST RING
WASHERS
C1 BUSHING
THRUST
WASHER
THRUST
WASHER
C2 BUSHING
C2 GEAR
(34T)
THRUST
C5 GEAR
WASHER
(30T)
Cham fered Side

COUNTERSHAFT
Sharped Edge
Side
11-14
If the crankshaft rem oved, install the crankshaft first
(page 11-18).
Apply m olybdenum oil solution to the shift fork
grooves.
Apply clean engine oil to the transm ission gear
teeth.
Install the m ainshaft and countershaft together into

M AINSHAFT
the left crankcase. Be sure to install the three end
w ashers (m ainshaft; left only/countershaft; both
ends).
COUNTERSHAFT
Each shift fork has an identification m arks; “ R/L”
(right and left), “ C” (center),. "C" M ARK
Install the shift forks into the shifter gear grooves
w ith the m arks facing up (left crankcase side).
"R/L" M ARKS
Apply clean engine oil to the guide grooves in the SHIFT FORKS
shift drum and install it, w hile aligning the shift fork
guide pins w ith the guide grooves.
SHIFT DRUM
11-15
Apply clean engine oil to the shift fork shaft and SHIFT FORKS SHAFT
insert it through the shift forks into the right crank-
case.
Rotate the m ainshaft by hand to see if the gears
rotate freely.
Assem ble the crankcase (page 11-19).
CRANKSHAFT
REM OVAL
Rem ove the transm ission (page 11-7).
CRANKSHAFT
Rem ove the crankshaft from the right crankcase.
INSPECTION
CRANKSHAFT RUNOUT
Place the crankshaft on a stand or V-blocks.
Set the dial indicator on the shafts.
Rotate the crankshaft tw o revolutions and read the
runout.
47.5 m m (1.87 in) 43.0 m m (1.69 in)
11-16
BIG END SIDE CLEARANCE
M easure the side clearance of the connecting rod
big end w ith feeler gauge.
BIG END RADIAL CLEARANCE

M easure the radial clearance of the connecting rod
big end.
TIM ING SPROCKET

If the timing Check the tim ing sprocket teeth for w ear or dam age.
sprocket teeth are
Rem ove the tim ing sprocket if necessary.
w orn or damaged,
When installing the tim ing sprocket, w hile align the CRANK PIN
check the cam
center of the tim ing sprocket teeth w ith the center of
chain, tensioner
the crank pin.
and cam sprocket.
TIM ING
SPROCKET
BEARING REPLACEM ENT
INSPECTION
Turn the inner race of bearing w ith your finger.
The bearing should turn sm oothly and quietly.
Also check that bearing outer races fit tightly in the
crankcase.
11-17
REM OVAL
Drive out the crankshaft bearing from the right CRANKSHAFT
crankcase.
BEARING
INSTALLATION
If the crankshaft bearing inner race is rem oved,
install it as show n. IN SIDE
INNER RACE
Lubricate the all bearings w ith engine oil.

ATTACHM ENT DRIVER
Drive new bearings into the right crankcase w ith fol-
low ing tools:
TOOLS:
Crankshaft bearing:
Attachment, 52 x 55 mm 07NAD-P200100
Pilot, 30 mm 07746-0040700
PILOT
INSTALLATION
Install the crankshaft into the right crankcase.
CRANKSHAFT
Install the transm ission (page 11-13).
11-18
CRANKCASE ASSEM BLY

Clean the left and right crankcase m ating surfaces
thoroughly, being careful not to dam age them and
check for dam age.
Apply a light but through coating of sealant to all
crankcase m ating surface except the oil passage
area.
Install the dow el pins.

DOWEL PINS
Do not force the Install the left crankcase over the right crankcase.
LEFT CRANKCASE
crankcase halves
together, If there is
excessive force
required, some-
thing is w rong.
Remove the right
crankcase and
check for mis-
aligned parts.
RIGHT CRANKCASE
Install the left crankcase bolts, and tighten the bolts
BOLTS
in a crisscross pattern in 2-3 steps.
11-19
When installing the Install the bearing retainer plates and bolts to the BOLTS/
retainer plate, pull- specified torque. PLATES
PLATES
ing the crankshaft
and hook the plate TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Hook
tab to the crank-
BOLTS
shaft bearing
groove.
CRANKSHAFT
Install and tighten the right crankcase bolt.

BOLT
Apply m olybdenum oil solution to the push plug. SPRING

When installing the Install the push plug and spring.
push plug, make
sure the crankshaft
bearing outer
touches the taper
part of push plug. PUSH PLUG
BEARING PUSH PLUG
Apply locking agent to the threads of the push plug BOLT PUSH PLUG PLATE
bolt.
Install the push plug plate and bolt.
Tighten the bolt to the specified torque.
11-20
Install the cam chain through the crankcase. PLATE
Install the cam chain to the sprocket. GUIDE
Install the tensioner guide and tensioner guide

plate.
Install and tighten the tensioner guide plate bolts.
Install the rem oved parts in the reverse order of
rem oval (page 11-3).
CHAIN BOLTS
11-21
11-22
12. FRONT WHEEL/ SUSPENSION/ STEERING
SYSTEM COM PONENTS ···························· 12-2 FRONT WHEEL ···········································12-12
SERVICE INFORM ATION ···························· 12-3 FORK ···························································12-18
TROUBLESHOOTING ·································· 12-5 STEERING STEM ········································12-26
HANDLEBAR················································ 12-6
12
12-1
FRONT WHEEL/ SUSPENSION/ STEERING
SYSTEM COM PONENTS
74 N·m (7.5 kgf·m , 26 N·m (2.7 kgf·m ,

55 lbf·ft) 19 lbf·ft)
44 N·m (4.5 kgf·m ,

33 lbf·ft)
26 N·m (2.7 kgf·m ,

19 lbf·ft)
32 N·m (3.3 kgf·m ,

24 lbf·ft)
59 N·m (6.0 kgf·m , 44 lbf·ft)
12-2
GENERAL
• When servicing the front w heel, fork or steering stem , support the m otorcycle using a safety stand or hoist.
• A contam inated brake disc or pad reduces stopping pow er. Discard contam inated pads and clean a contam inated disc
w ith a high quality brake degreasing agent.
• After the front w heel installation, check the brake operation by applying the brake lever.
• When using the pin spanner, use a deflecting beam type torque w rench 25 cm (10 in) long. The pin spanner increases
the torque w rench’s leverage, so the torque w rench reading w ill be less than the torque actually applied to the top corn
race. The specification given is the actual torque applied to the top corn race, not the reading on the torque w rench. Do
not overtighten the top corn race. The specification later in the text gives both actual and indicated torque.
• Refer to hydraulic brake system inform ation (page 14-2).
SPECIFICATIONS
Unit: m m (in)
Cold tire Driver only 175 kPa (1.75 kgf/cm 2, 25 psi) –
pressure Driver and passenger 175 kPa (1.75 kgf/cm 2, 25 psi) –
Pipe runout – 0.20 (0.008)
Recom m ended fluid Fork fluid –
Fluid capacity 150 ± 1.0 cm 3 (5.06 ± 0.03 US oz, 5.26 ± –
0.04 lm p oz)
TORQUE VALUES
Front brake disc bolt 24 N·m (2.5 kgf·m , 18 lbf·ft) Apply a locking agent to the threads.
Front axle nut 59 N·m (6.0 kgf·m , 44 lbf·ft) U-nut
Handlebar low er holder nut 26 N·m (2.7 kgf·m , 19 lbf·ft) U-nut
Handlebar upper holder bolt 26 N·m (2.7 kgf·m , 19 lbf·ft)
M aster cylinder holder bolt 9 N·m (0.9 kgf·m , 7 lbf·ft)
Fork socket bolt 20 N·m (2.0 kgf·m , 15 lbf·ft) Apply a locking agent to the threads.
Fork cap 22 N·m (2.2 kgf·m , 16 lbf·ft)
Bottom bridge pinch bolt 32 N·m (3.3 kgf·m , 24 lbf·ft)
Top bridge bolt 44 N·m (4.5 kgf·m , 33 lbf·ft)
Steering bearing adjustm ent nut See page 12-29
Steering stem nut 74 N·m (7.5 kgf·m , 55 lbf·ft)
12-3
TOOLS
Attachm ent, 37 x 40 m m Attachm ent, 42 x 47 m m Pilot, 12 m m
070GD-002I150 070GD-002I160 070GD-004I130
Driver Bearing rem over shaft Rem over head, 12 m m

070GD-001I100 070GD-005I100 070GD-005I130
Oil seal rem over Fork seal driver Piston rem over front cushion
070SRTKSP002 070SRTKSP001 070SRTKSP003
Steering cone installer Steering cone installer (Fram e) Ball race rem over
070SRTKSP007 070SRTKSP006 070SRTKSP005
12-4
Spoke w rench, 5.8 x 6.1 m m Socket w rench steering
07701-0020300 070SRTKSP004
TROUBLESHOOTING
Hard steering
• Steering stem adjusting nut too tight
• Dam aged steering head beating/race
• Insufficient tire pressure
• Faulty tire
Steers to one side or does not track straight
• Bent fork
• Bent front axle
• Wheel installed incorrectly
• Faulty steering head bearing
• Bent fram e
• Faulty w heel bearing
• Worn sw ingarm pivot com ponents
• Weak front fork
Front w heel w obbling
• Bent rim
• Worm w heel bearings
• Bent or loose spoke
• Faulty tire
Wheel turns hard
• Faulty w heel bearing
• Faulty speedom eter gear
• Bent front axle
• Brake drag
Soft suspension
• Weak front fork spring
• Insufficient fork fluid
• Tire pressure too low
Hard suspension
• Incorrect fork fluid viscosity
• Bent fork pipes
• Clogged fluid passage
• Dam aged fork pipe and/or fork slider
Front suspension noisy
• Insufficient fluid in fork
• Loose front fork fasteners
12-5
HANDLEBAR
REM OVAL
Rem ove the w ire bands and rear view m irrors.
REAR VIEW M IRRORS
WIRE BANDS
Disconnect the front brake light sw itch connectors.
M ASTER CYLINDER
Rem ove the bolts, holder and brake m aster cylinder.
BOLTS
CONNECTORS HOLDER
Rem ove the right handlebar sw itch housing screw s.
RIGHT HANDLEBAR
Separate the right handlebar sw itch housing. SWITCH HOUSING
SCREWS
Disconnect the throttle cable from the throttle pipe,

then rem ove the throttle pipe. THROTTLE CABLE
THROTTLE PIPE
12-6
Rem ove the bolts, holder and clutch lever bracket.
CLUTCH LEVER BRACKET
HOLDER BOLTS
Rem ove the screw s and separate the left handlebar
sw itch housing. LEFT HANDLEBAR
SWITCH HOUSING
SCREWS
Disconnect the choke cable from the choke lever.
CHOKE CABLE
Rem ove the handlebar grip and choke lever. HANDLEBAR GRIP CHOKE LEVER
12-7
Loosen the handlebar low er holder nuts.
NUT
Rem ove the bolts, handlebar upper holders and
handlebar from the top bridge. BOLTS
HANDLEBAR HOLDER
Rem ove the nuts, w ashers, cushion rubbers and
handlebar low er holders.
HOLDER
RUBBERS
WASHER
NUT
INSTALLATION
Install the handlebar low er holders, cushion rub-
bers, w ashers and nuts.
HOLDER
Tem porarily tighten the handlebar low er holder
RUBBERS
nuts.
WASHER
NUT
12-8
Place the handlebar to the top bridge.
Place the handlebar holders w ith the punch m arks PUNCH M ARKS HANDLEBAR
facing forw ard and install the holder bolts.
Align the punch m ark on the handlebar w ith the
m ating surface of the low er holder.
Tighten the forw ard bolts first, then the rear bolts.
BOLTS
Align HOLDER
Tighten the handlebar low er holder nuts.
NUT
Install the choke lever onto the left side of handle-

bar. CHOKE LEVER
Apply Honda Bond A or its equivalent to the inside
surface of the grips and to the clean surface of the
left handlebar.
Allow the adhesive Wait 3 – 5 m inutes and install the grip.
to dry for 1 hour Rotate the grips for even application of the adhe-
before using. sive.
HANDLEBAR GRIP
Apply silicon grease to the choke cable end.

Connect the choke cable to the choke lever. CHOKE CABLE
CHOKE LEVER
12-9
Install the left handlebar sw itch housing, w hile
aligning the locating pin in the housing w ith the
hole in the handlebar.
Align
Install the screw s and tighten the forw ard screw

first, then the rear screw .
SCREWS
Install the clutch lever bracket and the bracket
holder w ith the “ UP” m ark facing up. CLUTCH LEVER BRACKET HOLDER
Align the m ating surface of the clutch lever bracket

w ith the punch m ark on the handlebar.
Align
Install the clutch lever bracket bolts and tighten the
upper bolt first, then tighten the low er bolt.
"UP" M ARK
BOLTS
Apply grease to the throttle pipe rotating area of the
handlebar.
Install the throttle grip on the handlebar.
THROTTLE PIPE
12-10
Apply silicon grease to the throttle cable end.
Connect the throttle cable end to the throttle pipe. THROTTLE CABLE
THROTTLE PIPE
Install the right handlebar sw itch housing, w hile
aligning its locating pin w ith the hole on the handle- RIGHT HANDLEBAR
bar. SWITCH HOUSING
Align
Install the screw s and tighten the forw ard screw

first, then the rear screw .
SCREWS
Align the m ating surface of the m aster cylinder w ith
the punch m ark on the handlebar. M ASTER CYLINDER BOLTS
Install the m aster cylinder holder bolts and tighten
the front bolt first, then tighten the rear bolt.
Align HOLDER
12-11
Connect the brake light sw itch connectors.
CONNECTORS
Install the w ire bands and rear view m irrors.

REAR VIEW M IRRORS
Check the throttle grip free play (page 3-6).
Adjust the clutch lever free play (page 3-22).
WIRE BANDS
FRONT WHEEL
REM OVAL
Raise and support the m otorcycle using safety
SPEEDOM ETER CABLE
stand or a box.
Rem ove the speedom eter cable w hile pushing the
cable tab.
Rem ove the axle nut.
Rem ove the axle and front w heel.
NUT TAB
Rem ove the side collar.
SIDE COLLAR
12-12
Rem ove the speedom eter gear box.
SPEEDOM ETER
GEAR BOX
INSPECTION
Place the axle in V-blocks and m easure the runout
w ith a dial indicator.
Actual runout is 1/2 of the total indicator reading.
Check the w heel rim runout by placing the w heel in

a turning stand.
Spin the w heel by hand and read the runout using a
dial indicator.
SERVICE LIM IT:

Axial: 1.0 mm (0.04 in)
Radial: 1.0 mm (0.04 in)
Turn the inner race of each bearing w ith your finger,

the bearing should turn sm oothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the bear- Rem ove and discard the bearings if the races do not
ings in pairs. turn sm oothly, quietly, or if they fit loosely in the
hub.
12-13
DISASSEM BLY
Rem ove the left dust seal from the left side of the
front w heel. DUST SEAL
Rem ove the speedom eter gear retainer.

RETAINER
Rem ove the right dust seal from the right side of the
DUST SEAL
front w heel.
Rem ove the brake disc m ounting bolts and brake

BRAKE DISC
disc.
BOLTS
12-14
Install the bearing rem over head into the bearing.
From the opposite side, install the bearing rem over BEARING REM OVER SHAFT
shaft and drive the bearing out of the w heel hub.
Rem ove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 12 mm 070GD-005I130
Bearing remover shaft 070GD-005I100
REM OVER HEAD
ASSEM BLY
SIDE COLLAR BRAKE DISC

BEARING (6301)
RETAINER
24 N·m (2.5 kgf·m ,
18 lbf·ft)
DUST SEAL
DUST SEAL
DISTANCE COLLAR
BEARING (6301) SPEEDOM ETER

GEAR BOX
WHEEL CENTER ADJUSTM ENT

Adjust the hub position so that the distance from
the left end surface of the hub center to the side of
rim is 8.8 ± 1 m m (0.35 ± 0.04 in) as show n.
Tighten the spokes in 2 or 3 progressive steps.
TOOL:
Spoke w rench, 5.8 x 6.1 mm 07701-0020300

Check the rim runout (page 12-13).
8.8 ± 1 m m
BASE POINT (0.35 ± 0.04 in)
12-15
WHEEL ASSEM BLY
Never install the old Pack all bearing cavities w ith grease.
Fully seated DRIVER
bearing, once the Drive in a new right bearing squarely w ith its sealed
bearing has been side facing up until it is fully seated.
removed, the bear- Apply a thin coat of grease to the distance collar and
ing must be install it.
replaced w ith new Drive in a new left bearing squarely w ith its sealed
ones. side facing up. DISTANCE
COLLAR
TOOLS:
Pilot, 12 mm 070GD-004I130
BEARINGS ATTACHM ENT PILOT

Do not get grease Apply a locking agent to the he brake disc bolt
BRAKE DISC
on the brake disc or threads.
stopping pow er w ill
Install and tighten the brake disc bolts in a criss-
be reduced.
cross pattern in 2 or 3 steps.
BOLTS
Apply grease to a new right dust seal lip.

Install the dust seal to the right w heel hub.
DUST SEAL
Install the speedom eter gear retainer to the w heel

hub, w hile aligning the tabs on the retainer w ith the RETAINER
slots on the hub.
Align
12-16
Apply grease to a new left dust seal lip.
Install the dust seal to the left w heel hub.
DUST SEAL
INSTALLATION
Install the speedom eter gear box into the left w heel
SPEEDOM ETER
hub, w hile aligning the tabs w ith the slots.
GEAR BOX
Align
Install the side collar into the right w heel hub.

SIDE COLLAR
Be careful not to Install the front w heel betw een the fork legs, w hile
damage the pads. aligning the speedom eter gear box groove w ith the FRONT AXLE
boss on the fork leg so that the brake disc is posi-
tioned betw een the pads.
Apply a thin coat of grease to the front axle surface.
Install the front axle from right side.
Align
12-17
Install and tighten the axle nut to the specified
SPEEDOM ETER CABLE
torque.

Install the speedom eter cable to the speedom eter
gear box.
NUT TAB
FORK
REM OVAL
TOP BRIDGE BOLT
– front fender (page 2-5)
– brake caliper (page 14-16)
Rem ove the top bridge bolt and w asher.
If the fork w ill be Loosen the bottom pinch bolt and low er the fork
disassembled, leg, then rem ove it.
loosen the fork cap
w hen bottom pinch
bolts fastened
w hile having
removed fork
dow nw ard.
WASHER
PINCH BOLT
Rem ove the fork cap.
FORK CAP
Rem ove the fork spring.

FORK SPRING
12-18
Drain the fork fluid by pum ping the fork pipe several
tim es.
Rem ove the dust seal.

DUST SEAL
Be careful not to Rem ove the oil seal stopper ring.

scratch the fork STOPPER
pipe. RING
Rem ove the fork socket bolt and sealing w asher.

TOOL:
Piston rem over fr. cushion 070SRTKSP003
FORK SLIDER FORK
PIPE
SOCKET BOLT/ PISTON REM OVER

SEALING WASHER FRONT CUSHION
12-19
Rem ove the fork pipe from the fork slider.
Rem ove the oil lock piece from the fork slider.
FORK SLIDER
FORK PIPE
OIL LOCK PIECE
Rem ove the fork piston and rebound spring from

the fork pipe.
FORK PISTON
FORK PIPE
REBOUND SPRING
Rem ove the oil seal using a the oil seal rem over.
OIL SEAL REM OVER
TOOL:
Oil seal remover 070SRTKSP002
OIL SEAL
Rem ove the back-up ring from the fork slider.

BACK-UP RING
FORK SLIDER
12-20
INSPECTION
FORK SPRING
Check the fork spring for fatigue or dam age.
M easure the fork spring free length.
FORK PIPE/ SLIDER/ PISTON

Check the fork pipe, slider and piston for score
m arks, scratches, or excessive or abnorm al w ear. FORK PIPE
Check the rebound spring for fatigue or dam age. FORK
PISTON
REBOUND
SPRING
FORK SLIDER
Check the piston ring for w ear or dam age.
PISTON RING
Replace any com ponents that are w orn or dam age.
Set the fork pipe in V-blocks and read the runout

w ith a dial indicator.
The actual runout is 1/2 of the total indicator read-
ing.
12-21
FORK PIPE BUSHING
Visually inspect the slider bushings.
Replace the fork slider if they are w orn, or if the BUSHING BACK-UP RING
Teflon coating is w orn and 3/4 or over of the copper
surface appears.
Check the back-up ring; replace it if there is any dis-
tortion at the points indicated by arrow s on the fig-
ure.
COPPER SURFACE CHECK POINTS
ASSEM BLY
FORK CAP
FORK PIPE 22 N·m (2.2 kgf·m ,
FORK PISTON RING 16 lbf·ft)
DUST SEAL
STOPPER
RING
O-RING
FORK
PISTON
OIL SEAL
BACK-UP RING
FORK
FORK SPRING
SLIDER
SOCKET
BOLT
20 N·m (2.0 kgf·m , SEALING OIL LOCK REBOUND
15 lbf·ft) WASHER PIECE SPRING
Before assem bly, w ash all parts w ith a high flash or

non-flam m able solvent and w ipe them dry.
FORK PISTON
Install the rebound spring and fork piston into the
fork pipe.
TOOL: FORK PIPE
REBOUND SPRING
12-22
Install the oil lock piece onto the fork piston end.
Install the fork pipe into the fork slider.
FORK SLIDER
FORK PIPE
OIL LOCK PIECE
Apply a locking agent to the fork socket bolt threads

and install it w ith a new sealing w asher. SEALING WASHER
SOCKET BOLT
FORK SLIDER FORK

Tighten the socket bolt. PIPE
TOOL:
SOCKET BOLT/ PISTON REM OVER

SEALING WASHER FRONT CUSHION
Install the back-up ring into the fork slider.

BACK-UP RING
FORK SLIDER
12-23
Apply fork fluid to a new oil seal lips, then install it
into the fork slider w ith its m arking facing up. DRIVER
Drive the oil seal into the fork slider using the spe-
cial tools. OIL SEAL
TOOLS:
Fork seal driver 070SRTKSP001
FORK SLIDER ATTACHM ENT
Install the oil seal stopper ring into the groove of the
STOPPER
fork slider.
RING
Install a new dust seal.

DUST SEAL
Pour the specified am ount of recom m ended fork

fluid into the fork pipe.
RECOM M ENDED FORK OIL: Fork fluid

FORK FLUID CAPACITY:
150 ± 1.0 cm 2 (5.06 ± 0.03 US oz, 5.26 ± 0.04 Imp oz)
165 m m
Pum p the fork tube several tim es to rem ove trapped (6.5 in)
air from the low er portion of the fork pipe.
Com press the fork leg fully and m easure the oil
level from the top of the fork pipe.
OIL LEVEL: 165 mm (6.5 in)
12-24
Pull the fork pipe up and install the fork spring w ith
its tapered (narrow coil pitch) end facing dow n.
Apply fork fluid to a new O-ring and install it onto

the fork cap. FORK CAP
O-RING
Tighten the fork cap Install the fork cap onto the fork pipe.
after installing the
fork pipe into the
fork bridges.
FORK PIPE
INSTALLATION
Tem porarily install the fork leg up through the bot-
tom bridge and tighten the bottom pinch bolt. FORK CAP
Tighten the fork cap to the specified torque.
Loosen the bottom pinch bolt and install the fork leg
up through the top bridge.
Install the w asher and top bridge bolt.
Tighten the top bridge bolt to the specified torque.
TOP BRIDGE BOLT/

WASHER
12-25
Tighten the bottom pinch bolt to the specified
torque.

– brake caliper (page 14-18)
BOTTOM
PINCH BOLT
STEERING STEM
REM OVAL
IGNITION SWITCH 3P
– front cow l (page 2-3) CONNECTOR
– com bination m eter (page 17-6)
Disconnect the follow ing:
– left handlebar sw itch 9P (Black) connector
– right handlebar sw itch 6P connector
– headlight 6P (Black) connector
– ignition sw itch 3P connector
– tachom eter w ire connector
CONNECTORS
Rem ove the bolt and m eter stay.
BOLT
M ETER STAY
– handlebar (page 12-6)
– fork (page 12-18)
Rem ove the bolt and brake hose holder from the
bottom bridge.
BRAKE HOSE
HOLDER BOLT
12-26
Rem ove the steering stem nut, w asher and top
STEERING
bridge.
STEM NUT
WASHER
Loosen the adjusting nut using the special tool.
SOCKET WRENCH ADJUSTING NUT
TOOL: STEERING
Socket w rench steering 070SRTKSP004
Hold the steering stem and rem ove the adjusting
nut.
STEERING
STEM
Be careful not to Rem ove the follow ing:
TOP CONE RACE UPPER STEEL
loose the steel
– top cone race BALL (18)
balls.
– upper steel ball (18) STEERING
– steering stem
STEM
– low er steel ball (18)
LOWER STEEL
BALL (18)
BALL RACE REPLACEM ENT
Rem ove the ball races using the special tool.
TOP BALL BALL RACE
TOOL: RACE REM OVER
Ball race remover 070SRTKSP005
BALL RACE BOTTOM

REM OVER BALL RACE
12-27
Install a new top ball race and a new bottom ball
race using the special tool.
TOOLS: TOP BALL

Steering cone installer 070SRTKSP006 RACE
STEERING
CONE
INSTALLER
STEERING CONE
INSTALLLER
BOTTOM
BALL RACE
BOTTOM CONE RACE REPLACEM ENT
Avoid dam aging the steering stem thread, tem po-
STEERING BOTTOM
rarily install the stem nut.
Rem ove the bottom cone race. STEM CONE RACE
STEM NUT
Press a new bottom cone race onto the steering
stem using the special tool.
TOOL:
Steering cone installer 070SRTKSP007
BOTTOM
CONE
12-28
INSTALLATION
GREASE WITH STEERING 74 N·m (7.5 kgf·m ,
EXTREM E PRESSURE STEM NUT 55 lbf·ft)
ADJUSTING NUT
WASHER
TOP CONE RACE
UPPER STEEL BALL (18)
TOP BALL RACE
BOTTOM BALL RACE
LOWER STEEL BALL (18)
BOTTOM CONE RACE

STEERING STEM
DUST SEAL
Apply grease w ith extrem e pressure to all bearing UPPER STEEL

area. BALL (18)
Install the steel balls in the bottom cone race and
top ball race. STEERING
STEM
Upper steel ball: 18
Low er steel ball: 18
Install the steering stem and top cone race.
TOP CONE
RACE
LOWER STEEL
BALL (18)
Install the adjusting nut and tighten it to the speci-

fied torque. ADJUSTING NUT SOCKET WRENCH
STEERING
TOOL:
12-29
Turn the steering stem left and right several tim es.
STEERING
STEM
Refer to torque Tem porarily loosen the adjusting nut com pletely,
w rench reading then retighten the adjusting nut to the specified SOCKET WRENCH
information on page torque. STEERING
12-3 ‘‘Service Infor-
mation‘‘. TOOL:
TORQUE:
Actual: 3.4 N·m (0.4 kgf·m, 2.5 lbf·ft)
Check that there is no vertical play and that the
steering stem rotates sm oothly.
ADJUSTING NUT
Install the top bridge.

STEERING
Install the w asher and steering stem nut. STEM NUT
WASHER
Loosen the bottom Install the fork and tem porarily tighten the top
pinch bolts w hen bridge bolts. STEERING
tighten the stem STEM NUT
Tighten the steering stem nut to the specified
nut.
torque.
Turn the steering stem left and right several tim es
and recheck that there is no vertical play and that
the steering stem rotates sm oothly.
12-30
Install the brake hose holder and tighten the bolt.
BRAKE HOSE
HOLDER BOLT
Install the m eter stay and tighten the m eter stay
bolts. BOLT

– handlebar (page 12-8)
M ETER STAY
Connect the follow ing:
IGNITION SWITCH 3P
– left handlebar sw itch 9P (Black) connector CONNECTOR
– right handlebar sw itch 6P connector
– headlight 6P (Black) connector
– ignition sw itch 3P connector
– tachom eter w ire connector
– com bination m eter (page 17-6)
– front cow l (page 2-3)
CONNECTORS
STEERING BEARING PRELOAD
Raise the front w heel off the ground.
Position the steering stem to the straight ahead
position.
Hook a spring scale to the fork tube betw een the
fork top and bottom bridges.
M ake sure that there is no cable or w ire harness
interference. 90°
Pull the spring scale keeping the scale at a right
angle to the steering stem .
Read the scale at the point w here the steering stem
just starts to m ove.
STEERING BEARING PRELOAD:
0.7 – 1.3 kgf (1.64 – 2.81 lbf)
If the readings do not fall w ithin the lim its, readjust
the steering top thread.
12-31
M EM O
13. REAR WHEEL/ BRAKE/ SUSPENSION
SYSTEM COM PONENTS ···························· 13-2 REAR DRUM BRAKE ··································13-17
SERVICE INFORM ATION ···························· 13-3 PILLION STEP/ BRAKE PEDAL···················13-19
TROUBLESHOOTING ·································· 13-7 SHOCK ABSORBER····································13-23
REAR WHEEL··············································· 13-8 SWINGARM ················································13-24
DRIVEN FLANGE ······································· 13-13
13
13-1
SYSTEM COM PONENTS
REAR W HEEL/ BRAKE/ SUSPENSION
44 N·m (4.5 kgf·m ,

33 lbf·ft)
54 N·m (5.5 kgf·m ,

40 lbf·ft)
44 N·m (4.5 kgf·m ,

33 lbf·ft)
22 N·m
59 N·m (6.0 kgf·m , (2.2 kgf·m ,
44 lbf·ft) 16 lbf·ft)
68 N·m
(6.9 kgf·m ,
50 lbf·ft)
13-2
GENERAL
Frequent inhalation of brake shoe dust, regardless of m aterial com position could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assem blies. Use an OSHA-approved vacuum cleaner.
• When servicing the rear w heel and suspension, support the m otorcycle using a safety stand or hoist.
• This m otorcycle is equipped w ith the TUFFUP tube in rear w heel only. Do not install it to the front w heel.
• Use genuine Honda replacem ent bolts and nuts for all suspension pivots and m ounting points.
• The TUFFUP tube is able to repair sam e as a usual tube. Follow bellow caution:
– Do not inflate a TUFFUP tube larger than the tire size as you do in a conventional tube, or air w ill flow into the liquid
room and low er its perform ance.
– When finding a hole inflate a TUFFUP tube to the sam e size as the inside of the tire and look for a hole w here liquid
leaks out.
– When fixing the TUFFUP tube, hold the area w here a patch is attached higher than other parts of the tube so that the
liquid does not flow over the area. Then w ipe off the liquid thoroughly and attach a patch firm ly or it m ay cause air
leak.
REPAIR POINT
• TUFFUP tube cannot alw ays prevent tire puncture.

• Alw ays use proper size TUFFUP tube for the tire.
• Because of its construction, foreign object(s) m ay be stuck into the tube even if the tire seem s to be inflated to the
proper pressure. If any foreign objects are found during m aintenance, rem ove them and repair as soon as possible.
• Som etim es air leak does not stop after a nail etc. Is rem oved from the tire. In that case, tapping the tread of the tire sev-
eral tim es can stop the air leak. Even if the air leak stops after tapping, it m ay starts leaking again. Repair it as soon as
possible.
• When a tire rim is w et or a tire seem s under-inflated, check for any abnorm alities on the tire and repair if necessary.
• When the liquid contacts w ith your skin or eye(s), rinse w ith plenty of w ater im m ediately.
• Like a conventional tube, dam age over 3 m m cannot be repaired. In that case the w hole tube m ust be replaced.
• Alw ays use a new TUFFUP tube that is proper for tire size w hen replacing.
• Alw ays inflate to the specified pressure.
• TUFFUP tube cannot prevent puncture in the follow ing case:

– A burst
– Dam age on other area than tread (non-liquid room area)
– A hole caused by rusty nail etc.
– When the NOTICE statem ents are not properly observed
13-3
SPECIFICATIONS
Unit: m m (in)
Cold tire pressure Driver only 225 kPa (2.25 kgf/cm 2, 33 psi) –
Driver and passenger 280 kPa (2.80 kgf/cm 2, 41 psi) –
Axial – 1.0 (0.04)
Slack 20 – 30 (0.8 – 1.2) –
Drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)
TORQUE VALUES
Driven flange sleeve nut 59 N·m (6.0 kgf·m , 44 lbf·ft)
Driven sprocket nut 64 N·m (6.5 kgf·m , 47 lbf·ft) U-nut
Rear axle nut 68 N·m (6.9 kgf·m , 50 lbf·ft) U-nut
Rear brake arm nut 10 N·m (1.0 kgf·m , 7 lbf·ft) U-nut
Shock absorber m ounting nut 44 N·m (4.5 kgf·m , 33 lbf·ft) U-nut
Brake panel stopper arm joint nut 22 N·m (2.2 kgf·m , 16 lbf·ft)
Sw ingarm pivot nut 54 N·m (5.5 kgf·m , 40 lbf·ft) U-nut
13-4
TOOLS
Pilot, 15 m m Pilot, 20 m m Pilot, 25 m m
07746-0040300 070GD-004I160 07746-0040600
Attachm ent, 22 x 24 m m Attachm ent, 24 x 26 m m Attachm ent, 42 x 47 m m

07746-0010800 070GD-002I120 070GD-002I160
Bearing rem over shaft Bearing rem over head, 15 m m Spoke w rench, 5.8 x 6.1 m m
070GD-005I100 070SRTKSP012 07701-0020300
Bearing rem over set, 20 m m Rem over handle Rem over w eight
07936-3710600 07936-3710100 070M C-KPLI300
13-5
Driver
070GD-001I100
13-6
TROUBLESHOOTING
Rear w heel w obbles
• Bent rim
• Worn or dam aged rear w heel bearings
• Worn or dam aged driven flange bearing
• Faulty rear tire
• Loose or broken spokes
• Worn or dam aged sw ingarm bearings
• Bent fram e or sw ingarm
• Axle fastener not tightened properly
• Tire pressure too low
Wheel turns hard
• Brake drag
• Faulty w heel bearings
• Faulty driven flange bearing
• Bent axle
• Drive chain too tight (page 3-15)
Soft suspension
• Incorrect suspension adjustm ent
• Weak shock absorber springs
• Oil leakage from dam per unit
• Low tire pressure
Hard suspension
• Incorrect suspension adjustm ent
• Bent shock absorber dam per rod
• Dam aged suspension or sw ingarm pivot bearings
• Bent sw ingarm pivot or fram e
• High tire pressure
Steers to one side or does not track straight
• Drive chain adjusters not adjusted equally
• Bent axle
• Bent fram e
• Worn sw ingarm pivot com ponents
Rear suspension noise
• Loose suspension fasteners
• Worn or dam aged suspension pivot bearings
• Faulty shock absorber
13-7
REAR WHEEL
REM OVAL
Raise the rear w heel off the ground by placing a
w ork stand or box under the fram e.
Rem ove the follow ing: CUSHION COTTER PIN
– cotter pin RUBBERR
– joint nut
– w asher
– cushion rubber
– joint bolt
– brake panel stopper arm
STOPPER
ARM
BOLT
NUT WASHER
Disconnect the brake rod by rem oving the adjusting

nut, and rem ove the spring and joint pin. AXLE NUT
Rem ove the axle nut.
ADJUSTING
NUT
ROD
JOINT PIN SPRING
Rem ove the axle, collar and right side adjusting
plate. COLLAR AXLE
ADJUSTING
PLATE
Rem ove the rear w heel from the fram e.
REAR WHEEL
13-8
Rem ove the dam per rubbers and O-ring.
DAM PER RUBBERS
O-RING
Rem ove the brake panel.
BRAKE PANEL
INSPECTION
AXLE
Set the axle in V-blocks. Turn the axle and m easure
the runout using a dial indicator.
Actual runout is 1/2 the total indicator reading.
WHEEL BEARING
Turn the inner race of each bearing w ith your finger.
The bearings should turn sm oothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the bear- Rem ove and discard the bearings if they do not turn
ings in pairs. sm oothly, quietly, or if they fit loosely in the hub.
13-9
WHEEL RIM
Check the rim runout by placing the w heel in a turn-
ing stand.
Spin the w heel by hand, and read the runout using a
dial indicator.
SERVICE LIM IT:
Axial: 1.0 mm (0.04 in)
Check the spokes and tighten any that are loose
(page 13-11).
DISASSEM BLY
WHEEL BEARING
Install the rem over head into the bearing.
From the opposite side of the w heel, install the BEARING REM OVER SHAFT
bearing rem over shaft and drive the bearing out of
the w heel hub.
Rem ove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 15 mm 070SRTKSP012
REM OVER HEAD

ASSEM BLY
BEARING (6302)
DAM PER RUBBER
DISTANCE COLLAR
BEARING (6302)
O-RING
13-10
WHEEL CENTER ADJUSTM ENT
Adjust the hub position so that the distance from
the right end surface of the hub center to the side of
rim is 3 ± 1 m m (0.12 ± 0.04 in) as show n.
TOOL:
Spoke w rench, 5.8 x 6.1 mm 07701-0020300

Check the rim runout (page 13-10).
3 ± 1 mm
BASE POINT (0.12 ± 0.04 in)
WHEEL BEARING
Pack new bearing cavities w ith grease.
Drive in a new right side bearing squarely w ith the Fully seated DRIVER
sealed side facing up until it is fully seated.
DISTANCE
Apply a thin coat of grease to the distance collar and COLLAR
install it.
Drive in a new left side bearing w ith the sealed side
facing up.
TOOLS:
Pilot, 15 mm 07746-0040300
BEARINGS ATTACHM ENT PILOT
INSTALLATION
Do not get grease Install the brake panel.
on the brake drum
BRAKE PANEL
and shoe linings.
Apply grease to a new O-ring.

DAM PER RUBBERS
Install the O-ring and dam per rubbers.
O-RING
13-11
Place the rear w heel in the sw ingarm , w hile aligning
the dam per rubbers grooves w ith the drive flange
Align
bosses.
REAR WHEEL
Apply a thin coat of grease to the axle outer surface.

COLLAR AXLE
Insert the axle from the left side through the adjust-
ing plate, sw ingarm , rear w heel and collar.
ADJUSTING
PLATE
Install the axle nut.

Tighten the axle nut to the specified torque. AXLE NUT

Install the spring onto the brake rod and the joint
pin into the brake arm . Connect the brake rod to the
brake arm w ith the adjusting nut. ADJUSTING
NUT
ROD
JOINT PIN SPRING
– joint bolt
– brake panel stopper arm CUSHION COTTER PIN
– cushion rubber RUBBERR
– w asher
Install and tighten the joint nut.
Install the new cotter pin. STOPPER
Adjust the brake pedal free play (page 3-21). ARM
BOLT
NUT WASHER
13-12
DRIVEN FLANGE
REM OVAL
SLEEVE ADJUSTING
– drive chain case (page 3-17) NUT NUT
– rear w heel (page 13-8)
Loosen the sleeve nut.
Loosen the drive chain adjuster lock nut and adjust
nut so the driven flange can be m oved all the w ay
forw ard. M ove the driven flange for m axim um
chain slack.
LOCK NUT
Derail the drive chain from the driven sprocket.
SLEEVE ADJUSTING DRIVE
Rem ove the sleeve nut and adjusting plate. NUT PLATE CHAIN
Rem ove the driven flange assem bly from the sw ing-
arm .
DRIVEN FLANGE
ASSEM BLY
INSPECTION
DRIVEN SPROCKET
Check the condition of the driven sprocket teeth.
Replace the sprocket if it is w orn or dam aged.
WEAR
• If the driven sprocket requires replacem ent,
inspect the drive chain and drive sprocket.
• Never install a new drive chain on a w orn
sprocket or a w orn chain on new sprockets. Both
chain and sprocket m ust be in good condition, or
the replacem ent chain or sprocket w ill w ear rap-
idly.
DAM AGE
NORM AL
DRIVEN FLANGE BEARING

Turn the inner race of bearing w ith your finger.
The bearing should turn sm oothly and quietly. Also
check that the bearing outer race fits tightly in the
driven flange.
Rem ove and discard the bearing if they do not turn
sm oothly, quietly, or if they fit loosely in the driven
flange.
13-13
DISASSEM BLY
DRIVEN SPROCKET
Rem ove the axle sleeve and collar.
COLLAR
AXLE SLEEVE
Rem ove the nuts and driven sprocket. DRIVEN

NUTS
SPROCKET
Rem ove the dust seal.

DUST SEAL

Drive out the driven flange bearing.
BEARING
13-14
ASSEM BLY
AXLE SLEEVE
DRIVEN SPROCKET
BEARING (6005)
DRIVEN FLANGE
COLLAR
64 N·m (6.5 kgf·m ,

47 lbf·ft)

Pack new bearing cavities w ith grease.
DRIVER
Drive in a new bearing squarely until it is fully
seated.
TOOLS:
Driver 070GD-001I100 ATTACHM ENT
Pilot, 25 mm 07746-0040600
PILOT BEARING
DRIVEN SPROCKET
Apply grease to the lip of a new dust seal.
Install the dust seal.
DUST SEAL
13-15
Install the driven sprocket w ith the cham fered side
facing of the drive flange side. DRIVEN NUTS
SPROCKET
Install the nuts and tighten them .
Cham fered side
Install the collar and axle sleeve.

COLLAR
AXLE SLEEVE
INSTALLATION
Install the driven flange assem bly onto the sw ing-
arm , w hile aligning the cut-out of the axle sleeve
w ith the sw ingarm . Align
DRIVEN FLANGE
ASSEM BLY
Install the adjusting plate and sleeve nut.

SLEEVE ADJUSTING DRIVE
Install the drive chain over the driven sprocket. NUT PLATE CHAIN
– drive chain case (page 3-19)
Adjust the drive chain slack (page 3-15).
DRIVEN FLANGE
ASSEM BLY
13-16
Tighten the sleeve nut to the specified torque.
SLEEVE NUT
Tighten the rear axle nut to the specified torque.

LOCK NUT AXLE NUT
Tighten the both sides of adjusting nuts and lock
nuts.
Recheck the drive chain slack and free w heel rota-
tion.
Check the rear brake pedal free play (page 3-21).
ADJUSTING NUT
REAR DRUM BRAKE

INSPECTION
Rem ove the rear w heel (page 13-8).
M easure the rear brake drum I.D.
DISASSEM BLY
Rem ove the brake panel (page 13-8).
SPRINGS
Alw ays replace the Expand the brake shoes and rem ove them from the
brake shoes in brake panel.
pairs.
Rem ove the shoe springs from the brake shoes.
BRAKE SHOES
13-17
BOLT NUT INDICATOR
– nut and bolt
– brake arm
– w ear indicator
– felt seal
– brake cam
FELT BRAKE
BRAKE ARM SEAL CAM
ASSEM BLY
SHOE SPRINGS
BRAKE PANEL
BRAKE SHOES
INDICATOR
BRAKE CAM
10 N·m (1.0 kgf·m , 7 lbf·ft)
FELT SEAL BRAKE ARM
Apply grease to the spindle groove in the brake

BRAKE
cam .
Install the brake cam to the brake panel. PANEL
BRAKE
CAM
13-18
Apply gear oil to a new felt seal and install it.
Install the w ear indicator, w hile aligning the punch INDICATOR
m ark w ith the w ide tooth of the indicator.
Align
FELT BRAKE
SEAL CAM
Install the brake arm , w hile aligning the punch
m arks. BOLT NUT
Install the bolt and tighten the nut.
BRAKE ARM Align

Apply grease to the anchor pin and brake cam slid-
ing surfaces. SHOES
Assem ble the brake shoes and springs as show n.

Install the shoe assem bly onto the brake panel.
Wipe any excess grease from the brake cam and
anchor pin.
Install the brake panel (page 13-11).
SPRINGS
PILLION STEP/ BRAKE PEDAL

REM OVAL
PILLION STEP
Support the m otorcycle placing a w ork stand or box JOINT PIN
under the fram e. SPRING
– brake adjusting nut
– brake rod (from the joint pin)
– rod spring
– joint pin
ADJUSTING NUT ROD
13-19
Rem ove the rear brake return spring.
REAR BRAKE
RETURN SPRING
Rem ove the sw ingarm pivot nut and right pillion

step m ount bolt. PIVOT NUT
Rem ove the right pillion step.
RIGHT
BOLT PILLION STEP
Rem ove the rear brake light sw itch spring.

REAR BRAKE LIGHT
SWITCH SPRING

PIVOT BOLT
– sw ingarm pivot bolt
– left pillion step m ount bolt
– left pillion step
LEFT PILLION
BOLT STEP
13-20
BRAKE PEDAL
BRAKE
– cotter pin PEDAL
– w asher
– brake pedal
COTTER PIN WASHER

BRAKE ROD COTTER PIN
– cotter pin JOINT PIN
– joint pin
– brake rod
INSTALLATION
BRAKE PEDAL
Connect the brake rod to the pedal w ith the joint pin
and a new cotter pin. BRAKE ROD
COTTER PIN
JOINT PIN
Apply grease to the brake pedal pivot shaft.

BRAKE
Install the follow ing: PEDAL
– brake pedal PIVOT SHAFT
– w asher
– cotter pin
COTTER PIN WASHER
13-21
PILLION STEP
PIVOT BOLT
– left pillion step
– sw ingarm pivot bolt
– left pillion step m ount bolt
LEFT PILLION
BOLT STEP
Install the rear brake light sw itch spring.
REAR BRAKE LIGHT
SWITCH SPRING
Install the right pillion step.

PIVOT NUT
Install the sw ingarm pivot nut.
Install the right pillion step m ount bolt.
RIGHT
BOLT PILLION STEP
Install the rear brake return spring.
REAR BRAKE
RETURN SPRING
13-22
Install the follow ing: JOINT PIN SPRING
– joint pin
– rod spring (to the brake rod)
– brake rod (to the joint pin)
– brake adjusting nut
Adjust the brake pedal free play (page 3-21).
ADJUSTING NUT ROD
SHOCK ABSORBER
REM OVAL
Place the m otorcycle on its center stand.
– chain case (page 3-17)
Rem ove the shock absorber low er m ounting bolt
and nut.
LOWER M OUNTING
BOLT/NUT
Rem ove the shock absorber upper m ounting bolt, UPPER M OUNTING SHOCK
nut and shock absorber.
BOLT/NUT ABSORBER
INSPECTION
Visually inspect the shock absorber for w ear or
dam age. SHOCK ABSORBER
– dam per rod for bend or dam age.
– dam per unit for leakage or other dam age.
– bushing for w ear or dam age
Check for sm ooth dam per operation.
Replace the shock absorber as an assem bly if neces-
sary.
13-23
INSTALLATION
Shock absorber Install the shock absorber.
shall be installed
SHOCK
w ith adjust label ABSORBER
right side.
LABEL
Install the upper m ounting bolt and nut. UPPER M OUNTING SHOCK
Tighten the upper m ounting nut to the specified BOLT/NUT ABSORBER
torque.
Install the low er m ounting bolt and nut.

Tighten the low er m ounting nut to the specified
torque.
– drive chain cases (page 3-19)
Check the operation of the shock absorber (page 3-
23).
LOWER M OUNTING
BOLT/NUT
SWINGARM
REM OVAL
AIR CLEANER
DRAIN HOSE
– driven flange (page 13-13)
Rem ove the air cleaner drain hose, carburetor drain
hose and battery breather hose from the sw ingarm .
BATTERY CARBURETOR
BREATHER DRAIN HOSE
13-24
Rem ove the drive chain adjusters.
CHAIN
ADJUSTER
Disconnect the rear brake return spring from the

sw ingarm . SPRING
Rem ove the shock absorber low er m ounting bolt

and nut.
LOWER M OUNTING
BOLT/NUT
Rem ove the sw ingarm pivot nut.
PIVOT NUT
13-25
Rem ove the sw ingarm pivot bolt from the left side.
REAR BRAKE LIGHT
Be careful not to Rem ove the sw ingarm . SWITCH SPRING
damage the rear
brake light sw itch
spring.
SWING ARM
PIVOT BOLT
DISASSEM BLY
Rem ove the chain slider w hile releasing the bosses
from the tabs. CHAIN SLIDER
Check the chain slider for w ear or dam age.

The chain slider m ust be replaced if it is w orn to the
w ear lim it cutout.
CUTOUT

STOPPER ARM
– cotter pin
– joint nut COTTER PIN
– w ashers
– joint bolt
WASHERS JOINT BOLT/NUT
13-26
Rem ove the dust seal caps.
DUST SEAL CAP
Rem ove the collars.
COLLAR
Inspect the sw ingarm dust seal cap, collar, and pivot

bearings for w ear or dam age. DUST SEAL CAP
Check the sw ingarm dam age.
COLLAR
Rem ove the needle bearings from the sw ingarm .
TOOLS:
Bearing remover set, 20mm 07936-3710600
Remover handle 07936-3710100
SHAFT NEEDLE
BEARING
WEIGHT
13-27
ASSEM BLY
22 N·m (2.2 kgf·m , 16 lbf·ft)

STOPPER ARM
22 N·m
(2.2 kgf·m ,
16 lbf·ft)
NEEDLE
BEARING
CHAIN
COLLAR ADJUSTER
SWING ARM
CHAIN SLIDER
DUST SEAL DUST SEAL
Apply grease to the new needle bearings.

DRIVER ATTACHM ENT
Press the needle bearings into the sw ingarm so that
the needle bearing surface is 7 m m (0.3 in) from the 7 m m (0.3 in)
end of sw ingarm pivot, using the special tools and a
hydraulic press.
TOOLS:
Pilot, 20 mm 070GD-004I160
PILOT
NEEDLE
BEARING
Apply grease to the collar surfaces and install them

into the sw ingarm pivots.
COLLAR
13-28
Apply grease to the dust seal cap lips.
Install the dust seal caps.
Install the chain slider tabs to the sw ingarm holes.
DUST SEAL CAP

STOPPER ARM
– joint bolt COTTER PIN
– w ashers
Install and tighten the joint nut.
Install the new cotter pin.
WASHERS JOINT BOLT/NUT
Install the chain slider w hile aligning tabs w ith

grooves. CHAIN SLIDER
CHAIN SLIDER
Align
INSTALLATION
Apply a thin coat of grease to the sw ingarm pivot
bolt surface. REAR BRAKE LIGHT
SWITCH SPRING
Be careful not to Install the sw ingarm and pivot bolt from the left
damage the rear side.
brake light sw itch
spring.
SWING ARM
PIVOT BOLT
13-29
Install the sw ingarm pivot nut.
Tighten the pivot nut to the specified torque. PIVOT NUT
Install the shock absorber low er m ounting bolt and

nut.
Tighten the nut to the specified torque.
LOWER M OUNTING
BOLT/NUT
Carrying out as Connect the rear brake return spring to the sw ing-
show n that the arm . SPRING
direction of a brake
return spring.
Install the drive chain adjusters.
CHAIN
ADJUSTER
13-30
Install the air cleaner drain hose, carburetor drain
hose and battery breather hose to the sw ingarm . AIR CLEANER
DRAIN HOSE
– driven flange (page 13-16)
Adjust the brake pedal free play (page 3-21).
Adjust the drive chain slack (page 3-15).
BATTERY CARBURETOR
BREATHER HOSE DRAIN HOSE
13-31
M EM O
14. HYDRAULIC BRAKE
SYSTEM COM PONENTS ···························· 14-2 BRAKE PAD/ DISC·········································14-7
SERVICE INFORM ATION ···························· 14-3 M ASTER CYLINDER·····································14-9
TROUBLESHOOTING ·································· 14-4 BRAKE CALIPER ·········································14-16
BRAKE FLUID REPLACEM ENT/

AIR BLEEDING ············································· 14-5
14
14-1
HYDRAULIC BRAKE
SYSTEM COM PONENTS
HYDRAULIC BRAKE
34 N·m (3.5 kgf·m , 25 lbf·ft)
1.0 N·m (0.1 kgf·m ,

0.7 lbf·ft)
6.0 N·m (0.6 kgf·m ,

4.4 lbf·ft)
34 N·m (3.5 kgf·m , 25 lbf·ft)
30 N·m (3.1 kgf·m , 22 lbf·ft)
14-2
HYDRAULIC BRAKE
GENERAL
Frequent inhalation of brake pad dust, regardless of m aterial com position, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assem blies. Use an OSHA-approved vacuum cleaner.
Spilling brake fluid w ill severely dam age instrum ent lenses and painted surface. It is also harm ful to som e rubber parts. Be
careful w henever you rem ove the reservoir cap; m ake sure the front reservoir is horizontal first.
• A contam inated brake disc or pad reduces stopping pow er. Discard contam inated pads and clean a contam inated disc
w ith a high quality brake degreasing agent.
• Check the brake system by applying the brake lever or pedal after the air bleeding.
• Never allow contam inates (dirt, w ater, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system m ust be bled.
• Alw ays use fresh DOT 3 or DOT 4 brake fluid from a sealed container w hen servicing the system . Do not m ix different
types of fluid, they m ay not be com patible.
• Alw ays check brake operation before riding the m otorcycle.
SPECIFICATION
Unit: m m (in)
M aster cylinder I.D. 12.000 – 12.043 (0.4724 – 0.4741) 12.055 (0.4746)
M aster piston O.D. 11.957 – 11.984 (0.4707 – 0.4718) 11.945 (0.4703)
TORQUE VALUES
Caliper bleed valve 14 N·m (1.4 kgf·m , 10 lbf·ft)
M aster cylinder reservoir cap screw 1.2 N·m (0.1 kgf·m , 0.9 lbf·ft)
Brake caliper m ounting bolt 30 N·m (3.1 kgf·m , 22 lbf·ft)
Front brake light sw itch screw 1.2 N·m (0.1 kgf·m , 0.9 lbf·ft)
Brake lever pivot bolt 1.0 N·m (0.1 kgf·m , 0.7 lbf·ft)
Brake lever pivot nut 6.0 N·m (0.6 kgf·m , 4.4 lbf·ft)
Brake hose oil bolt 34 N·m (3.5 kgf·m , 25 lbf·ft)
Brake caliper slide pin 14 N·m (2.2 kgf·m , 16 lbf·ft) Apply locking agent to the threads.
TOOL
Snap ring pliers

07914-SA50001
14-3
HYDRAULIC BRAKE
TROUBLESHOOTING
Brake lever soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contam inated brake pad/disc
• Worn caliper piston seal
• Worn m aster cylinder piston cups
• Worn brake pad/disc
• Contam inated caliper
• Contam inated m aster cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deform ed brake disc
• Sticking/w orn caliper piston
• Sticking/w orn m aster cylinder piston
• Bent brake lever
Brake lever hard
• Clogged/restricted brake system
• Sticking/w orn caliper piston
• Worn caliper piston seal
• Sticking/w orn m aster cylinder piston
• Bent brake lever
Brake drags
• Contam inated brake pad/disc
• M isaligned w heel
• Badly w orn brake pad/disc
• Warped/deform ed brake disc
• Clogged/restricted fluid passage
• Sticking caliper piston
14-4
HYDRAULIC BRAKE
BRAKE FLUID REPLACEM ENT/ AIR
BLEEDING
BRAKE FLUID DRAINING
Turn the handlebar until the reservoir is parallel to
the ground before rem oving the reservoir cap. SCREWS RESERVOIR CAP
Rem ove the screw s, reservoir cap, diaphragm plate DIAPHRAGM
and diaphragm . PLATE
DIAPHRAGM
Connect a bleed hose to the caliper bleed valve.
BLEED HOSE BLEED VALVE
Loosen the bleed valve and pum p the brake lever
until no m ore fluid flow s out of the bleed valve.
BRAKE FLUID FILLING/ AIR BLEEDING

Do not mix different Fill the m aster cylinder reservoir w ith DOT 3 or DOT
types of fluid. There 4 brake fluid from a sealed container.
are not compatible.
Connect a autom atic refill system to the reservoir.
If an autom atic refill system is not used, add fluid
w hen the fluid level in the reservoir is low .
• Check the fluid level often w hile bleeding the
brake to prevent air from being pum ped into the
system .
• When using a brake bleeding tool, follow the

m anufacture’s operating instructions. BLEED VALVE BRAKE BLEEDER
If air enters the Connect a com m ercially available brake bleeder to

bleeder from the bleed valve.
around the bleed Operate the brake bleeder and loosen the bleed
valve threads, seal valve.
the threads w ith
Perform the bleeding procedure until the system is
teflon tape.
com pletely flushed/bled.
Close the bleed valve and operate the brake lever. If
it still feels spongy, bleed the system again.
After bleeding the system com pletely, tighten the
bleed valve to the specified torque.
14-5
HYDRAULIC BRAKE
If the brake bleeder is not available, perform the fol-
low ing procedure.
Pum p up the system pressure w ith the brake lever
until the lever resistance is felt.
BRAKE LEVER
Connect a bleed hose to the bleed valve and bleed BLEED HOSE BLEED VALVE
the system as follow s:
Do not release the 1. Squeeze the brake lever all the w ay and loosen
brake lever until the the bleed valve 1/2 of a turn. Wait several sec-
bleed valve has onds and then close the bleed valve.
been closed. 2. Release the brake lever slow ly and w ait several
seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding the system com pletely, tighten the
bleed valve.
Do not mix different Fill the reservoir to the casting ledge w ith DOT 3 or
types of fluid. There DOT 4 brake fluid from a sealed container. CASTING LEDGE
are not compatible.
Install the diaphragm , diaphragm plate and reser-

voir cap, then tighten the screw s to the specified SCREWS RESERVOIR CAP
torque. DIAPHRAGM
PLATE
DIAPHRAGM
14-6
HYDRAULIC BRAKE
BRAKE PAD/ DISC
BRAKE PAD REPLACEM ENT
Check the fluid Push the caliper pistons all the w ay in by pushing
level in the master the caliper body inw ard to allow installation of new
cylinder reservoir as brake pads.
this operation
causes the fluid
level to rise.
CALLIPER BODY
Rem ove the pad pin clip.
PAD PIN CLIP
Drive the pad pin out from the brake caliper.
PAD PIN
Rem ove the brake pads.
BRAKE PAD
14-7
HYDRAULIC BRAKE
M ake sure the pad spring is installed in position.
Install the brake pad w hile aligning pads tab w ith
caliper grooves. Align
PAD SPRING
Install the brake pad pin by pushing the pads

against the pad spring to align the pad pin holes in
the pads and caliper.
Drive the pad pin into the caliper.
PAD PIN
Install the pad pin clip.

Operate the brake lever to seat the caliper pistons
against the pads.
PAD PIN CLIP
14-8
HYDRAULIC BRAKE
BRAKE DISC INSPECTION
Visually inspect the brake disc for dam age or crack.
M easure the brake disc thickness at several points.
Replace the brake disc if the sm allest m easurem ent
is less than service lim it.
Check the brake disc for w arpage.

Check the w heel bearings for excessive play, if the
w arpage exceeds the service lim it.
Replace the brake disc if the w heel bearings are nor-
m al.
M ASTER CYLINDER
REM OVAL
Drain the brake fluid from the hydraulic system
(page 14-5). SCREWS RESERVOIR CAP
Rem ove the right rear view m irror. DIAPHRAGM
Rem ove the screw s, reservoir cap, diaphragm plate PLATE
and diaphragm .
REAR VIEW
DIAPHRAGM M IRROR
Disconnect the brake light sw itch connectors.
CONNECTORS
14-9
HYDRAULIC BRAKE
Rem ove the brake hose by rem oving the oil bolt and
sealing w ashers.
BRAKE HOSE
SEALING
WASHER
OIL BOLT
Rem ove the m aster cylinder holder bolts, holder
M ASTER
and m aster cylinder.
CYLINDER
BOLTS
HOLDER
DISASSEM BLY
Rem ove the brake lever pivot nut, bolt and brake
lever.
BOLT
BRAKE LEVER
NUT
Rem ove the screw and brake light sw itch.

BRAKE LIGHT SWITCH
SCREW
14-10
HYDRAULIC BRAKE
Rem ove the boot and push rod.
BOOT
PUSH ROD
Rem ove the push rod return spring.
RETURN SPRING
Rem ove the snap ring using the special tool.
SNAP RING
TOOL:
Snap ring pliers 07914-SA50001
Rem ove the m aster piston and spring.

Clean the m aster cylinder, reservoir and m aster pis-
ton in clean brake fluid.
M ASTER
PISTON
SPRING
14-11
HYDRAULIC BRAKE
INSPECTION
Check the m aster piston for scoring, scratches or
M ASTER CYLINDER
dam age.
M ASTER
Check the piston cups for w ear, deterioration or PISTON
dam age.
Check the m aster cylinder for scoring, scratches or
dam age.
PISTON CUP
M easure the m aster cylinder I.D.

M easure the m aster piston O.D.

14-12
HYDRAULIC BRAKE
ASSEM BLY
1.2 N·m (0.1 kgf·m , 0.9 lbf·ft)
M ASTER
CYLINDER RESERVOIR CAP
M ASTER
PISTON SPRING
PISTON DIAPHRAGM
SNAP CUPS PLATE
SPRING RING
PUSH
ROD DIAPHRAGM
BOOT BRAKE LIGHT SWITCH
1.2 N·m (0.1 kgf·m , 0.9 lbf·ft)

PIVOT BOLT
1.0 N·m (0.1 kgf·m , PIVOT NUT
0.7 lbf·ft) 6.0 N·m (0.6 kgf·m , 4.4 lbf·ft)
BRAKE LEVER
Keep the piston, Install the spring onto the piston end.
cups, spring, snap
ring and boot as a
set; do not substi-
tute individual part. M ASTER
PISTON
Do not allow the Install the m aster piston into the m aster cylinder.
piston cup lips to
turn inside out.
SPRING
PISTON
CUP
Be certain the snap Install the snap ring into the groove in the m aster
SNAP RING
ring is firmly seated cylinder.
in the groove.
TOOL:
Snap ring pliers 07914-SA50001
14-13
HYDRAULIC BRAKE
Apply grease to the push rod-to-m aster piston con-
tact area.
Install the push rod return spring, push rod and RETURN
boot into the m aster cylinder. SPRING
Apply grease to the brake lever-to-push rod contact
area.
BOOT
PUSH ROD
Install the brake light sw itch to the m aster cylinder,
w hile aligning the brake light sw itch boss and m as-
ter cylinder hole.
Align
BRAKE LIGHT
SWITCH
Install the brake light sw itch screw and tighten it.

BRAKE LIGHT SWITCH
SCREW
Apply grease to the brake lever pivot bolt rotating

surface.
Install the brake lever to the m aster cylinder. BOLT
Install the pivot bolt and tighten it.
Install the pivot nut and tighten it.
BRAKE LEVER
NUT
14-14
HYDRAULIC BRAKE
INSTALLATION
Install the m aster cylinder and the holder.
M ASTER
Align the m ating surface of the m aster cylinder w ith CYLINDER
the punch m ark on the handlebar, and tighten the
front bolt first, then tighten the rear bolt.
BOLTS
HOLDER Align
Rest the brake hose joint betw een the stoppers on
the m aster cylinder.
Connect the brake hose w ith the oil bolt and new
sealing w ashers, and tighten the oil bolt to the spec- OIL BOLT
ified torque.

BRAKE HOSE
SEALING
WASHER
STOPPER
Connect the brake sw itch connectors.
CONNECTORS
Fill the brake fluid and air bleed the hydraulic sys-
tem (page 14-5). SCREWS RESERVOIR CAP
Install the diaphragm , diaphragm plate, reservoir DIAPHRAGM
cap and screw s. PLATE
Tighten the screw s to the specified torque.
Install the right rear view m irror.
REAR VIEW
DIAPHRAGM M IRROR
14-15
HYDRAULIC BRAKE
BRAKE CALIPER
REM OVAL
Drain the brake fluid from the hydraulic system BRAKE
(page 14-5). HOSE
Disconnect the brake hose from the brake caliper by
rem oving the oil bolt and sealing w asher.
Rem ove the tw o m ounting bolts and brake caliper. M OUNTING
OIL BOLTS
Rem ove the brake pads (page 14-7).
BOLT
SEALING BRAKE
WASHER CALIPER
DISASSEM BLY
PIN BOOT
– caliper bracket
– pin boots
– pad spring
BRACKET
PAD SPRING
Place a shop tow el over the piston.
Do not use high Position the caliper body w ith the piston dow n and
pressure air or bring apply sm all squirts of air pressure to the fluid inlet
the nozzle too close to rem ove the piston.
to the inlet.
Be careful not to Push the dust seal and piston seal in and lift them
damage the piston out.
sliding surface. PISTON SEAL
Clean the seal grooves, caliper cylinder and piston
w ith clean brake fluid.
DUST SEAL
14-16
HYDRAULIC BRAKE
INSPECTION
Check the caliper cylinder for scoring, scratches or
dam age.
M easure the caliper cylinder I.D.
Check the caliper piston for scoring, scratches or
dam age.
M easure the caliper piston O.D.
ASSEM BLY
CALIPER
PISTON
PISTON SEAL
DUST SEAL CALIPER BRACKET
CALIPER BODY
PAD PIN
CALIPER PIN BOOTS

CLIP PAD SPRING
BRAKE PADS
Install the new piston and dust seals into the seal
grooves in the caliper cylinder. DUST SEAL
Install the caliper piston into the caliper cylinder
w ith the opening side tow ard the pad.
PISTON SEAL CALIPER PISTON
14-17
HYDRAULIC BRAKE
Install the pad spring onto the caliper body.
PIN BOOT
Apply grease to the inside of new pin boots, and
install them into the caliper body.
Install the caliper bracket.
BRACKET
PAD SPRING
INSTALLATION
Install the brake pads (page 14-7).
M OUNTING STOPPER
Install the brake caliper onto the right fork leg. BOLTS
Apply locking agent to the caliper m ounting bolt
threads. BRAKE
Install the m ounting bolts and tighten them to the HOSE
specified torque.
Connect the brake hose to the brake caliper w ith the
oil bolt and new sealing w ashers. OIL
Rest the hose joint onto the stoppers and tighten BOLT
the oil bolt to the specified torque.
BRAKE SEALING
CALIPER WASHERS
Fill the brake fluid and air bleed the hydraulic sys-
tem (page 14-5).
14-18
15. BATTERY/ CHARGING SYSTEM
COM PONENT LOCATION ··························· 15-2 BATTERY·······················································15-6
SYSTEM DIAGRAM ····································· 15-2 CHARGING SYSTEM INSPECTION ·············15-8
SERVICE INFORM ATION ···························· 15-3 ALTERNATOR COIL······································15-9
TROUBLESHOOTING ·································· 15-5 REGULATOR/ RECTIFIER ···························15-10
15
15-1
COM PONENT LOCATION
REGULATOR/RECTIFIER
BATTERY
ALTERNATOR
SYSTEM DIAGRAM
15-2
GENERAL
• The battery gives off explosive gases; keep sparks, flam es and cigarettes aw ay. Provide adequate ventilation w hen
charging.
• The battery contains sulfuric acid (electrolyte). Contact w ith skin or eyes m ay cause severe burns. Wear protective
clothing and a face shield.
– If electrolyte gets on your skin, flush w ith w ater.
– If electrolyte gets in your eyes, flush w ith w ater for at least 15 m inutes and call a physician im m ediately.
• Electrolyte is poisonous.
– If sw allow ed, drink large quantities of w ater or m ilk and call your local Poison Control Center or a physician
im m ediately.
• Alw ays turn OFF the ignition sw itch before disconnecting any electrical com ponent.
• Som e electrical com ponents m ay be dam aged if term inals or connectors are connected or disconnected w hile the igni-
tion sw itch is ON and current is present.
• If the hose is blocked, the battery’s internal pressure w ill not be relieved the breather m ay com e off, or the battery crack
as a result.
• For extended storage, rem ove the battery, give it a full charge, and store it in a cool, dry space. For m axim um service
life, charge the stored battery every tw o w eeks.
• For a battery rem aining in a stored m otorcycle, disconnect the negative battery cable from the battery term inal.
• Tap w ater w ill shorten the service life of the battery.
• Im m ediately w ash off any spilled electrolyte.
• The battery can be dam aged if overcharged or undercharged, or if left to discharge for a long period. These sam e con-
ditions contribute to shortening the "life span" of the battery. Even under norm al use, the perform ance of the battery
deteriorates after 2–3 years.
• Battery voltage m ay recover after battery charging, but under heavy load, battery voltage w ill drop quickly and eventu-
ally die out. For this reason, the charging system is often suspected as the problem . Battery overcharge often results
from problem s in the battery itself, w hich m ay appear to be an overcharging sym ptom . If one of the battery cells is
shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these
conditions, the electrolyte level goes dow n quickly.
• Before troubleshooting the charging system , check for proper use and m aintenance of the battery. Check if the battery
is frequently under heavy load, such as having the headlight and taillight ON for long periods of tim e w ithout riding the
m otorcycle.
• The battery w ill self-discharge w hen the m otorcycle is not in use. For this reason, charge the battery every 2 w eeks to
prevent sulfation from occurring.
• When checking the charging system , alw ays follow the steps in the troubleshooting flow chart (page 15-5).
• Filling a new battery w ith electrolyte w ill produce som e voltage, but in order to achieve its m axim um perform ance,
alw ays charge the battery. Also, the battery life is lengthened w hen it is initially charged.
• Refer to See page 10-7 for alternator rem oval and disassem bly.
BATTERY CHARGING
For battery charging, do not exceed the charging current and tim e specified on the battery. Using excessive current or
extending the charging tim e m ay dam age the battery.
BATTERY TESTING
Refer to the instruction of the Operation M anual for the recom m ended battery tester. The recom m ended battery tester
puts a “ load” on the battery so the actual battery condition of the load can be m easured.
Recommended battery tester BM -210 or equivalent
15-3
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 2.5 Ah
Current leakage 0.1 m A m ax.
ity (20°C/68°F) Needs charging Below 1.230
Charging current Norm al 0.25 A/5 – 10 h
Quick 2.5 A/0.5 h
Alternator Capacity 0.125 kW/5,000 m in -1 (rpm )
Charging coil resistance (20°C/68°F) 0.2 – 1.0 Ω
15-4
TROUBLESHOOTING
BATTERY IS DAM AGED OR WEAK
1. BATTERY TEST
Rem ove the battery (page 15-6).
Check the battery condition using the recom m ended battery tester.
RECOM M ENDED BATTERY TESTER: BM -210 or equivalent
Is the battery in good condition?
NO – Faulty battery.
YES – GO TO STEP 2.
2. CURRENT LEAKAGE TEST
Install the battery (page 15-6).
Check the battery current leakage test (Leak test; page 15-8).
Is the current leakage below 0.1 mA?
NO – GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/ RECTIFIER CONNECTOR
Disconnect the regulator/rectifier 4P connector and recheck the battery current leakage.
Is the current leakage below 0.1 mA?
YES – Faulty regulator/rectifier
NO – • Shorted w ire harness
• Faulty ignition sw itch
4. CHARGING VOLTAGE INSPECTION
M easure and record the battery voltage using a digital m ultim eter (page 15-7).
Start the engine.
M easure the charging voltage (page 15-9).
Com pare the m easurem ents to the results of the follow ing calculation.
STANDARD:
M easured battery Voltage < M easured charging voltage < 15.5 V
Is the measured charging voltage w ithin the standard voltage?
YES – Faulty battery
5. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil (page 15-9).
Is the alternator charging coil resistance w ithin 0.2 – 1.0 Ω (20°C/ 68°F)?
YES – Faulty charging coil
6. REGULATOR/ RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier 4P connector (page 15-10).
Are the measurements correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related w ire
• Loose or poor contacts of related term inal
• Shorted w ire harness
15-5
BATTERY
Disconnect the negative (–) w ire connector and then
the positive (+) w ire connector.
Rem ove the positive (+) w ire connector from battery
holder clam p. NEGATIVE (–) POSITIVE (+)
Disconnect the battery breather hose. CONNECTOR CONNECTOR
Rem ove the bolt, battery holder plate and rem ove
the battery.
Connect the posi- Install the battery in the reverse order of rem oval.
tive terminal first
and then the nega- BATTERY
tive terminal. BREATHER
HOSE
HOLDER PLATE
BOLT CLAM P
M ake sure that the battery breather hose is correctly

aw ay as to obstruct the passage of the air.
sure w ill not be relived, the breather m ay com e
BATTERY INSPECTION
Check for cracked or broken case or plates.
Check the plates for sulfation.
Replace the battery if dam aged or sulfated.
Check the each cell’s electrolyte level.
If low , add distilled w ater to bring the level to the
upper level m ark.
• In order to obtain an accurate test reading w hen
checking the charging system , the battery m ust
be fully charged and in good condition. Perform
the follow ing inspections and tests before
attem pting to troubleshooting charging system
problem s.
15-6
SPECIFIC GRAVITY
• The battery electrolyte contains sulfuric acid.
Avoid contact w ith skin, eyes or clothing.
The specific gravity m ust be checked w ith a hydro
m eter. HYDRO
M ETER
Test each cell by draw ing electrolyte into the
hydrom eter.
SPECIFIC GRAVITY:
Fully charged: 1.270 – 1.290 (20°C/ 68°F) ELECTROLYTE
Needs charging: Below 1.230 (20°C/ 68°F)
• If the difference in specific gravity betw een cells
exceeds 0.01, re-charge the battery. If the differ-
ence in specific gravity successive, replace the
battery.
• There is a change in specific gravity of approxi-
m ately 0.007 per 10°C change in tem perature. Be
sure to consider this w hen taking m easurem ents.
• Reading of the hydrom eter’s fluid level should be
taken horizontally.
GRAVITY
TEM PERATURE °C
VOLTAGE INSPECTION
M easure the battery voltage using a com m ercially
available digital m ultim eter. NEGATIVE (–) POSITIVE (+)
CONNECTOR CONNECTOR
VOLTAGE:
Fully charged: 12.7 – 12.9 V
Under charged: Below 12.3 V
If the battery voltage is below 12.3 V, charge the bat-
tery.
15-7
BATTERY CHARGING
CHARGER
Rem ove the cell caps.
Fill the cells w ith distilled w ater to the upper level
line, if necessary.
Turn pow er ON/ Connect the charger positive (+) cable to the battery
OFF at the charger, positive (+) term inal.
not at the battery Connect the charger negative (–) cable to the battery
terminal. negative (–) term inal.
• Quick-charging should only be done in an em er-
gency; slow charging is preferred.
• For battery charging, do not exceed the charging
current and tim e specified on the battery. Using
excessive current or extending the charging tim e BATTERY
m ay dam age the battery.
CHARGING CURRENT/ TIM E:

Standard: 0.25 A/ 5 – 10 h
Quick: 2.5 A/ 0.5 h
Charge the battery until specific gravity is 1.270 –
1.290.
GRAVITY
TIM E
CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE INSPECTION
NEGATIVE (–)
With the ignition sw itch turned to “ OFF” , discon- CONNECTOR
nect the negative (–) connector. (WIRE HARNESS)
Connect the am m eter (+) probe to the w ire harness
negative (–) w ire connector and the am m eter (–)
probe to the battery negative (–) w ire connector.
With the ignition sw itch turned to “ OFF” , check for
current leakage.
• When m easuring current using a tester, set it to a
high range, and then bring the range dow n to an
appropriate level. Current flow higher than the
range selected m ay blow the fuse in the tester. NEGATIVE (–)
• While m easuring current, do not turn the ignition CONNECTOR
sw itch to “ ON” . A sudden surge of current m ay (BATTERY)
blow the fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 0.1 mA max.
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one
by one and m easuring the current.
15-8
CHARGING VOLTAGE INSPECTION
NEGATIVE (–) POSITIVE (+)
Be sure the battery is in good condition before per- CONNECTOR CONNECTOR
form ing this test.
Warm up the engine to norm al operating tem pera-
ture.
Connect the m ultim eter betw een the battery posi-
tive (+) and negative (–) w ire connector.
• To prevent a short, m ake absolutely certain
w hich are the positive (+) and negative (–) con-
nector.
• Do not disconnect the battery or any cable in the
charging system w ithout first turning the ignition
sw itch to “ OFF” . Failure to follow this precaution
can dam age the tester or electrical com ponents.
With the headlight high beam , m easure the voltage
on the m ultim eter w hen the engine runs at 5,000
m in -1 (rpm ).
Standard: M easured battery voltage < M easured
charging voltage < 15.5 V at 5,000-1 (rpm)
ALTERNATOR COIL
INSPECTION
Disconnect the alternator 2P connector.
ALTERNATOR 2P
CONNECTOR
M easure the resistance betw een each w ire term inal

of the alternator side connector.
STANDARD :
Charging coil (White – Green): 0.2 – 1.0 Ω
Replace the alternator stator if resistance is out of
specification.
See page 10-7 for alternator stator replacem ent.
ALTERNATOR 2P
CONNECTOR
15-9
REGULATOR/ RECTIFIER
SYSTEM INSPECTION
Disconnect the regulator/rectifier 4P connector, and

check it for loose contacts or corroded term inals.
If the charging voltage reading (page 15-9) is out of
the specification, check the follow ing at the w ire
harness side connector:
Item Terminal Specification
Battery Red (+) Battery voltage
charging and should register
line ground (-)
Charging coil line White and 0.2 – 1.0 Ω
ground at (20°C/68°F)
4P CONNECTOR
Ground line Green and Continuity
ground should exist
If all lines are norm al and there are no loose connec-
tions at the regulator/rectifier connector, replace the
regulator/rectifier unit.

BOLT EARTH TERM INAL
Disconnect the regulator/rectifier 4P connector.
Rem ove the bolt, earth term inal and regulator/recti-
fier from fram e.
Earth terminal shall Install the regulator/rectifier in the reverse order of
be butted to stop- rem oval.
per.
STOPPER
REGULATOR/
RECTIFIER 4P CONNECTOR
15-10
16. IGNITION SYSTEM
COM PONENT LOCATION ··························· 16-2 IGNITION TIM ING ········································16-7
SYSTEM DIAGRAM ····································· 16-2 IGNITION COIL ·············································16-8
SERVICE INFORM ATION ···························· 16-3 ICM (IGNITION CONTROL M ODULE) ·········16-8
TROUBLESHOOTING ·································· 16-4 THROTTLE POSITION SENSOR ··················16-9
IGNITION SYSTEM INSPECTION ··············· 16-5
16
16-1
IGNITION SYSTEM
COM PONENT LOCATION
IGNITION SYSTEM
IGNITION SWITCH
IGNITION CONTROL
M ODULE (ICM )
THROTTLE
POSITION SENSER
IGNITION COIL
IGNITION PULSE BATTERY

GENERATOR
SYSTEM DIAGRAM
Fuse 15A Color

W - White
R - Red
G - Green
L - Blue
Battery B - Black
G Y - Yellow
R
Regulator
Rectifier
R R/B Capacitor Y/R

W Discharge Throttle
Y/L Sensor
Ignition (CDI)
L/Y
B/Y
ACG
P
U
L IGNITION
S COIL
E
R
G G G G L/G
16-2
IGNITION SYSTEM
GENERAL
• When servicing the ignition system , alw ays follow the steps in the troubleshooting sequence on (page 16-4).
• The ignition tim ing cannot be adjusted since the Ignition Control M odule (ICM ) is factory preset.
• The Ignition Control M odule (ICM ) m ay be dam aged if dropped. Also if the connector is disconnected w hen current is
flow ing, the excessive voltage m ay dam age the m odule. Alw ays turn off the ignition sw itch before servicing.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Use spark plug of the correct heat range. Using a spark plug w ith an incorrect heat range can dam age the engine.
• After replacing the ICM or throttle position sensor, perform the initializing procedure.
SPECIFICATION
ITEM SPECIFICATION
Ignition coil prim ary peak voltage 100 V m inim um
Ignition pulse generator peak voltage 0.7 V m inim um
Ignition tim ing (“ F” m ark) 8° BTDC at idle
tion sensor Resistance (20°C/68°F) 4.0 – 6.0 Ω
TORQUE VALUES
Tim ing hole cap 10 N·m (1.0 kgf·m , 7 lbf·ft)
Throttle position sensor screw 3.4 N·m (0.4 kgf·m , 2.5 lbf·ft)
TOOL
Peak voltage adaptor
07HGJ-0020100
w ith com m ercially available digital

m ultim eter (im pedance 10 M Ω/DCV
m inim um )
or Im rie diagnostic tester (m odel
625)
16-3
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the follow ing before diagnosing the system .
– Faulty spark plug
– Loose spark plug cap or spark plug w ire
– Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
No spark at plug
Unusual condition Probable cause (check in numerical order)
Ignition coil Low peak voltage. 1. The m ultim eter im pedance is too low ; below 10 M Ω/
prim ary DCV.
voltage 2. Cranking speed is too slow .
3. The sam pling tim e of the tester and m easured pulse
w ere not synchronized. (System is norm al if m easured
voltage is over the standard voltage at least once.)
4. Poorly connected connectors or an open circuit in the
ignition system .
5. Faulty ignition coil.
6. Faulty ignition control m odule (ICM ) (in case w hen
above No. 1 – 5 are norm al).
No peak voltage. 1. Incorrect peak voltage adapter connections.
2. Battery is undercharged.
3. Faulty ignition sw itch.
4. Loose or poorly connected ICM connectors.
5. Open circuit or poor connection in the Red/Black w ire
of the ICM .
6. Open circuit or poor connection in the green w ire of
the ICM .
7. Faulty peak voltage adapter.
8. Faulty ignition pulse generator. (M easure the peak
voltage.)
9. Faulty ICM (in case w hen above No.1 – 8 are norm al).
Peak voltage is norm al, but no spark 1. Faulty spark plug or leaking ignition coil secondary
jum ps at the plug. current.
2. Faulty ignition coil.
Ignition pulse Low peak voltage. 1. The m ultim eter im pedance is too low .
generator 2. Cranking speed is too slow .
3. The sam pling tim e of the tester and m easured pulse
w ere not synchronized. (System is norm al if m easured
voltage is over the standard voltage at least once.)
4. Faulty ignition pulse generator (in case w hen above
No.1 – 3 are norm al).
No peak voltage. 1. Faulty peak voltage adapter.
2. Faulty ignition pulse generator.
16-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark at the plug, check all connec-
tions for loose or poor contact before m easuring
the peak voltage.
• Use a com m ercially available digital m ultim eter
w ith an im pedance of 10 M Ω/DCV m inim um .
• The display value differs depending upon the
internal im pedance of the m ultim eter.
• If using the Im rie diagnostic tester (m odel 625),
follow the m anufacturer’s instructions.
Connect the peak voltage adaptor to the digital m ul-
tim eter, or use the Im rie diagnostic tester. DIGITAL M ULTIM ETER
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
w ith commercially available digital multimeter
(impedance 10 M Ω/ DCV minimum)
PEAK VOLTAGE ADAPTOR
IGNITION COIL PRIMARY PEAK VOLTAGE

• Check all system connections before this inspec-
tion. Poor connected connectors can cause incor-
rect readings.
• If the system is disconnected, incorrect peak volt-
age m ight be m easured.
• Check the cylinder com pression and check that
the spark plug is installed correctly in the cylin-
der head.
Shift the transm ission into neutral and disconnect
the spark plug cap from the spark plug.
Connect a know n good spark plug to the spark plug
cap and ground it to the cylinder head as done in a
spark test.
GOOD KNOWN SPARK PLUG
16-5
IGNITION SYSTEM
IGNITION COIL
With the ignition coil prim ary w ire connected, con-
nect the peak voltage tester or adaptor probes to the
ignition coil prim ary term inal and body ground.
TOOL:
CONNECTION:
Black/ Yellow w ire terminal (–) – Body ground (+)
PEAK VOLTAGE ADAPTOR
Turn the ignition sw itch to “ ON” .
Avoid touching the Crank the engine w ith the kickstarter and read igni-
spark plug or tester tion coil prim ary peak voltage.
probes to prevent
electric shock.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is abnorm al, follow the checks
described in the troubleshooting chart (page 16-4).
IGNITION PULSE GENERATOR PEAK

VOLTAGE
• Check the cylinder com pression and m ake sure
the spark plug is installed correctly in the cylin-
der head.
ICM 4P CONNECTOR
Disconnect the ICM 4P connector.
Connect the peak voltage tester or adaptor probes
to the ignition pulse generator w ire term inals of the
4P connector.
TOOL:
CONNECTION:
Blue/ Yellow w ire terminal (+) – Green w ire termi- PEAK VOLTAGE ADAPTOR
nal (–)
Shift the transm ission into neutral.
Crank the engine w ith the kickstarter and read igni-
tion pulse generator peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage m easured at the ICM connector is
abnorm al, m easure the peak voltage at the ignition
pulse generator w ire connector.
16-6
IGNITION SYSTEM
IGNITION PULSE GENERATOR
Disconnect the ignition pulse generator w ire con- WIRE CONNECTOR
nector (Blue/Yellow ) and connect the tester probes
to the ignition pulse generator side w ire connector
term inal and body ground.
In the sam e m anner as at the ICM connector, m ea-
sure the peak voltage and com pare it to the voltage
m easured at the ICM connector.
• If the peak voltage m easured at the ICM is abnor-
m al and the one m easured at the ignition pulse
generator is norm al, the w ire harness has an
open or short circuit, or loose connection.
• If both peak voltages are abnorm al, follow the PEAK VOLTAGE ADAPTOR
checks described in the troubleshooting chart
(page 16-4).
See page 10-7 for ignition pulse generator replace-
m ent.
IGNITION TIM ING

Warm up the engine.
TIM ING HOLE CAP
Stop the engine and rem ove the tim ing hole cap.
Read the instruc- Connect a tim ing light to the spark plug w ire.
tions for timing light TIM ING LIGHT
Start the engine and let it idle.
operation.
The ignition tim ing is correct if the “ F” m ark on the

INDEX NOTCH
flyw heel aligns w ith the index notch on the left
crankcase cover.
‘‘F‘‘ M ARK
16-7
IGNITION SYSTEM
Coat a new O-ring w ith engine oil and install it onto
the tim ing hole cap. TIM ING HOLE CAP
Install the tim ing hole cap and tighten it.
O-RING
IGNITION COIL
Disconnect the spark plug cap from the spark plug. WIRE CONNECTOR IGNITION COIL
Disconnect the w ire connectors from the ignition
coil.
Rem ove the bolt and ignition coil.
BOLT
ICM (IGNITION CONTROL M ODULE)

SYSTEM INSPECTION
Disconnect the ICM 4P connectors.
Check the follow ing at the w ire harness side con-
nector:
Item Terminal Specification

Battery Red/Black (+) Battery voltage
charging and should register
line Green (-)
Ground line Green and Continuity
ground should exist
ICM 4P CONNECTOR
16-8
IGNITION SYSTEM
ICM BRACKET
Disconnect the ICM 2P, 4P connectors and tachom e-
ter w ire connector. 4P CONNECTOR
Rem ove the ICM from the bracket.
WIRE
CONNECTOR 2P CONNECTOR
THROTTLE POSITION SENSOR

INSPECTION
INPUT VOLTAGE
THROTTLE
Disconnect the throttle position sensor 3P connec-
POSITION SENSOR
tor.
3P CONNECTOR
Check the follow ing at the w ire harness side con-
nector:
CONNECTION:
Yellow / Red (+) – Blue/ Green (–)
STANDARD: 4.75 – 5.25 V

If the m easurem ent is out of specification, check the
follow ing:
– Loose connection of the ICM 2P connector
– Open circuit in w ire harness
OPEARATION INSPECTION
Connect the throttle position sensor 3P connector.
Disconnect the ICM 2P connector.
Check that the resistance at the ICM 2P connector
term inals w hile operating the throttle grip.
CONNECTION:
Yellow / Red – Yellow / Blue
RESISTANCE: 4.0 – 6.0 kΩ
Item Resistance
Full close to full open Decreases
Full open to full close Increases
ICM 2P CONNECTOR
If the resistance at the ICM 2P connector is abnor-
m al, m easure the resistance at throttle position sen-
sor 3P connector.
16-9
IGNITION SYSTEM
Disconnect the throttle position sensor 3P connec-
tor.
Check that the resistance at throttle position sensor
3P connector term inals w hile operating the throttle
A
grip.
CONNECTION: A – B
B
RESISTANCE: 4.0 – 6.0 kΩ
Item Resistance
Full close to full open decreases
Full open to full close increases THROTTLE POSITION
– If the resistance at throttle position sensor 3P SENSOR 3P CONNECTOR
connector is norm al, the w ire harness has an
open circuit or loose connection.
– If both resistance are abnorm al, replace throttle
position sensor (page 16-10).

Disconnect the throttle position sensor 3P connec- SCREW
tor.
Rem ove the screw and throttle position sensor.
THROTTLE
3P CONNECTOR POSITION SENSOR
Install the throttle position sensor w hile aligning the

groove of the sensor w ith the flat of the shaft as THROTTLE POSITION
show n. SENSOR
Align
Rotate the throttle position sensor and align the

hole in the sensor w ith the screw hole in the carbu- SCREW
retor.
Install and tighten the screw .
Connect the throttle position sensor 3P connectors.
Check the throttle operation (page 3-6).
THROTTLE POSITION
SENSOR 3P CONNECTOR
16-10
IGNITION SYSTEM
INITIALIZING PROCEDURE
• After replacing the ICM or throttle position sen-
sor, perform the initializing procedure.
• If tachom eter needle indicate the 10,000 r/m in for
5 seconds in any step of the initializing proce-
dure, turn the ignition sw itch “ OFF” and repeat
the procedures from the step 1.
• The initializing procedure w ill fail autom atically,
if any step is not com pleted w ithin 8 seconds.
If so, turn the ignition sw itch “ OFF” and repeat
the procedures from the step 1.
1. Rem ove the left side cover (page 2-4).
Rem ove the left rear cow l (page 2-6). IGNITION PULSE
GENERATOR WIRE
Disconnect the ignition pulse generator w ire con-
CONNECTOR
nector (page 10-4).
Connect the posi- Connect the battery to the ignition pulse genera-
tive terminal first tor w ire connector and regulator/rectifier m ount
and then the nega- bolt.
tive terminal.
CONNECTION:
Blue/ Yellow w ire terminal (+) –
Regulator/ rectifier mount bolt (–)
Complete each 2. Turn the ignition sw itch “ ON” , the tachom eter
step w ithin 8 sec- needle should indicate the 1,000 r/m in. TACHOM ETER
onds.
IGNITION
SWITCH 1,000 r/m in
Complete each 3. Turn the throttle grip to the fully opened posi-
step w ithin 8 section, the tachom eter needle should indicate the TACHOM ETER
onds. 2,000 r/m in.
THROTTLE GRIP 2,000 r/m in
16-11
IGNITION SYSTEM
Complete each 4. Turn the throttle grip to the fully closed position,
step w ithin 8 sec- the tachom eter needle should indicate the 3,000 TACHOM ETER
onds. r/m in.
Complete each 5. Turn the throttle grip to the fully opened posi-
step w ithin 8 section, the tachom eter needle should indicate the TACHOM ETER
onds. 4,000 r/m in.
Complete each 6. Turn the throttle grip to the fully closed position,
step w ithin 8 sec- the tachom eter needle should indicate the 5,000 TACHOM ETER
onds. r/m in.
When the tachom eter needle indicate soon about
7,000 r/m in, the initializing procedure is success-
ful.
5,000 r/m in
16-12
17. LIGHTS/ M ETER/ SWITCHES
COM PONENT LOCATION ··························· 17-2 HANDLEBAR SWITCHES ···························17-10
SERVICE INFORM ATION ···························· 17-3 BRAKE LIGHT SWITCHES··························17-12
HEADLIGHT·················································· 17-4 NEUTRAL SWITCH·····································17-12
BRAKE/ TAIL LIGHT ····································· 17-5 FUEL GAUGE/ FUEL LEVEL SENSOR ·······17-14
TURN SIGNAL LIGHTS ······························· 17-6 HORN ··························································17-16
COM BINATION M ETER······························· 17-6 PASSING RELAY ········································17-17
TACHOM ETER ············································· 17-8 TURN SIGNAL RELAY································17-18
IGNITION SWITCH······································· 17-9
17
17-1
COM PONENT LOCATION
LIGHTS/ M ETER/ SW ITCHES
FRONT BRAKE
LIGHT SWITCH
COM BINATION
M ETER
FUEL LEVEL
SENSOR
TURN SIGNAL
RELAY
PASSING
RELAY
NEUTRAL SWITCH
REAR BRAKE
LIGHT SWITCH
SYSTEM DIAGRAM
Color
W - White
R - Red
G - Green
L - Blue
Dipper B - Black
Lighting Dimmer Y - Yellow
Switch Switch Passing
Regulator L/W Switch
Rectifier LO HI
Y
G
L/B
BR W B B
W
Passing
L/R Relay
Fuse
10A
L
R/B
High
Beam Ignition
Charging/ Head Indicator Switch
Lighting Light
Coil R
Fuse
15A
Speedometer Tail
G Illumination Lamp
Bulbs - 3 nos. Bulb Battery
12V, 2.5 AH)
17-2
GENERAL
• A halogen headlight bulb becom es very hot w hile the headlight is "ON", and rem ains hot for a w hile after it is turned
"OFF".
Be sure to let it cool dow n before servicing.
• Keep all flam m able m aterials aw ay from the electric heating elem ent. Wear protective clothing, insulated gloves and
eye protection.
• Note the follow ing w hen replacing the halogen headlight bulb.
– Wear clean gloves w hile replacing the bulb. Do not put finger prints on the headlight bulb, as they m ay create hot
spots on the bulb and cause is to fail.
– If you touch the bulb w ith your bare hands, clean it w ith a cloth m oistened w ith alcohol to prevent its early failure.
– Be sure to install the dust cover after replacing the bulb.
• Check the battery condition before perform ing any inspection that requires proper battery voltage.
• A continuity test can be m ade w ith the sw itches installed on the m otorcycle.
• The follow ing color codes are used throughout this section.
Bu = Blue G = Green Lg = Light Green R = Red

Bl = Black Gr = Gray O = Orange W = White
Br = Brow n Lb = Light Blue P = Pink Y = Yellow
SPECIFICATIONS
ITEM SPECIFICATION
Bulbs Headlight (Hi/low beam ) 12 V - 35/35 W
Instrum ent light 12 V - 1.7 W x 3
Fuse M ain 15 A
Sub 10A
(20°C/68°F) Em pty 90 - 100 Ω
TORQUE VALUES
Fuel level sensor m ounting nut 10 N·m (1.0 kgf·m , 7 lbf·ft)
17-3
HEADLIGHT
BULB REPLACEM ENT
CONNECTOR
Disconnect the headlight connector.
Rem ove the dust cover.

Unhook the bulb retainer.
Rem ove the headlight bulb.
"TOP" M ARK
Avoid touching Install a new bulb, w hile aligning the tabs of the
halogen headlight bulb w ith the slots of the headlight unit.
bulb. Finger prints DUST COVER
Hook the bulb retainer into the headlight unit
can create hot
groove.
spots that cause a
bulb to brake. Install the dust cover w ith the "TOP" m ark facing up.
BULB
RETAINER
Connect the headlight connector.

CONNECTOR
Install the front cow l (page 2-3).
17-4
HEADLIGHT UNIT
REM OVAL/ INSTLATION
Rem ove the headlight adjusting bolt.
ADJUSTING BOLT

CLIP
Disconnect the headlight connector.
Rem ove the clips and headlight unit.
Adjust the headlight beam vertically (page 3-22).
CONNECTOR
BRAKE/ TAIL LIGHT

BULB REPLACEM ENT
Rem ove the screw s, brake/tail light lens and inner
lens.
Push the bulb in, turn it counterclockw ise and
rem ove it.
Replace the bulb w ith a new one.
Installation is in the reverse order of rem oval. BULB
INNER
LENS LENS
SCREWS
17-5
TURN SIGNAL LIGHTS
BULB REPLACEM ENT
Rem ove the screw and turn signal light lens.
Push the bulb in, turn it counterclockw ise and SCREW
rem ove it.
BULB LENS
COM BINATION M ETER

BULB REPLACEM ENT
Rem ove the com bination m eter (page 17-6).
Rem ove the m eter bulb sockets.
Center bulb: Push the bulb in, turn it counterclockw ise and
rem ove it.
Right/left bulb: Pull out the bulb from the socket.
BULB

SPEEDM ETER
Disconnect the com bination m eter 9P connector CABLE
and tachom eter w ire connector.
Rem ove the speedom eter cable.
9P CONNECTOR WIRE CONNECTOR
17-6
M ETER
– nuts/w ashers/rubbers
– com bination m eter assem bly
NUTS/
WASHERS/
RUBBERS
DISASSEM BLY
Rem ove the screw s, m eter upper cover and upper
case. SCREWS UPPER COVER
UPPER CASE
Rem ove the w ire connector screw s, harness band
screw and speedom eter m ounting screw s. SCREWS SPEEDOM ETER BULB SOCKET
– bulb sockets
– w ire harness
– speedom eter
– tachom eter
– fuel gauge
TACHOM ETER
BAND SCREW WIRE HARNESS
17-7
ASSEM BLY
Assem ble the m eter in the reverse order of disassem bly.
UPPER CASE
UPPER COVER
BULB
TACHOM ETER
SPEEDOM ETER
FUEL GAUGE M ETER CASE WIRE HARNESS
TACHOM ETER
GROUND LINE INSPECTION
Rem ove the com bination m eter assem bly (page 17-
6).
Tem porarily Connect the com bination m eter 9P
connector and tachom eter w ire connector.
9P CONNECTOR WIRE CONNECTOR
17-8
Check for continuity betw een the Green w ire term i-
nal and body ground.
There should be continuity.
If there is no continuity, check for open circuit in the
Green w ire.
POWER VOLTAGE LINE INSPECTION

Turn the ignition sw itch "ON" and m easure the volt-
age betw een the Black (+) and Green (–) w ire term i-
nals.
There should be battery voltage.

If there is no battery voltage, check for open circuit
in the Black and/or Green w ire. +
-
V
INPUT LINE INSPECTION
Start the engine and m easure the voltage betw een
the Yellow /Green (+) and Green (–) w ire term inals.
There should be at least 6V pulse voltage.

If there is no continuity, check the follow ing; +
– open circuit in the Yellow /Green w ire
– ignition control m odule (ICM ) (page 16-8)
-
If there is continuity and ICM is norm al, replace the
tachom eter (page 17-7). V
IGNITION SWITCH
INSPECTION
Disconnect the ignition sw itch 3P connectors.
Check for continuity at the term inals in each sw itch IGNITION SWITCH 3P
position according to the table. CONNECTORS
IGNITION SWITCH
17-9
Rem ove the top bridge (page 12-26).
Rem ove the follow ing: SCREW
– ignition sw itch m ounting screw s
– ignition sw itch
IGNITION
SWITCH
Apply a locking agent to the ignition sw itch m ount-

ing screw s threads. SCREW
– ignition sw itch
– ignition sw itch m ounting screw s
Install the top bridge (page 12-29).
IGNITION
SWITCH
HANDLEBAR SWITCHES
RIGHT HANDLEBAR SWITCH
6P CONNECTOR
Disconnect the right handlebar sw itch 6P connector.
Check for continuity betw een the term inals in each

sw itch position according to the table.
LIGHTING SWITCH
LIGHTING
SWITCH
17-10
LEFT HANDLEBAR SWITCH
Disconnect the left handlebar sw itch 9P (Black) con-
nector.
9P (BLACK) CONNECTOR
Check for continuity betw een the term inals in each

sw itch position according to the table. DIM M ER SWITCH PASSING SWITCH
DIM M ER SWITCH
TURN SIGNAL
TURN SIGNAL SWITCH SWITCH HORN SWITCH
HORN SWITCH
PASSING SWITCH
17-11
BRAKE LIGHT SWITCHES
FRONT
Disconnect the front brake light sw itch connectors.
FRONT BRAKE
There should be continuity w ith the brake lever
LIGHT SWITCH
applied, and there should be no continuity w hen the
brake lever is released.
REAR
2P CONNECTOR
Disconnect the rear brake light sw itch 2P connector
and check for continuity betw een the term inals.
There should be continuity w ith the brake pedal
applied, and there should be no continuity w hen the
brake pedal is released.
BRAKE PEDAL
NEUTRAL SWITCH
INSPECTION
Disconnect the neutral sw itch w ire connector.
NEUTRAL SWITCH WIRE CONNECTOR
17-12
Shift the gear position into the neutral.
Check for continuity betw een the Light Green/Red
term inal and body ground.
There should be continuity w ith the transm ission is
in neutral, and no continuity w hen the transm ission
is into gear.
REM OVAL
Disconnect the neutral sw itch connector (page 17-
12).
Rem ove the neutral sw itch m ounting bolts. NEUTRAL SWITCH
BOLTS
Rem ove the neutral sw itch and O-ring.

O-RING
NEUTRAL SWITCH
Rem ove the drive piece and spring.
DRIVE PIECE SPRING
17-13
INSTALLATION
Check the drive piece for w ear or dam age, replace if
necessary.
• Bent the drive piece by force or crush the contact
point w ill cause poor electricity connection.
Install the spring and drive piece.
DRIVE PIECE SPRING

to the neutral sw itch.
O-RING
NEUTRAL SWITCH
Carrying out as Install the neutral sw itch.

show n that the
Install the neutral sw itch m ounting bolts and tighten NEUTRAL SWITCH
direction of the
them .
neutral sw itch tab.
Route the neutral sw itch w ire to the left crankcase
cover grooves properly.
Install the left crankcase rear cover (page 6-8).
Connect the neutral sw itch connector (page 17-12).
BOLTS
TAB
FUEL GAUGE/ FUEL LEVEL SENSOR

SYSTEM INSPECTION
If the needle does not move
1. Fuel Level Sensor Inspection
Rem ove the fuel tank bolt and rise the fuel tank FUEL LEVEL SENSOR 2P
(page 2-4). (BROWN) CONNECTOR
Disconnect the fuel level sensor 2P (Brow n) con-
nector.
M easure the resistance at the fuel level sensor
term inals.
Standard: 4 – 100 Ω (20°C/ 68°F)

Is the resistance w ithin 4 – 100 Ω (20°C/ 68°F)?
NO – Inspect the fuel level sensor (page 17-
15).
17-14
2. Fuel Level Sensor Output Line Inspection
Check the continuity betw een the fuel level sen-
sor connector term inal of the w ire harness side COM BINATION
and com bination m eter. M ETER TERM INAL
CONNECTION:
Yellow / White – Yellow / White
Green – Green
Is there continuity?
NO – Open circuit in Yellow /White or Green
w ire.
FUEL LEVEL SENSOR
CONNECTOR
3. Fuel gauge pow er input line Inspection

Turn the ignition sw itch "OFF".
BLACK TERM INAL
Rem ove the com bination m eter (page 17-6).
Turn the ignition sw itch "ON" and m easure the
voltage betw een the m eter term inal and ground.
Connection: Black (+) – Ground (–)
Standard: Battery voltage
Does the battery voltage exist?
NO – Open or short circuit in Black w ire.
YES – faulty fuel gauge, or open circuit in
Green w ire betw een the fuel level sen-
sor and ground.
FUEL LEVEL SENSOR INSPECTION

Rem ove the fuel level sensor (page 17-16).
Connect the ohm m eter to the fuel level sensor ter-
m inals.
Inspect the resistance of the float at the top and bot-
tom positions.
FULL
FULL EM PTY
Resistance (20°C/68°F) 4 – 10 Ω 90 – 100 Ω
EM PTY
17-15
Drain the fuel from the fuel tank into the approved
gasoline container.
Rem ove the fuel tank (page 2-4). NUTS
Rem ove the nuts.
Rem ove the fuel level sensor unit and O-ring.

FUEL LEVEL
SENSOR UNIT
O-RING
Install a new O-ring to the fuel tank.

FUEL LEVEL
Be careful not to Install the fuel level sensor unit into the fuel tank. SENSOR UNIT
damage the float
arm.
O-RING FLOAT
Install the nuts, then tighten them .

NUTS
FUEL LEVEL SENSOR UNIT
17-16
HORN
Disconnect the w ire connectors from the horn.
Rem ove the bolt and horn. BOLT HORN
WIRE CONNECTORS
INSPECTION
Disconnect the w ire connectors from the horn.
Connect the battery voltage to the horn term inals.
The horn is norm al if it sounds w hen the battery
voltage is connected across the horn term inals.
PASSING RELAY
TURN SIGNAL RELAY
Disconnect the passing relay 5P connector from the
relay.
Rem ove the passing relay from the fram e.
TURN SIGNAL RELAY

5P CONNECTOR
17-17
INSPECTION
Connect the ohm m eter to the passing relay connec-
tor term inals.
Connection: A – B
A–C
Connect the battery to the passing relay connector
term inals.
Connection: D – E
Refer to chart and check for continuity betw een the
term inals w hen 12V battery is connected.
A –B A –C TURN SIGNAL
12V battery is RELAY
no continuity continuity
connected
12V battery is not
continuity no continuity
connected
17-18
TURN SIGNAL RELAY
INSPECTION
1. Recommended Inspection
Check the follow ing
– battery condition
– burned out bulb or non-specified w attage
– burned fuse
– ignition sw itch and turn signal sw itch func-
tion
– loose connector
Are the above items in good condition?
NO – Replace or repair the m alfunction
part(s)
2. Turn Signal Circuit Inspection
Disconnect the turn signal relay 2P connector
from the relay.
Short the Black/Blue and Gray term inals of the
turn signal relay connector w ith a jum per w ire.
Start the engine and check the turn signal light
by turning the sw itch "ON".
Is the light come on?
YES – • Faulty turn signal relay
• Poor connection of the connector.
NO – Broken w ire harness
TURN SIGNAL RELAY
2P CONNECTOR

TURN SIGNAL
Disconnect the turn signal relay 2P connector from RELAY
the relay.
Rem ove the turn signal relay from the fram e.
TURN SIGNAL RELAY

2P CONNECTOR
17-19
17-20
18. WIRING DIAGRAM
WIRING DIAGRAM ······································ 18-3
18
18-1
19. TROUBLESHOOTING
ENGINE DOES NOT START OR POOR PERFORM ANCE AT LOW

IS HARD TO START····································· 19-2 AND IDLE SPEED··········································19-5
ENGINE LACKS POWER ····························· 19-3 POOR PERFORM ANCE AT HIGH SPEED ····19-6
POOR HANDLING·········································19-6
19
19-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
TROUBLESHOOTING
1. Fuel Line Inspection

Check fuel flow to carburetor.
Does fuel reach the carburetor?
NO – • Clogged fuel hose or fuel strainer
• Clogged fuel valve
• Clogged fuel fill cap breather
2. Spark Plug Inspection
Rem ove and inspect spark plug.
Is the spark plug w et?
YES – • Flooded carburetor
• Throttle valve open
• Dirty air cleaner
• Im properly adjusted pilot screw
3. Spark Test
Perform spark test.
Is there w eak or no spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system w ires
• Broken or shorted spark plug w ire
• Faulty ignition coil
• Faulty igniting pulse generator
• Faulty ignition control m odule (ICM )
4. Engine Starting Condition
Start engine by follow ing norm al procedure.
Does the engine start then stops?
YES – • Im proper choke operation
• Incorrectly adjusted carburetor
• Leaking carburetor insulator
• Im proper ignition tim ing (Faulty ICM or ignition pulse generator)
• Contam inated fuel
5. Cylinder Compression
Test cylinder com pression.
Is the compression low ?
YES – • Valve clearance too sm all
• Valve stuck open
• Worn cylinder and piston rings
• Dam aged cylinder head gasket
• Seized valve
• Im proper valve tim ing
19-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspection
Raise w heel off the ground and spin by hand.
Does the w heel spin freely?
NO – • Brake dragging
• Worn or dam aged w heel bearings
• Bent axle
2. Tire Pressure Inspection
Check tire pressure.
Are the tire pressures low ?
YES – • Faulty tire valve
• Punctured tire
3. Clutch Inspection
Accelerate rapidly from low to second.
Does the engine speed change accordingly w hen clutch is engaged?
NO – • Clutch slipping
• Worn clutch discs
• Warped clutch plates
• Weak clutch spring
• Sticking clutch lifter m echanism
• Additive in engine oil
4. Engine Condition Inspection
Accelerate lightly.
Does the engine speed increase?
NO – • Fuel/air m ixture too rich or lean
• Clogged air cleaner
• Restricted fuel flow
• Clogged m uffler
• Clogged fuel fill cap breather
5. Engine Condition Inspection
Accelerate or run at high speed.
Is there knocking?
YES – • Worn piston and cylinder
• Use of poor quality fuel
• Excessive carbon build-up in com bustion cham ber
• Ignition tim ing too advance (Faulty ICM )
• Lean fuel m ixture
6. Ignition Timing Inspection
Check ignition tim ing.
Is the ignition timing correct?
NO – • Faulty ignition control m odule (ICM )
• Faulty ignition pulse generator
19-3
TROUBLESHOOTING
7. Engine Oil Inspection
Check oil level and condition.
Is there correct level and good condition?
NO – • Oil level too high
• Oil level too low
• Contam inated oil
8. Spark Plug Inspection
Rem ove and inspect spark plug.
Is the spark plug fouled or discolored?
NO – • Plugs not serviced frequently enough
• Incorrect spark plug used
• Incorrect spark plug gap
9. Cylinder compression Inspection
Test the cylinder com pression.
Is the compression low ?
YES – • Valve clearance too sm all
• Valve stuck open
• Worn cylinder and piston rings
• Dam aged head gasket
• Im proper valve tim ing
10. Carburetor Inspection
Check carburetor for clogging.
Is the carburetor for clogged?
YES – Carburetor not serviced frequently enough.
11. Lubrication Inspection
Rem ove cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
NO – • Clogged oil passage
• Clogged oil strainer
19-4
TROUBLESHOOTING
POOR PERFORM ANCE AT LOW AND IDLE SPEED
1. Pilot Screw Inspection
Check carburetor pilot screw adjustm ent.
Is the adjustment correct?
NO – See page 5-19
2. Intake Air Leak Inspection
Check for leaking carburetor insulator.
Is there leaking?
YES – • Loose carburetor insulator bands
• Dam aged insulator
3. Spark Test
Perform spark test.
Is there w eak or intermittent spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system w ires
• Broken or shorted spark plug w ire
• Faulty ignition coil
• Faulty ignition control m odule (ICM )
19-5
TROUBLESHOOTING
POOR PERFORM ANCE AT HIGH SPEED
1. Fuel Line Inspection
Disconnect fuel line at carburetor.
Does fuel flow freely?
NO – • Clogged fuel line
• Clogged fill cap breather
• Faulty fuel valve
• Clogged fuel strainer
2. Carburetor Inspection
Check carburetor for clogging.
Is the carburetor clogged?
YES – Carburetor not serviced frequently enough.
4. Valve Timing Inspection
Check valve tim ing.
Is the valve timing correct?
NO – Cam sprocket not installed properly.
5. Valve Spring Inspection
Check valve springs.
Are the valve springs w eak?
YES – Faulty valve spring.
POOR HANDLING
Steering is heavy
• Steering bearing adjustm ent nut too tight
• Dam aged steering head bearings
Either w heel is w obbling
• Excessive w heel bearing play
• Bent rim
• Im properly installed w heel hub
• Excessively w orn sw ingarm pivot bearings
• Bent fram e
M otorcycle pulled to one side
• Front and rear w heels not aligned
• Bent fork
• Bent sw ingarm
• Bent axle
• Bent fram e
19-6
20. INDEX
AIR CLEANER ·································································· 3-7 FUEL STRAINER SCREEN··············································· 3-5
A
AIR CLEANER HOUSING ················································ 5-5 FUEL SYSTEM SPECIFICATIONS··································· 1-5

ALTERNATOR COIL ······················································ 15-9 FUEL TANK ······································································ 2-4
BATTERY GEARSHIFT LINKAGE··················································· 9-15
B G
BATTERY/CHARGING SYSTEM ······························ 15-6 GENERAL INFORM ATION ·············································· 1-2

M AINTENANCE ························································ 3-19 GENERAL SPECIFICATIONS··········································· 1-4
BATTERY/CHARGING SYSTEM SPECIFICATIONS······· 1-9 HANDLEBAR·································································· 12-6
H
BRAKE CALIPER·························································· 14-16 HANDLEBAR SWITCHES ············································ 17-10

BRAKE FLUID ································································ 3-20 HEADLIGHT ··································································· 17-4
BRAKE FLUID REPLACEM ENT/AIR BLEEDING··········· 14-5 HEADLIGHT AIM ··························································· 3-22
BRAKE LIGHT SWITCHES HORN ··········································································· 17-16
LIGHT/M ETER/SWITCHES ····································· 17-12 HYDRAULIC BRAKE SPECIFICATIONS·························· 1-8
M AINTENANCE ························································ 3-22 ICM (IGNITION CONTROL M ODULE) ·························· 16-8
I
BRAKE PAD/DISC·························································· 14-7 IGNITION COIL ······························································ 16-8

BRAKE PEDAL/PILLION STEP ···································· 13-19 IGNITION SWITCH ························································ 17-9
BRAKE SHOES/PADS WEAR········································ 3-20 IGNITION SYSTEM INSPECTION ································· 16-5
BRAKE SYSTEM ···························································· 3-21 IGNITION SYSTEM SPECIFICATIONS ··························· 1-9
BRAKE/TAIL LIGHT ······················································· 17-5 IGNITION TIM ING ························································· 16-7
CABLE & HARNESS ROUTING ···································· 1-17 KICKSTARTER ······························································· 9-18
C K
CAM CHAIN TENSIONER LIFTER ································ 7-25 KICKSTARTER IDLE GEAR············································ 9-17
CAM SHAFT HOLDER DISSASEM BLY/ASSEM BLY ···· 7-11 LEFT CRANKCASE COVER ··········································· 10-4
L
CAM SHAFT HOLDER/CLINDER HEAD LEFT SIDE COVER ··························································· 2-4

INSTALLATION ····························································· 7-23 LIGHTS/M ETER/SWITCHES SPECIFICATIONS ············· 1-9
CAM SHAFT HOLDER/CLINDER HEAD REM OVAL········ 7-9 LUBRICATION & SEAL POINTS ··································· 1-14
CARBURETOR ································································· 5-8 LUBRICATION SYSTEM DIAGRAM ······························· 4-2
CHARGING SYSTEM INSPECTION······························ 15-8 LUBRICATION SYSTEM SPECIFICATIONS ··················· 1-5
CHOKE OPERATION ······················································· 3-6 M AINTENANCE SCHEDULE··········································· 3-4
M
CLUTCH ··········································································· 9-8 M ASTER CYLINDER······················································ 14-9

CLUTCH SYSTEM ························································· 3-22 M ODEL IDENTIFICATION ··············································· 1-2
CLUTCH/GEARSHIFT LINKAGE/ NEUTRAL SWITCH······················································ 17-12
N
KICKSTARTER SPECIFICATIONS··································· 1-6 NUTS, BOLTS, FASTENERS········································· 3-24

COM BINATION M ETER ················································ 17-6 OIL PUM P········································································· 4-4
O
COM PONENT LOCATION PASSING RELAY ························································· 17-17

P
BATTERY/CHARGING SYSTEM ······························ 15-2 PILOT SCREW ADJUSTM ENT······································ 5-19

IGNITION SYSTEM ··················································· 16-2 PRIM ARY DRIVE GEAR/CRANKSHAFT COLLAR ········ 9-21
LIGHTS/M ETER/SWITCHES ····································· 17-2 REAR COWL····································································· 2-6
R
CRANKCASE ASSEM BLY··········································· 11-18 REAR DRUM BRAKE ··················································· 13-17

CRANKCASE BREATHER················································ 3-8 REAR FENDER ································································· 2-8
CRANKCASE SEPARATION ········································· 11-6 REAR GRIP······································································· 2-6
CRANKSHAFT ····························································· 11-16 REAR WHEEL································································· 13-8
CRANKSHAFT/TRANSM ISSION ·································· 11-2 REAR WHEEL/SUSPENSION SPECIFICATIONS············ 1-8
CRANKSHAFT/TRANSM ISSION SPECIFICATIONS······ 1-7 REGULATOR/RECTIFIER············································· 15-10
CYLINDER COM PRESSION ············································ 7-6 RIGHT CRANKCASE COVER··········································· 9-5
CYLINDER HEAD COVER················································ 7-6 RIGHT SIDE COVER························································· 2-4
CYLINDER HEAD DISSASSEM BLY/ASSEM BLY ········· 7-14 SAREE GAURD ································································ 2-8
S
CYLINDER HEAD/VALVES SPECIFICATIONS················ 1-5 SEAT················································································· 2-3

CYLINDER/PISTON·························································· 8-4 SECONDARY AIR SUPPLY SYSTEM 20
CYLINDER/PISTON SPECIFICATIONS ··························· 1-6 FUEL SYSTEM ·························································· 5-23
DRIVE CHAIN ································································· 3-15 M AINTENANCE ························································ 3-15
D
DRIVEN FLANGE························································· 13-13 SERVICE INFORM ATION

EM ISSION CONTROL SYSTEM S ································· 1-25 ALTERNATOR/STARTER CLUTCH··························· 10-3
E
ENGINE & FRAM E TORQUE VALUES ························· 1-10 BATTERY/CHARGING SYSTEM ······························· 15-3
ENGINE IDLE SPEED····················································· 3-14 CLUTCH/GEARSHIFT LINKAGE ································· 9-3
ENGINE INSTALLATION················································· 6-6 CRANKSHAFT/TRANSM ISSION ······························ 11-3
ENGINE OIL ··································································· 3-11 CYLINDER HEAD/VALVES·········································· 7-3
ENGINE OIL CENTRIFUGAL FILTER ···························· 3-13 CYLINDER/PISTON ····················································· 8-3
ENGINE OIL STRAINER SCREEN ··································· 4-4 ENGINE REM OVAL/INSTALLATION·························· 6-3
ENGINE REM OVAL ························································· 6-4 FRAM E/BODY PANELS/EXHAUST SYSTEM ············ 2-2
EXHAUST PIPE/M UFFLER·············································· 2-9 FRONT WHEEL/SUSPENSION/STEERING ·············· 12-3
FLYWHEEL····································································· 10-6 FUEL SYSTEM ···························································· 5-3
F
FORK ············································································ 12-18 HYDRAULIC BRAKE·················································· 14-3

FRONT COWL·································································· 2-3 IGNITION SYSTEM ··················································· 16-3
FRONT FENDER ······························································ 2-5 LIGHTS/M ETER/SWITCHES ····································· 17-3
FRONT WHEEL ···························································· 12-12 LUBRICATION SYSTEM ············································· 4-3
FRONT WHEEL/SUSPENSION/STEERING M AINTENANCE ·························································· 3-2
SPECIFICATIONS ···························································· 1-8 REAR WHEEL/BRAKE/SUSPENSION······················· 13-3
FUEL GAUGE/FUEL LEVEL SENSOR························· 17-14 SERVICE RULES ······························································ 1-2
FUEL LINE········································································ 3-5 SHOCK ABSORBER····················································· 13-23
FUEL STRAINER···························································· 5-24 SIDE STAND ·································································· 3-23
20-1
INDEX
SPARK PLUG ··································································· 3-8 TROUBLESHOOTING
STANDARD TORQUE VALUES ···································· 1-10 BATTERY/CHARGING SYSTEM ·······························15-5
STARTING ENRICHM ENT (SE) VALVE·························· 5-7 CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER········9-4
STATOR/IGNITION PULSE GENERATOR···················· 10-7 CRANKSHAFT/TRANSM ISSION ······························11-5
STEERING HEAD BEARINGS ······································· 3-25 CYLINDER HEAD/VALVES ··········································7-5
STEERING STEM ························································· 12-26 CYLINDER/PISTON ······················································8-3
SUSPENSION ································································ 3-23 ENGINE DOES NOT START OR IS
SWINGARM ································································· 13-24 HARD TO START ·······················································19-2
SYSTEM COM PONENTS ENGINE LACKS POWER ···········································19-3
ALTERNATOR/STARTER CLUTCH ·························· 10-2 FRAM E/BODY PANELS/EXHAUST SYSTEM ·············2-2
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER ······· 9-2 FRONT WHEEL/SUSPENSION/STEERING ··············12-5
CRANKSHAFT/TRANSM ISSION ······························ 11-2 FUEL SYSTEM ·····························································5-4
CYLINDER HEAD/VALVES·········································· 7-2 HYDRAULIC BRAKE ··················································14-4
CYLINDER/PISTON ····················································· 8-2 IGNITION SYSTEM ···················································16-4
ENGINE REM OVAL/INSTALLATION ························· 6-2 LUBRICATION SYSTEM ·············································4-3
FRONT WHEEL/SUSPENSION/STEERING·············· 12-2 POOR HANDLING ·····················································19-6
FUEL SYSTEM ···························································· 5-2 POOR PERFORM ANCE AT HIGH SPEED ·················19-6
HYDRAULIC BRAKE·················································· 14-2 POOR PERFORM ANCE AT LOW AND
REAR WHEEL/BRAKE/SUSPENSION ······················ 13-2 IDLE SPEED ·······························································19-5
SYSTEM DIAGRAM REAR WHEEL/BRAKE/SUSPENSION ·······················13-7
BATTERY/CHARGING SYSTEM ······························· 15-2 TURN SIGNAL LIGHTS··················································17-6
IGNITION SYSTEM ··················································· 16-2 TURN SIGNAL RELAY ·················································17-18
TACHOM ETER······························································· 17-8 VALVE CLEARANCE ························································3-9
T V
THROTTLE OPERATION ················································· 3-6 WHEELS/TIRES ······························································3-24

W
THROTTLE POSITION SENSER···································· 16-9 WIRING DIAGRAM ························································18-3

TRANSM ISSION ···························································· 11-7
20-2
TYPE CODE
CBF150M-5 ADDENDUM
Throughout this manual, the following abbreviations are used to identify individual model.
CODE AREA TYPE
ID India
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and
the reliability of the vehicle. Any error or oversight while servicing a vehicle Improper service or repairs can create an
can result in faulty operation, damage to the vehicle, or injury to others. unsafe condition that can cause your customer
or others to be seriously hurt or killed.
For Your Safety Follow the procedures and precautions in this
Because this manual is intended for the professional service technician, we manual and other service materials carefully.
do not provide warnings about many basic shop safety practices (e.g., Hot
parts–wear gloves). If you have not received shop safety training or do not
feel confident about your knowledge of safe servicing practice, we
recommended that you do not attempt to perform the procedures described Failure to properly follow instructions and
in this manual. precautions can cause you to be seriously hurt
or killed.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions in this
arise in performing service and repair procedures. Only you can decide manual carefully.
whether or not you should perform a given task.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
INTRODUCTION
This addendum contains the information for the CBF150M-5.
Refer to CBF150 MANUAL (No.62KSPAM5) for service procedures and data not included in this addendum.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages
and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: November, 2004

©Honda Motor Co., Ltd.
21. CBF150M-5 ADDENDUM
MODEL IDENTIFICATION···························· 21-2 LUBRICATION & SEAL POINTS ················21-15
GENERAL SPECIFICATIONS······················· 21-4 CABLE & HARNESS ROUTING ·················21-18
LUBRICATION SYSTEM AIR CLEANER HOUSING ···························21-21

SPECIFICATIONS········································· 21-5
ENGINE REMOVAL/INSTALLATION
FUEL SYSTEM SPECIFICATIONS··············· 21-5 SYSTEM COMPONENTS ···························21-23
CYLINDER HEAD/VALVES ALTERNATOR/STARTER CLUTCH

SPECIFICATIONS········································· 21-5 SYSTEM COMPONENTS ···························21-24
CYLINDER/PISTON SPECIFICATIONS ······· 21-6 LEFT CRANKCASE COVER ························21-25
CLUTCH/GEARSHIFT LINKAGE/ FLYWHEEL ··················································21-27

KICKSTARTER SPECIFICATIONS ··············· 21-6
STARTER CLUTCH ·····································21-29
ALTERNATOR/STARTER CLUTCH
SPECIFICATIONS········································· 21-6 BATTERY·····················································21-32
CRANKSHAFT/TRANSMISSION ELECTRIC STARTER

SPECIFICATIONS········································· 21-7 COMPONENT LOCATION··························21-33
FRONT WHEEL/SUSPENSION/STEERING ELECTRIC STARTER

SPECIFICATIONS········································· 21-8 SYSTEM DIAGRAM····································21-33
REAR WHEEL/BRAKE/SUSPENSION ELECTRIC STARTER SERVICE

SPECIFICATIONS········································· 21-8 INFORMATION ···········································21-34
HYDRAULIC BRAKE SPECIFICATIONS ······ 21-8 ELECTRIC STARTER

TROUBLESHOOTING·································21-35
BATTERY/CHARGING SYSTEM
SPECIFICATIONS········································· 21-9 STARTER MOTOR ······································21-37
ELECTRIC STARTER SPECIFICATIONS······ 21-9 STARTER RELAY SWITCH·························21-44
IGNITION SYSTEM SPECIFICATIONS ······· 21-9 NEUTRAL DIODE········································21-46
LIGHTS/METER/SWITCHES CLUTCH SWITCH ·······································21-46

SPECIFICATIONS········································· 21-9
RIGHT HANDLEBAR SWITCHES ···············21-47
STANDARD TORQUE VALUES ················ 21-10
WIRING DIAGRAM ·····································21-48
ENGINE & FRAME TORQUE VALUES ····· 21-10
21-1
CBF150M-5 ADDENDUM
MODEL IDENTIFICATION
CBF150M-5 ADDENDUM
21-2
CBF150M-5 ADDENDUM
The frame serial number is stamped on the right side of the steering
head.
FRAME SERIAL NUMBER

The engine serial number is stamped on the lower left side of the
crankcase. ENGINE SERIAL NUMBER
The carburetor identification number is stamped on the left side of the

carburetor body.
CARBURETOR IDENTIFICATION NUMBER

The color label is attached as shown. When ordering color-coded
parts, always specify the designated color code.
COLOR LABEL
21-3
CBF150M-5 ADDENDUM
ITEM SPECIFICATION
DIMENSIONS Overall length 2,078 mm (81.8 in)
Overall width 749 mm (29.5 in)
Overall height 1,092 mm (43.0 in)
Wheelbase 1,337 mm (52.6 in)
Seat height 790 mm (31.1 in)
Footpeg height 295 mm (11.6 in)
Ground clearance 164 mm (6.5 in)
Dry weight 131 kg (289 lbs)
Curb weight 144 kg (318 lbs)
Maximum weight capacity 170 kg (375 lbs)
FRAME Frame type Diamond type
Front wheel travel 117 mm (4.6 in)
Rear suspension Swingarm
Rear wheel travel 101 mm (4.0 in)
Rear damper One side operation
Rear tire size 3.00-18 52P
Front tire brand MRF NYLOGRIP ZAPPER - FS
Rear tire brand MRF NYLOGRIP ZAPPER
Rear brake Mechanical drum (leading-trailing)
Caster angle 26° 00’
Trail length 97 mm (3.8 in)
Fuel tank capacity 13.0 liter (3.43 US gal, 2.86 lmp gal)
Fuel tank reserve capacity 1.0 liter (0.26 US gal, 0.22 lmp gal)
ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical
Bore and stroke 57.3 x 57.8 mm (2.26 x 2.28 in)
Displacement 149.2 cm3 (9.10 cu-in)
Compression ratio 9.1:1
Valve train Chain driven OHC with rocker arm
Intake valve opens at 1 mm (0.04 in) lift 7° BTDC
closes at 1 mm (0.04 in) lift 28° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 27° BBDC
closes at 1 mm (0.04 in) lift 3° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Engine dry weight 29.1 kg (64.2 lbs)
CARBURETOR Carburetor type CV (constant velocity) type
Throttle bore 26 mm (1.02 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Transmission 5 speeds
Primary reduction 3.350 (67/20)
Gear ratio 1st 3.076 (40/13)
2nd 1.789 (34/19)
3rd 1.304 (30/23)
4th 1.090 (24/22)
5th 0.937 (30/32)
1-N-2-3-4-5
Starting system Electric starter motor/Kickstarter
Regulator/rectifier SCR shorted, single phase half-wave recti-
fication
21-4
CBF150M-5 ADDENDUM
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil After draining 1.0 liter (1.1 US qt, 0.9 lmp qt) –
capacity After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) –
Recommended engine oil Honda 4-stroke oil or equivalent motor –
oil
Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)
Side clearance 0.05 – 0.11 (0.002 – 0.004) 0.15 (0.006)
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Carburetor identification number VK4FA
Main jet #115
Slow jet #38
Float level 13.0 mm (0.51 in)
Idle speed 1,400 ± 100 min-1 (rpm)
Throttle grip free play 2 – 6 mm (0.08 – 0.24 in)
PAIR control valve specified vacuum 58.7 kPa (440 mm Hg)
CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)
Cylinder compression at 1,000 min-1 (rpm) 1,402 kPa (14.3 kgf/cm2, 203 psi) –
EX 0.12 (0.005) –
valve guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Stem-to-guide clear- IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
ance EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)
Valve seat width IN/EX 0.9 – 1.1 (0.035 – 0.043) 1.5 (0.06)
OUTER 35.95 (1.415) 35.14 (1.383)
Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm-to-shaft clear- IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
ance
Camshaft Cam lobe height IN 32.994 – 33.234 (1.2990 – 1.3084) 32.96 (1.298)
EX 32.880 – 33.120 (1.2945 – 1.3039) 32.85 (1.293)
Cylinder head warpage – 0.05 (0.002)
21-5
CBF150M-5 ADDENDUM
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Second 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.85 (0.033)
Connecting rod small end I.D. 14.010 – 14.028 (0.5516 – 0.5523) 14.06 (0.554)
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SPECIFICATIONS

Unit: mm (in)
Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.6 (0.10)
Plate warpage – 0.20 (0.008)
Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909)
I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in)
Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.60 (1.795)
21-6
CBF150M-5 ADDENDUM
CRANKSHAFT/TRANSMISSION SPECIFICATIONS
Unit: mm (in)
Crankshaft Runout 0.03 (0.001) 0.08 (0.003)
ance
ance
Transmission Gear I.D. M4, M5 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)
C2 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C3 23.025 – 23.046 (0.9065 – 0.9073) 23.07 (0.908)
Bushing O.D. M4, M5 19.959 – 19.980 (0.7858 – 0.7866) 19.91 (0.784)
C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)
C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)
Gear-to-bushing M4, M5, C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance C2 0.015 – 0.057 (0.0006 –0.0022) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Bushing I.D. M4, C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
Mainshaft / coun- M4, C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667)
tershaft O.D. C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785)
C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785)
Bushing-to-shaft M4, C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
shift fork shaft Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)
21-7
CBF150M-5 ADDENDUM
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
Minimum tire thread depth – 1.5 (0.06)
Cold tire Driver only 175 kPa (1.75 kgf/cm2, 25 psi) –
pressure Driver and passenger 175 kPa (1.75 kgf/cm2, 25 psi) –
Pipe runout – 0.20 (0.008)
Recommended fluid Fork fluid –
Fluid capacity 150 ± 1.0 cm3 (5.06 ± 0.03 US oz, 5.26 ± –
0.04 lmp oz)
REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Unit: mm (in)
Cold tire pressure Driver only 225 kPa (2.25 kgf/cm2, 33 psi) –
Driver and passenger 280 kPa (2.80 kgf/cm2, 41 psi) –
Axial – 1.0 (0.04)
Slack 20 – 30 (0.8 – 1.2) –
Drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)

Unit: mm (in)
Master cylinder I.D. 12.000 – 12.043 (0.4724 – 0.4741) 12.055 (0.4746)
Master piston O.D. 11.957 – 11.984 (0.4707 – 0.4718) 11.945 (0.4703)
21-8
CBF150M-5 ADDENDUM
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V – 7 Ah
Current leakage 0.1 mA max.
ity (20° C/68° F) Needs charging Below 1.230
Charging current Normal 0.7 A/5 – 10 h
Quick 7 A/0.5 h
Alternator Capacity 0.125 kW/5,000 min-1 (rpm)
Charging coil resistance (20° C/68° F) 0.2 – 1.0 Ω
ELECTRIC STARTER SPECIFICATIONS

Unit: mm (in)
Starter motor brush length 10.00 – 10.05 (0.394 –0.396) 6.5 (0.26)

ITEM SPECIFICATION
Spark plug Standard CPR8EA-9 (NGK) or RG6YC (CHAMPION)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil primary peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 8° BTDC at idle
tion sensor Resistance (20° C/68° F) 4.0 – 6.0 Ω
LIGHTS/METER/SWITCHES SPECIFICATIONS
ITEM SPECIFICATION
Bulbs Headlight (Hi/low beam) 12 V - 35/35 W
Instrument light 12 V - 1.7 W x 3
Fuse Main 20A
Sub 15A
(20° C/68° F) Empty 90 - 100 Ω
21-9
CBF150M-5 ADDENDUM
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
(Include SH flange bolt) 6 mm flange bolt 12 (1.2, 9)
8 mm bolt and nut 22 (2.2, 16) (Include NSHF) and nut
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 26 (2.7, 20)
ENGINE & FRAME TORQUE VALUES


3. U-nut
ENGINE
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
Spark plug 1 10 16 (1.6, 12)
Timing hole cap 1 14 10 (1.0, 7)
Oil drain bolt 1 12 30 (3.1, 22)
LUBRICATION
THREAD TORQUE
ITEM Q'TY REMARKS
Oil pump plate screw 1 4 3 (0.3, 2.2)
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
SE valve lock nut 1 10 2.3 (0.2, 1.7)
Slow jet 1 5 1.5 (0.2, 1.1)
Main jet 1 5 2.1 (0.2, 1.6)
Float chamber screw 3 4 2.1 (0.2, 1.6)
Vacuum chamber cover screw 2 4 2.1 (0.2, 1.6)
Fuel valve lock nut 1 16 27 (2.8, 20)
21-10
CBF150M-5 ADDENDUM
CYLINDER HEAD/VALVES
THREAD TORQUE
ITEM Q'TY REMARKS
CYLINDER/PISTON
THREAD TORQUE
ITEM Q'TY REMARKS
THREAD TORQUE
ITEM Q'TY REMARKS
THREAD TORQUE
ITEM Q'TY REMARKS
Flywheel lock nut 1 14 74 (7.5, 55) NOTE 1
Starter clutch bolt 6 6 16 (1.6, 12) NOTE 2
Ignition pulse generator mounting bolt 2 6 12 (1.2, 9) NOTE 2
CRANKSHAFT/TRANSMISSION
THREAD TORQUE
ITEM Q'TY REMARKS
Mainshaft bearing setting plate bolt 2 6 12 (1.2, 9) NOTE 2
OTHERS
THREAD TORQUE
ITEM Q'TY REMARKS
21-11
CBF150M-5 ADDENDUM
EXHAUST PIPE STUD BOLT:
20.5 – 22.5 mm
(0.81 – 0.89 in)
Embed to incomplete thread

INSULATOR BAND SCREW:
7 – 9 mm
(0.3 – 0.4 in)
CYLINDER STUD BOLT:
113.4 – 115.4 mm
(4.46 – 4.54 in)
21-12
CBF150M-5 ADDENDUM
FRAME
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Brake/tail light unit mount nut 3 6 5.1 (0.5, 3.8)
Exhaust pipe stud bolt 2 8 11 (1.1, 8) page 21-12
THREAD TORQUE
ITEM Q'TY REMARKS
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
Spoke 36 BC3.5 3.7 (0.4, 2.7)
Handlebar lower holder nut 2 8 26 (2.7, 19) NOTE 3
Master cylinder holder bolt 2 6 9 (0.9,7)
Rear view mirror lock nut 2 10 34 (3.5, 25)
Fork cap 2 26 22 (2.2, 16)
Top bridge bolt 2 10 44 (4.5, 33)
Steering bearing adjustment nut 1 26 – page 12-29
REAR WHEEL/BRAKE/SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
Spoke 36 BC3.5 3.7 (0.4, 2.7)
Shock absorber mounting nut 2 10 44 (4.5, 33) NOTE 3
Swingarm pivot nut 1 14 54 (5.5, 40) NOTE 3,5
HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TY REMARKS
Master cylinder reservoir cap screw 2 4 1.2 (0.1, 0.9)
Brake caliper mounting bolt 2 8 30 (3.1, 22)
Front brake light switch screw 1 4 1.2 (0.1, 0.9)
21-13
CBF150M-5 ADDENDUM
IGNITION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
LIGHTS/METER/SWITCHES
THREAD TORQUE
ITEM Q'TY REMARKS
Fuel level sensor mounting nut 4 6 10 (1.0, 7)
21-14
CBF150M-5 ADDENDUM
LUBRICATION & SEAL POINTS
ENGINE
LOCATION MATERIAL REMARKS
Crankcase mating area Liquid sealant
Alternator wire grommet seating surface

Oil pump rotors Engine oil
Oil pump drive gear teeth
Camshaft lobes
Primary drive gear teeth
Primary driven gear teeth
Electric starter idle gear shaft entire surface
Electric starter idle gear teeth
Electric starter driven gear teeth
Transmission gear teeth
Each O-ring
Each dust seal lip Multi-purpose grease
Each oil seal lip
Valve stem sliding surface Molybdenum oil solution
Piston pin entire surface (a mixture of engine oil
Clutch outer guide entire surface and molybdenum disul-
Clutch outer rotating area fide grease in a ratio of
Kickstarter drive gear teeth 1:1)
Starter clutch rolling surfaces
Crankshaft connecting rod small end inner surface
M4, M5, C1, C2, C3 gear rotating surface
M4, M5, C1, C2, C3 gear bushing entire surface
M3, C4, C5 gear shift fork grooves
21-15
CBF150M-5 ADDENDUM
Shift drum stopper arm bolt threads Locking agent Coating width:
6.5 ± 1.0 mm from tip
Gear shift cam bolt threads Coating width:
Starter clutch bolt threads Coating width:
Ignition pulse generator mounting bolt threads Coating width:
Mainshaft bearing setting plate bolt threads Coating width:
Alternator stator wire guide bolt threads Coating width:
Crankshaft bearing push plug bolt threads Coating width:
21-16
CBF150M-5 ADDENDUM
FRAME
Steering head bearings Multi-purpose grease
Steering head cone race with extreme pressure
EXCELITE EP2 or equiva-
lent)
Axle bolt surface Multi-purpose grease
Front wheel dust seal lips
Rear wheel hub O-ring
area
Swingarm needle bearings
Swingarm pivot collar surface
Swingarm pivot dust seal cap lips
Swingarm pivot bolt and nut threads
Center stand pivot
Speedometer cable case inside
Speedometer gear inner surface and teeth
Clutch lever pivot
Brake lever pivot
Brake master cylinder push rod contacting area
Each dust seal lips
Each O-ring
(IDEMITSU AUTOLUB 30
or MECHANIC OIL 44 or
equivalent)
(SAE #80 – 90)
Brake master cylinder piston cups DOT3 or DOT4 brake fluid
Throttle cable case inside Molybdenum oil solution
Clutch cable case inside (a mixture of engine oil
and molybdenum disul-
fide grease in a ratio of
1:1)
Ignition switch mounting bolt threads
Fork oil seal lips
Handlebar grip inner surface Honda Bond A or equiva-
lent
21-17
CBF150M-5 ADDENDUM
CABLE & HARNESS ROUTING
LEFT HANDLEBAR
SWITCH WIRE
BRAKE HOSE
CLUTCH CABLE
THROTTLE
CABLE
CHOKE CABLE
RIGHT HANDLEBAR
SWITCH WIRE
IGNITION
SWITCH WIRE
SPPEEDOMETER
CABLE
LEFT HANDLEBAR
SWITCH 9P (BLACK)
CONNECTOR
COMBINATION METER LEFT HANDLEBAR

9P CONNECTOR SWITCH WIRE
CONNECTORS
TACHOMETER WIRE
CONNECTOR

CONNECTOR
21-18
CBF150M-5 ADDENDUM
FUEL LEVEL SENSOR WIRE CONNECTOR/

IGNITION PULSE GENERATOR WIRE CONNECTOR/
ALTERNATOR 2P CONNECTOR/
AIR
SUPPLY AIR SUCTION
IGNITION HOSE HOSE
COIL WIRE
RESONATOR
AIR CHAMBER
50 mm (1.97 in)
VACUUM HOSE
CRANKCASE
BREATHER
HOSE
ALTERNATOR/
IGNITION PULSE
GENERATOR WIRE AIR CLEANER HOUSING
DRAIN HOSE
NEUTRAL SWITCH
WIRE Drain hose shall be
BATTERY
installed along frame sub
BREATHER
tube in 50 mm (1.97 in)
HOSE
area.
21-19
CBF150M-5 ADDENDUM
Slant cut open

area facing THROTTLE SPARK PLUG
MAIN WIRE CHOKE
downward. CABLE WIRE
HARNESS CABLE
AIR VENT
HOSE
CLUTCH
STARTER CABLE
RELAY
SWITCH
STARTER MOTOR
CABLE
REAR BRAKE
LIGHT SWITCH 0° – 10°
WIRE CARBURETOR BATTERY CABLE
DRAIN HOSE
21-20
CBF150M-5 ADDENDUM
AIR CLEANER HOUSING
REMOVAL
Remove the following:
– fuel tank (page 2-4) BREATHER HOSE
– air cleaner element (page 3-7)
Loosen the air cleaner connecting boot band screw.
Disconnect the crank case breather hose.
BAND SCREW
Disconnect the resonator air chamber hose and air
cleaner housing drain hose. HOSE
DRAIN
HOSE
Remove the mounting bolts.

BOLTS
Disconnect the air vent hose from the carburetor

(page 5-7) and release the hose from the frame 2P CONNECTOR CLAMPS AIR VENT
clamps. HOSE
Disconnect the rear brake light switch 2P connector.

– starter relay switch (page 21-44)
– turn signal relay (page 17-19)
– air cleaner housing mounting bolt
Remove the air cleaner housing from right side.
AIR CLEANER
HOUSING BOLT
21-21
CBF150M-5 ADDENDUM
INSTALLATION
Install the air cleaner housing to the frame from
2P CONNECTOR CLAMPS AIR VENT
right side.
Install and tighten the mounting bolt. HOSE
Route all hoses as Install the following:

shown on page 21- – turn signal relay (page 17-19)
20. – starter relay switch (page 21-44)
Connect the air vent hose to the carburetor (page 5-
7) and clamp the hose to the frame.
Connect the rear brake light switch 2P connector.
AIR CLEANER
HOUSING BOLT
Install and tighten the mounting bolts.
BOLTS
While installing the Connect the resonator air chamber hose and air
drain hose, route cleaner housing drain hose. HOSE
the wire harness
properly page 21-
19.
DRAIN
HOSE
Carrying out as Connect the air cleaner connecting boot and tighten
shown that the the band screw. BAND SCREW
direction of the
BREATHER HOSE
Connect the crank case breather hose.
band screw.
Install the following:
– air cleaner element (page 3-7)
30°
21-22
CBF150M-5 ADDENDUM
SYSTEM COMPONENTS
54 N·m (5.5 kgf·m,

40 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
26 N·m (2.7 kgf·m,

19 lbf·ft)
21-23
CBF150M-5 ADDENDUM
SYSTEM COMPONENTS
74 N·m (7.5 kgf·m, 55 lbf·ft)
21-24
CBF150M-5 ADDENDUM
REMOVAL
Remove the fuel tank (page 2-4).
ALTERNATOR 2P
Disconnect the alternator 2P connector and ignition CONNECTOR
pulse generator wire connector.
IGNITION PULSE
GENERATOR WIRE
CONNECTOR
Remove the left crankcase rear cover (page 6-5).

Remove the neutral switch wire from the left crank- NEUTRAL
case grooves. SWITCH WIRE
Loosen the left crankcase cover bolts in a crisscross

pattern in several steps. LEFT CRANKCASE COVER
The left crankcase Remove the left crankcase cover bolts and cover.
cover (stater) is
magnetically
wheel, be careful to
remove.
BOLTS
Remove the dowel pins and gasket.
GASKET
DOWEL PINS
21-25
CBF150M-5 ADDENDUM
INSTALLATION
Install the new gasket and dowel pins.
GASKET
DOWEL PINS
The left crankcase Install the left crankcase cover and tighten the bolt
cover (stater) is in a crisscross pattern in several steps. LEFT CRANKCASE COVER
magnetically
wheel, be careful to
installation.
BOLTS
Route the neutral switch wire to the left crankcase
grooves. NEUTRAL
Install the left crankcase rear cover (page 6-8). SWITCH WIRE
Connect the alternator 2P connector and ignition

ALTERNATOR 2P
pulse generator wire connector.
CONNECTOR
IGNITION PULSE
GENERATOR WIRE
CONNECTOR
21-26
CBF150M-5 ADDENDUM
FLYWHEEL
REMOVAL
Remove the left crankcase cover (page 21-25).
COLLAR STARTER IDLE GEAR
Remove the collar, shaft and starter idle gear.
SHAFT
Hold the flywheel with the flywheel holder and

FLYWHEEL HOLDER NUT/ WASHER
remove the flywheel lock nut and washer.
TOOL:
Flywheel holder 07725-0040000
Remove the flywheel using the flywheel puller.

FLYWHEEL PULLER
TOOL:
Flywheel puller 07933-KM10001
FLYWHEEL
When remove the Remove the woodruff key and needle bearing.
woodruff key, be
NEEDLE BEARING
careful not to dam-
age the key groove
and crankshaft.
WOODRUFF KEY
21-27
CBF150M-5 ADDENDUM
INSTALLATION
When install the Clean any oil from the crankshaft taper.
woodruff key, be
NEEDLE BEARING
Install the needle bearing and woodruff key.
careful not to dam-
age the key groove
and crankshaft.
WOODRUFF KEY
Install the flywheel, while aligning the woodruff key

on the crankshaft with flywheel keyway.
Align
FLYWHEEL
Apply clean engine oil to the flywheel lock nut
FLYWHEEL HOLDER
threads and seating surface.
NUT/ WASHER
Install the washer and lock nut.
Hold the flywheel with the flywheel holder, tighten
the lock nut to the specified torque.
TOOL:
Apply clean engine oil to the starter idle gear and

shaft. COLLAR
STARTER IDLE GEAR
Install the starter idle gear, shaft and collar.
Install the left crankcase cover (page 21-26).
SHAFT
21-28
CBF150M-5 ADDENDUM
STARTER CLUTCH
DISASSEMBLY
Remove the flywheel (page 21-27).
STARTER DRIVEN GEAR
Remove the starter driven gear from the flywheel
while turning the driven gear counterclockwise.
Remove the starter clutch bolts while holding the

flywheel with a flywheel holder. BOLTS
TOOL:
FLYWHEEL
HOLDER
Remove the starter clutch assembly from the fly-

wheel. CLUTCH COVER
Remove the starter clutch cover.
STARTER CLUTCH
ASSEMBLY
Do not bend or tap Remove the following:

the plate when ROLLER GUIDE
– rollers SPRING
removing the spring
– spring guides
guides.
– springs
PLATE
21-29
CBF150M-5 ADDENDUM
INSPECTION
Check the spring for fatigue or damage.
Check the spring guides and rollers for wear or
damage.
SPRING
GUIDE
ROLLER
Check the roller contacting surface of the starter

driven gear for abnormal wear or damage.
Measure the starter driven gear boss O.D.
SERVICE LIMIT: 45.60 mm (1.795 in)
STARTER DRIVEN GEAR
ASSEMBLY
ONE-WAY CLUTCH
SPRING
ROLLER
GUIDE
FLYWHEEL
DRIVEN GEAR
NEEDLE BEARING
CLUTCH COVER
BOLTS 16 N·m (1.6 kgf·m, 12 lbf·ft)
21-30
CBF150M-5 ADDENDUM
Apply molybdenum oil solution to the rollers.
GUIDE SPRING
Do not bend or tap Install the following: ROLLER
the plate when – springs
installing the spring – spring guides
guides. – rollers
PLATE
Push the each roller and check the each roller,

spring guide and spring operation as follow: ROLLER ROLLER
– smooth operation of roller and spring guide SPRING SPRING
– spring is not bending
– spring guide is place in the plate as shown
GUIDE GUIDE
PLATE PLATE
Install the clutch cover and starter clutch assembly

to the flywheel, aligning the bolt hole of cover, CLUTCH COVER
starter clutch and flywheel.
STARTER CLUTCH
ASSEMBLY
Hold the flywheel using the flywheel holder.
TOOL: BOLTS
Clean and apply a locking agent to the starter clutch
bolt threads.
Install and tighten the starter clutch bolts to the
specified torque.
FLYWHEEL
HOLDER
21-31
CBF150M-5 ADDENDUM
Apply clean engine oil to the starter driven gear
teeth. STARTER DRIVEN GEAR
Install the starter driven gear to the flywheel while
turning the driven gear counterclockwise.
Make sure that the starter driven gear turns counter-
clockwise smoothly and does not turn clockwise.
Install the flywheel (page 21-28).
BATTERY
REMOVAL/INSTALLATION
Remove the left side cover (page 2-4).
POSITIVE (+) NEGATIVE (–)
Disconnect the negative (–) cable and then the posi- CABLE CABLE
tive (+) cable.
Disconnect the battery breather hose. BOLT
Remove the bolt and open the battery holder plate,
then remove the battery.
Connect the posi- Install the battery in the reverse order of removal.
tive cable first and
BREATHER
then the negative
cable.
HOSE
BATTERY
HOLDER PLATE
Make sure that the battery breather hose is correctly
away as to obstruct the passage of the air.
sure will not be relived, the breather may come
21-32
CBF150M-5 ADDENDUM
ELECTRIC STARTER
COMPONENT LOCATION
IGNITION STARTER SWITCH

SWITCH
STARTER
RELAY SWITCH
CLUTCH
SWITCH NUEUTRAL
DIODE
STARTER MOTOR
NEUTRAL SWITCH
ELECTRIC STARTER
SYSTEM DIAGRAM
21-33
CBF150M-5 ADDENDUM
ELECTRIC STARTER SERVICE INFORMATION
GENERAL
• Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious
injury.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting (page 21-35).
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
• Refer to the following:
– Starter clutch (page 21-29)
– Ignition switch (page 17-9)
– Starter switch (page 21-47)
– Neutral switch (page 17-12)
– Clutch switch (page 21-46)
SPECIFICATIONS
Unit: mm (in)
21-34
CBF150M-5 ADDENDUM
ELECTRIC STARTER TROUBLESHOOTING
Starter motor does not turn
1. Fuse Inspection
Check for blown fuse.
Is the fuse blown?
YES – Replace the fuse.
2. Battery Inspection
Make sure the battery is fully charged and in good condition.
Is the battery in good condition?
NO – Charge or replace the battery (page 21-32).
3. Battery Cable Inspection
Check the battery cables for loose or poorly connected terminal, and for an open circuit.
Is the battery cable in good condition?
YES – • Loose or poorly connected battery cables.
• Open circuit in the battery cable.
4. Starter Motor Cable Inspection
Check the starter motor cable for loose or poorly connected terminal, and for an open circuit.
Is the starter motor cable in good condition?
YES – • Loose or poorly connected starter motor cable.
• Open circuit in the starter motor cable.
5. Starter Relay Switch Operation Inspection
Check the operation of the starter relay switch (page 21-45).
Does the starter relay switch click?
6. Starter Motor Inspection
Connect the starter motor terminal to the battery positive terminal directly. (A large amount of cur-
rent flows, so do not use a thin wire.)
Does the starter motor turn?
YES – Faulty starter relay switch.
NO – Faulty starter motor.
7. Relay Coil Ground Line Inspection
Check the ground line of the starter relay switch (page 21-45).
Is the ground line normal?
NO – • Faulty neutral switch (page 17-12).
• Faulty neutral diode (page 21-46).
• Faulty clutch switch (page 21-46).
• Loose or poor contact of the related connector terminal.
• Open circuit in the wire harness.
21-35
CBF150M-5 ADDENDUM
8. Relay Coil Power Input Line Inspection
Check the power input line of the starter relay switch (page 21-45).
Is the power input line normal?
NO – • Faulty ignition switch (page 17-9).
• Faulty starter switch (page 21-47).
• Loose or poor contact of the related connector terminal.
• Open circuit in the wire harness.
9. Starter Relay Switch Inspection
Check the function of the starter relay switch (page 21-45).
Does the starter relay switch function properly?
NO – Faulty starter relay switch.
YES – Loose or poor contact of the starter relay switch connector.
Starter motor turns engine slowly

• Low battery voltage
• Poorly connected battery cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected ground cable terminal
Starter motor turns, but engine does not turn

• Starter motor is running backwards
– Case assembled improperly
– Terminals connected improperly
• Faulty starter clutch
• Damaged or faulty starter gear train
Starter relay switch clicks, but engine does not turn over
• Crankshaft does not turn due to engine problems
21-36
CBF150M-5 ADDENDUM
STARTER MOTOR
REMOVAL
Slide the rubber cap off the starter motor terminal,
and remove the terminal nut and starter motor STARTER RUBBER
cable. MOTOR CABLE CAP
Remove the two mounting bolts, ground cable and
starter motor from the crankcase. TERMINAL
NUT
GROUND
CABLE BOLTS
Remove the O-ring from the starter motor.
O-RING
DISASSEMBLY/INSPECTION
Remove the starter motor case bolts and O-rings.
BOLTS/O-RINGS
Record the location Remove the following:

SEAL RING INSULATED FRONT COVER
and number of
– front cover assembly WASHER
shims. The number
– seal ring
of the shims are dif-
– lock washer
ferent individually.
– insulated washer
– shims
SHIMS LOCK WASHER
21-37
CBF150M-5 ADDENDUM
Record the location Remove the following:
SEAL RING
and number of
– rear cover assembly
shims. The number
– seal ring
of the shims are dif-
– shims
ferent individually.
– armature
REAR COVER
ARMATURE SHIMS ASSEMBLY
Check the dust seal and needle bearing in the front
cover for deterioration, wear or damage.
DUST SEAL NEEDLE BEARING
Check for continuity between the cable terminal and

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

rear cover.
There should be no continuity.
21-38
CBF150M-5 ADDENDUM
SCREWS/
– springs BRUSH HOLDER
WASHERS
– screws/washers
– brush wire
– brush holder
BRUSH
WIRE
SPRINGS
Remove the Insulator plates.
INSULATOR PLATES

BRUSH/
– nut
TERMINAL
– washer INSULATORS
– insulators
– O-ring
– insulator plate
– brush/terminal
WASHER
O-RING
INSULATOR
NUT PLATE
Check the bushing in the rear cover for wear or
damage.
BUSHING
21-39
CBF150M-5 ADDENDUM
Measure the brush length.
Inspect the brush spring for excessive wear, fatigue

or damage, replace if necessary.
BRUSH SPRING
Do not use emery Inspect the commutator bars of the armature for
or sand paper on discoloration.
the commutator.
COMMUTATOR BARS
ARMATURE
Check for continuity between pair of commutator

bars.
These should be continuity.
21-40
CBF150M-5 ADDENDUM
Check for continuity between each commutator bar
and the armature shaft.
There should be no continuity.
ASSEMBLY
SHIMS
LOCK WASHER ARMATURE
SEAL RING INSULATED WASHER
FRONT COVER
O-RINGS
NUT
WASHER
SHIMS
BRUSH/ INSULATORS
TERMINAL
O-RING
REAR COVER
INSULATOR
PLATES
SPRING BRUSH HOLDER

MOTOR CASE SEAL RING

BRUSH/
– insulator plate
TERMINAL
– brush/terminal INSULATORS
– new O-ring
– insulators
– washer
– nut
WASHER
O-RING
INSULATOR
NUT PLATE
21-41
CBF150M-5 ADDENDUM
The insulator plate Tighten the nut.
will be damaged INSULATOR NUT
easily. Be careful PLATE
not to over tighten
the nut.
Install the insulator plates.
INSULATOR PLATES
Install the brush holder, washers and tighten the

screws with the brush wire. SCREWS/
BRUSH HOLDER
Install the springs into the brush holder. WASHERS
BRUSH
WIRE
SPRINGS
Install the shims Install the shims onto the armature shaft.
properly as noted
during removal.
SHIMS
21-42
CBF150M-5 ADDENDUM
Apply a thin coat of grease to the armature shaft
end. ARMATURE
Install the brushes into the brush holder.
Spread the brushes.
Be careful not to Install the armature into the rear cover assembly.
damage the brush
and armature.
BRUSHES
Install a new seal ring to the motor case.

ARMATURE/REAR COVER
The coil may be damaged if the magnet pulls the

armature against the case.
Align the rear cover Install the armature/rear cover into the motor case
tab with the motor while holding the armature tightly to keep the mag-
case groove. net of the case from pulling the armature against it.
Align
SEAL RING
Install the shims Install the shims and insulated washer onto the
INSULATED
properly as noted armature shaft. SEAL RING WASHER
during removal. Install a new seal ring onto the motor case.
Apply grease to the dust seal lip and needle bearing FRONT COVER
in the front cover.
Install the lock washer onto the front cover.
Install the front cover being careful not to damage
the dust seal lip.
SHIMS LOCK WASHER

Align the index lines on the front cover and motor
case.
O-RING
Install the new O-rings onto the motor case bolts.
Install the motor case bolts and tighten them.
BOLT
Align
21-43
CBF150M-5 ADDENDUM
INSTALLATION
Coat a new O-ring with clean engine oil and install it
into the starter motor groove.
O-RING
Install the starter motor into the left crankcase cover

and onto the crankcase. STARTER RUBBER
MOTOR CABLE CAP
Butt the stopper of Install the mounting bolts with the ground cable,
ground cable termi- and tighten the bolts.
nal against starter TERMINAL
motor, and then NUT
tighten with bolt.
While installing the Install the starter motor cable and terminal nut onto
starter motor cable, the motor terminal and tighten the nut.
route the wire har- Install the rubber cap over the motor terminal prop-
ness properly page erly.
21-20.
GROUND
CABLE BOLTS
STARTER RELAY SWITCH

Disconnect the negative (–) cable from the battery
(page 21-32).
Remove the right side cover (page 2-4).
Remove the bolt and starter relay switch stay.
STAY
BOLT
Disconnect the starter relay switch 4P (Red) connec-

tor. 4P (RED)
CONNECTOR
Remove the socket bolts, battery cable and starter
motor cable from the starter relay switch.
Remove the starter relay switch from the stay.
SOKET
BOLTS
STARTER RELAY
SWITCH STAY
21-44
CBF150M-5 ADDENDUM
OPERATION INSPECTION
Remove the right side cover (page 2-4).
Shift the transmission into neutral.
Turn the ignition switch to “ON” and push the
starter switch.
The coil is normal if the starter relay switch clicks.
If you don't hear the switch click, inspect the relay
switch circuits (page 21-45).
STARTER RELAY SWITCH
CIRCUIT INSPECTION
GROUND LINE
Turn the ignition switch to “OFF”.
Disconnect the starter relay switch 4P (Red) connec-
tor.
Check for continuity between the Green/Red wire
terminal of the wire harness side connector and
ground.
If there is continuity when the transmission is in
neutral or when the clutch lever is squeezed, the
ground circuit is normal.
4P (RED) CONNECTOR
POWER INPUT LINE

Connect the starter relay switch 4P (Red) connector.
Turn the ignition switch to “ON”.
Measure the voltage between the Yellow/Red wire
terminal (+) and ground (–).
If the battery voltage appears only when the starter
switch is pushed, the circuit is normal.
4P (RED) CONNECTOR
FUNCTION INSPECTION
Remove the starter relay switch (page 21-44).
Connect an ohmmeter to the starter relay switch Ω
cable terminals. STARTER
Connect the fully charged 12 V battery to the starter RELAY
relay switch connector terminals (A and B termi- SWITCH
nals).
There should be continuity between the cable termi-
nals while the battery is connected, and no continu- A B
ity when the battery is disconnected.
- +
BATTERY
21-45
CBF150M-5 ADDENDUM
NEUTRAL DIODE
INSPECTION
Remove the fuel tank (page 2-4).
NEUTRAL DIODE
Remove the neutral diode.
Check for continuity between the diode terminals.

When there is continuity, a small resistance value
will register.
If there is continuity in one direction, the diode is
normal.
A B
A
NEUTRAL DIODE
CLUTCH SWITCH
INSPECTION
Disconnect the clutch switch connectors.
CLUTCH SWITCH
There should be continuity with the clutch lever
applied, and there should be no continuity when the
clutch lever is released.
21-46
CBF150M-5 ADDENDUM
RIGHT HANDLEBAR SWITCHES
Remove the front cowl (page 2-3).
6P CONNECTOR
Disconnect the right handlebar switch 6P connector.
Check for continuity between the terminals in each

LIGHTING
switch position according to the table.
SWITCH
LIGHTING SWITCH
STARTER SWITCH
STARTER
SWITCH
21-47
CBF150M-5 ADDENDUM
WIRING DIAGRAM
21-48
22. CBF 150M-5SHOP
ADDENDUM
MANUAL - ADDENDUM
FRONT WHEEL ........................................ 22-2
REAR COWL ............................................. 22-8
22-1
Shop Manual - Unicorn (Oct. 05).p65 1 3/31/2007, 9:20 AM
SHOP MANUAL - ADDENDUM
FRONT WHEEL
REMOVAL SPEEDOMETER CABLE
Raise and support the motorcycle using safety stand or

a box.
Remove the speedometer cable while pushing the cable
tab.
Remove axle nut, U, 12 mm.
Remove the axle and front wheel.
NUT TAB
Remove the side collar.

SIDE COLLAR
Remove the speedometer gear box.

SPEEDOMETER
GEAR BOX
INSPECTION
Place the axle in V-blocks and measure the runout with
a dial indicator.
SERVICE LIMIT
LIMIT:: 0.2 mm (0.01 in)
22-2
Check the wheel rim runout by placing the wheel in a

turning stand.
Spin the wheel by hand and read the runout using a dial
indicator.
SERVICE LIMIT:
Axial: 1.0 mm (0.04 in)
RADIAL
Radial: 1.0 mm (0.04 in) READING
AXIAL
READING
Replace the Turn the inner race of each bearing with your finger,
bearings in pairs. the bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
hub.
Remove and discard the bearings if the races do not
turn smoothly, quietly, or if they fit loosely in the hub.
DISASSEMBLY
DUST SEAL
Remove the left dust seal from the left side of the front
wheel.
Remove the speedometer gear retainer.

RETAINER
22-3
Remove the right dust seal from the right side of the
front wheel.
DUST SEAL
Remove the hub brake disc assembly mounting nuts

BRAKE DISC HUB,BRAKE
and brake disc allen bolts.
DISC
ALLEN
BOLTS MOUNTING
NUTS
Install the bearing remover head into the bearing. From

the opposite side, install the bearing remover shaft and BEARING REMOVER SHAFT
drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
REMOVER HEAD
22-4
ASSEMBLY
SIDE COLLAR BRAKE DISC
BEARING (6301)
HUB
ALLEN BOLT RETAINER

42 N.m (4.3 kgf.m, 31 lbf.ft)
STUD DUST SEAL

MOUNTING NUT
15 N.m (1.5 kgf.m, 11 lbf.ft)
DUST SEAL
DISTANCE COLLAR
BEARING (6301) SPEEDOMETER

GEAR BOX
WHEEL CENTER ADJUSTMENT

Adjust the hub position so that the distance from the
left end surface of the hub center to the side of rim is
8.8 ± 1 mm (0.35 ± 0.04 in) as shown.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300
TORQUE: 3.7 N.m (0.4 kgf.m, 2.7 lbf.ft)
8.8 ± 1 mm
Check the rim runnout. BASE POINT (0.35 ± 0.04 in)
Never install the WHEEL ASSEMBLY

old bearing, once
Fully seated
DRIVER
the bearing has Pack all bearing cavities with grease.
been removed,
Drive in a new right bearing squarely with its sealed
the bearing must
be replaced with side facing up until it is fully seated.
new ones. Apply a thin coat of grease to the distance collar and
install it. DISTANCE
COLLAR
Drive in a new left bearing squarely with its sealed side
facing up.
TOOLS:
Pilot, 12 mm 070GD-004I130 BEARINGS ATTACHMENT PILOT
22-5
Do not get Install and tighten the hub brake disc assembly
grease on the BRAKE DISC HUB,BRAKE
mounting nuts in a crisscross pattern in 2 or 3 steps.
brake disc or DISC
stopping power TORQUE: 15 N.m (1.5 kgf.m, 11 lbf.ft)
will be reduced.
Install and tighten the allen bolts in a crisscross pattern
in 2 or 3 steps.
TORQUE: 42 N.m (4.3 kgf.m, 31 lbf.ft)
ALLEN
BOLTS MOUNTING
NUTS

Install the dust seal to the right wheel hub.
DUST SEAL
Install the speedometer gear retainer to the wheel hub,

while aligning the tabs on the retainer with the slots on RETAINER
the hub.
Align

Install the dust seal to the left wheel hub.
DUST SEAL
22-6
INSTALLATION
Install the speedometer gear box into the left wheel SPEEDOMETER
hub, while aligning the tabs with the slots. GEAR BOX
Align
Install the side collar into the right wheel hub.

SIDE COLLAR
Be careful not to Install the front wheel between the fork legs, while
damage the aligning the speedometer gear box groove with the boss
pads. on the fork leg so that the brake disc is positioned
between the pads. FRONT AXLE
Align
Install and tighten the axle nut to the specified torque.

SPEEDOMETER CABLE
Install the speedometer cable to the speedometer gear
box.
NUT TAB
22-7
REAR GRIP REAR GRIP
REMOVAL
Remove the seat.
Remove the mounting bolts and rear grip.
REAR COWL REAR COWL ASSY.

REMOVAL
- right side cover
- left side cover
Remove the two rear cowl mounting bolts.
Raise the rear cowl assembly and disconnect the brake/
tail light 3P connector.
Remove the rear cowl assembly.
DISASSEMBLY
CENTER REAR COWL
Remove two bolt flange and center rear cowl.
Remove the nuts, washers and brake/tail light unit.

BRAKE/
Remove the screws and separate the right/left rear TAIL LIGHT
cowl from Stay, tail light. UNIT
RIGHT LEFT
REAR REAR
COWL COWL
STAY,
TAIL
LIGHT
22-8
ASSEMBLY
RUBBER
Fit rubber stopper on Stay, Tail Light.
STOPPER
STAY, TAIL LIGHT
Fit three cushions on Stay, Tail Light.

CUSHION
Fit three collars on Stay, Tail Light after fitment of

cushions.
COLLAR
Assemble LH and RH rear cowl on Stay, tail light.
22-9
Assemble tail lamp on Stay, Tail Light.

Tighten all 3 nuts to complete the assembly.
TAIL LAMP
Turn the cowl upside down.

Install center rear cowl and tighten the two bolt flange.
The bolt flange must be first lightly tightened and at the
time of assembling on vehicle, it must be fully tightened.
While installing Connect the brake/tail light 3P connector.

the rear cowl,
route the wire Install rear cowl assembly on the vehicle.
harness properly.
Install the rear grip.

Install the seat on the vehicle.
22-10
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the
vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the
reliability of the vehicle. Any error or oversight while servicing a vehicle can
result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an
For Your Safety unsafe condition that can cause your customer
or others to be seriously hurt or killed.
Because this manual is intended for the professional service technician, we do
Follow the procedures and precautions in this
not provide warnings about many basic shop safety practices (e.g., Hot
manual and other service materials carefully.
parts–wear gloves). If you have not received shop safety training or do not feel
confident about your knowledge of safe servicing practice, we recommended
that you do not attempt to perform the procedures described in this manual.
Failure to properly fol low instructions and
Some of the most important general service safety precautions are given below. precautions can cause you to be seriously hurt
However, we cannot warn you of every conceivable hazard that can arise in or killed.
performing service and repair procedures. Only you can decide whether or not Follow the procedures and precautions in this
you should perform a given task. manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using
safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
INTRODUCTION
This addendum contains the information for the CBF150M-5.
Refer to CBF150 MANUAL (No.62KSPAM5) for service procedures and data not included in this addendum.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
•Safety Labels – on the vehicle
•Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
•Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED
ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd.
RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION
WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL
IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,
MOTOR SCOOTERS OR ATVS.
Honda Motorcycle & Scooter India Pvt. Ltd.

SERVICE DEPARTMENT
Date of Issue: March, 2007

Honda Motorcycle & Scooter India Pvt. Ltd.
23. CBF 150M-5 ADDENDUM
MODEL IDENTIFICATION ................................................. 23-4
GENERAL SPECIFICATION .............................................. 23-6
CABLE & HARNESS ROUTING FRONT COWL ............. 23-20
FRONT COWL / WIND SCREEN ...................................... 23-26
RIGHT SIDE COVER / LEFT SIDE COVER ....................... 23-27
FRONT WHEEL .................................................................. 23-29
REAR WHEEL ..................................................................... 23-35

MODEL IDENTIFICATION
23-4
The frame serial number is stamped on the right side of the

steering head.
VEHICLE IDENTIFICATION NUMBER
The engine serial number is stamped on the lower left side of

the crankcase.
ENGINE SERIAL NUMBER
The carburetor identification number is stamped on the left side of the

carburetor body.
CARBURETOR IDENTIFICATION NUMBER
The color label is attached as shown. When ordering color-coded parts,

always specify the designated color code. COLOR LABEL
23-5
ITEM SPECIFICATION
DIMENSIONS Overall length 2,095 mm (82.5 in)
Overall width 750 mm (29.6 in)
Overall height 1,100 mm (43.3 in)
Wheelbase 1,340 mm (52.8 in)
Seat height 798 mm (31.5 in)
Footpeg heigh 301 mm (11.9 in)
Ground clearance 179 mm (7.1 in)
Dry weight 134 kg (295.5 lbs)
Curb weight 146 kg (322 lbs)
Maximum weight capacity 170 kg (375 lbs)
FRAME Frame type Diamond type
Front wheel travel 117 mm (4.6 in)
Rear suspension Swingarm
Rear wheel travel 97 mm (4.0 in)
Rear damper Both side operation
Rear tire size 100/90-18 56P
Front tire brand MRF NYLOGRIP ZAPPER - FS
Rear tire brand MRF NYLOGRIP ZAPPER - Y
Rear brake Mechanical drum (leading-trailing)
Caster angle 26× 00’
Trail length 95 mm (3.8 in)
Fuel tank capacity 13.0 liter (3.43 US gal, 2.86 lmp gal)
Fuel tank reserve capacity 1.0 liter (0.26 US gal, 0.22 lmp gal)
ENGINE Cylinder arrangement Single cylinder inclined 15× from vertical
Bore and stroke 57.3 x 57.8 mm (2.26 x 2.28 in)
Displacement 149.2 cm3 (9.10 cu-in)
Compression ratio 9.1:1
Valve train Chain driven OHC with rocker arm
Intake valve opens at 1 mm (0.04 in) lift 7× BTDC
closes at 1 mm (0.04 in) lift 28× ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 27× BBDC
closes at 1 mm (0.04 in) lift 3× ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Engine dry weight 30.1 kg (66.4 lbs)
CARBURETOR Carburetor type CV (constant velocity) type
Throttle bore 26 mm (1.02 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Transmission 5 speeds
Primary reduction 3.350 (67/20)
Gear ratio 1st 3.076 (40/13)
2nd 1.789 (34/19)
3rd 1.304 (30/27)
4th 1.090 (24/22)
5th 0.937 (30/32)
1-N-2-3-4-5
Starting system Electric starter motor/Kickstarter
Regulator/rectifier SCR shorted, single phase half-wave
rectification
23-6
LUBRICATION SYSTEM SPECIFICATION

Engine oil capacity After draining 1.0 liter (1.1 US qt, 0.9 lmp qt) –
After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) –
Recommended engine oil Honda 4-stroke oil or equivalent motor oil –
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.20 (0.006 – 0.008) 0.25 (0.010)
Side clearance 0.05 – 0.11 (0.002 – 0.004) 0.15 (0.006)
FUEL SYSTEM SPECIFICATION

ITEM SPECIFICATIONS
Carburetor identification number AVK4FA
Main jet #115
Slow jet #38
Pilot screw initial opening 1.1/2 Turn out
Float level 13.0 mm (0.51 in)
Idle speed 1,400 ± 100 min-1 (rpm)
Throttle grip free play 2 – 7 mm (0.08 – 0.24 in)
PAIR control valve specified vacuum 58.7 kPa (440 mm Hg)
CYLINDER HEAD/VALVES SPECIFICATIONS

Cylinder compression at 1,000 min-1 (rpm) 1,402 kPa (14.3 kgf/cm2, 203 psi) –
EX 0.12 (0.005) –
Valve,
valve guide Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.92 (0.194)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)
Valve seat width IN/EX 0.9 – 1.1 (0.035 – 0.043) 1.5 (0.06)
OUTER 35.95 (1.415) 35.14 (1.383)
Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm-to-shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
Camshaft Cam lobe height IN 32.994 – 33.234 (1.2990 – 1.3084) 32.96 (1.298)
EX 32.880 – 33.120 (1.2945 – 1.3039) 32.85 (1.293)
Cylinder head warpage – 0.05 (0.002)
23-7
CYLINDER/PISTON SPECIFICATONS
Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Second 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.85 (0.033)
Connecting rod small end I.D. 14.010 – 14.028 (0.5516 – 0.5523) 14.06 (0.554)
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SPECIFICATIONS

Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.6 (0.10)
Plate warpage – 0.20 (0.008)
Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909)
I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.60 (1.795)
23-8
CRANKSHAFT/TRANSMISSION SPECIFICATIONS
Crankshaft Runout 0.03 (0.001) 0.08 (0.003)
Connecting rod big end radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
Connecting rod big end side clearance 0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032)
Transmission Gear I.D. M4, M5 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)
C2 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C3 23.025 – 23.046 (0.9065 – 0.9073) 23.07 (0.908)
Bushing O.D. M4, M5 19.959 – 19.980 (0.7858 – 0.7866) 19.91 (0.784)
C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)
C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)
Gear-to-bushing M4, M5, C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance C2 0.015 – 0.057 (0.0006 –0.0022) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Bushing I.D. M4, C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
Mainshaft / M4, C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667)
countershaft C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785)
O.D. C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785)
Bushing-to-shaft M4, C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
shift fork shaft Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)
23-9
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Cold tire Driver only 175 kPa (1.75 kgf/cm², 25 psi) –
pressure Driver and passenger 175 kPa (1.75 kgf/cm², 25 psi) –
Fork Spring free length 481 (18.94) 458 (18.0)
Pipe runout – 0.20 (0.008)
Recommended fluid Fork fluid (Honda ultra cusion oil) –
Fluid capacity 158 ± 1.0 cm³ (5.23 ± 0.03 US oz, –
5.43 ± 0.04 lmp oz)
REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Cold tire pressure Driver only 200 kpa (2.00 kgf/cm², 29 psi) –
Driver and passenger 200 kpa (2.00 kgf/cm², 29 psi) –
Axial – 1.0 (0.04)
Drive chain
Size/link 428/126 –
Slack 20 – 30 (0.8 – 1.2) –
Drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)

Master cylinder I.D. 12.000 – 12.043 (0.4724 – 0.4741) 12.055 (0.4746)
Master piston O.D. 11.957 – 11.984 (0.4707 – 0.4718) 11.945 (0.4703)
23-10
BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Battery Capacity 12 V – 7 Ah
Current leakage 0.1 mA max.
Specific gravity Fully charged 1.270 – 1.290
(20×C/68×F) Needs charging Below 1.230
Charging current
Normal 0.7 A/5 – 10 h
Quick 7 A/0.5 h
Alternator Capacity 0.130 kW/5,000 min-1 (rpm)
Charging coil resistance (20×C/68×F) 0.2 – 1.0 Ω
ELECTRIC STARTER SPECIFICATIONS


ITEM SPECIFICATION
Spark plug Standard CPR8EA-9 (NGK) or UR5DC (BOSCH)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil primary peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 8× BTDC at idle
Throttle position Input voltage 4.75 – 5.25 V
sensor Resistance (20×C/68×F) 4.0 – 6.0 Ω
LIGHTS/METER/SWITCHES SPECIFICATIONS
ITEM SPECIFICATION
Bulbs Headlight (Hi/low beam) 12 V - 35/35 W
Instrument light 12 V - 1.7 W x 3
Fuse Main 20A
Sub 15A
(20×C/68×F) Empty 90 - 96 Ω
23-11

FASTENER TYPE TORQUE FASTENER TYPE TORQUE
5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
(Include SH flange bolt) 6 mm flange bolt 12 (1.2, 9)
8 mm bolt and nut 22 (2.2, 16) (Include NSHF) and nut
ENGINE & FRAME TORQUE VALUES

NOTE
3. U-nut
ENGINE
MAINTENANCE
ITEM Q'TY THREAD TORQUE REMARKS
Spark plug 1 10 16 (1.6, 12)
Timing hole cap 1 14 10 (1.0, 7)
Oil drain bolt 1 12 30 (3.1, 22)
LUBRICATION
Oil pump plate screw 1 4 3 (0.3, 2.2)
FUEL SYSTEM
SE valve lock nut 1 10 2.3 (0.2, 1.7)
Slow jet 1 5 1.5 (0.2, 1.1)
Main jet 1 5 2.1 (0.2, 1.6)
Float chamber screw 3 4 2.1 (0.2, 1.6)
Vacuum chamber cover screw 2 4 2.1 (0.2, 1.6)
Fuel valve lock nut 1 16 27 (2.8, 20)
23-12
CYLINDER HEAD/VALVES
CYLINDER/PISTON
Flywheel lock nut 1 14 74 (7.5, 55) NOTE 1
Starter clutch bolt 6 6 16 (1.6, 12) NOTE 2
Ignition pulse generator mounting bolt 2 6 12 (1.2, 9) NOTE 2
CRANKSHAFT/TRANSMISSION
Mainshaft bearing setting plate bolt 2 6 12 (1.2, 9) NOTE 2
OTHERS
23-13
EXHAUST PIPE STUD BOLT: 20.5 – 22.5 mm

(0.81 – 0.89 in)
INSULATOR BAND SCREW: 7 – 9 mm

(0.3 – 0.4 in)
CYLINDER STUD BOLT:
113.4 – 115.4 mm
(4.46 – 4.54 in)
23-14
FRAME
FRAME/BODY PANELS/EXHAUST SYSTEM
Brake/tail light unit mount nut 3 6 5.1 (0.5, 3.8)
Exhaust pipe stud bolt 2 8 11 (1.1, 8)
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
Handlebar lower holder nut 2 8 26 (2.7, 19) NOTE 3
Master cylinder holder bolt 2 6 9 (0.9,7)
Rear view mirror lock nut 2 10 34 (3.5, 25)
Fork cap 2 26 22 (2.2, 16)
Top bridge bolt 2 10 44 (4.5, 33)
Steering bearing adjustment nut 1 26 3.4
REAR WHEEL/BRAKE/SUSPENSION

Shock absorber mounting nut 2 10 44 (4.5, 33) NOTE 3
Swingarm pivot nut 1 14 54 (5.5, 40) NOTE 3
HYDRAULIC BRAKE
Master cylinder reservoir cap screw 2 4 1.2 (0.1, 0.9)
Brake caliper mounting bolt 2 8 30 (3.1, 22)
Front brake light switch screw 1 4 1.2 (0.1, 0.9)
23-15
CARBURETOR
LIGHTS/METER/SWITCHES
Fuel level sensor mounting nut 4 6 10 (1.0, 7)
23-16

ENGINE
Crankcase mating area Liquid sealant
Alternator wire grommet seating surface

Oil pump rotors Engine oil
Oil pump drive gear teeth
Camshaft lobes
Primary drive gear teeth
Primary driven gear teeth
Electric starter idle gear shaft entire surface
Electric starter idle gear teeth
Electric starter driven gear teeth
Transmission gear teeth
Each O-ring
Each dust seal lip Multi-purpose grease
Each oil seal lip
Valve stem sliding surface Molybdenum oil solution
Piston pin entire surface (a mixture of engine oil
Clutch outer guide entire surface and molybdenum disulfide
Clutch outer rotating area grease in a ratio of 1:1)
Kickstarter drive gear teeth
Starter clutch rolling surfaces
Crankshaft connecting rod small end inner surface
M4, M5, C1, C2, C3 gear rotating surface
M4, M5, C1, C2, C3 gear bushing entire surface
M3, C4, C5 gear shift fork grooves
23-17

Shift drum stopper arm bolt threads Locking agent Coating width:
Gear shift cam bolt threads Coating width:
Starter clutch bolt threads Coating width:
Ignition pulse generator mounting bolt threads Coating width:
Mainshaft bearing setting plate bolt threads Coating width:
Alternator stator wire guide bolt threads Coating width:
Crankshaft bearing push plug bolt threads Coating width:
23-18
FRAME
Steering head bearings Multi-purpose grease
Steering head cone race with extreme pressure
EXCELITE EP2 or equivalent)
Axle bolt surface Multi-purpose grease
Front wheel dust seal lips
Rear wheel hub O-ring
area
Swingarm needle bearings
Swingarm pivot collar surface
Swingarm pivot dust seal cap lips
Swingarm pivot bolt and nut threads
Center stand pivot
Speedometer cable case inside
Speedometer gear inner surface and teeth
Clutch lever pivot
Brake lever pivot
Brake master cylinder push rod contacting area
Each dust seal lips
Each O-ring
(IDEMITSU AUTOLUB 30
or MECHANIC OIL 44 or
equivalent)
(SAE #80 – 90)
Brake master cylinder piston cups DOT3 or DOT4 brake fluid
Throttle cable case inside Molybdenum oil solution
Clutch cable case inside (a mixture of engine oil
and molybdenum disul
fide grease in a ratio of 1:1)
Ignition switch mounting bolt threads
Fork oil seal lips
Handlebar grip inner surface Honda Bond A or equivalent
23-19
CABLE & HARNESS ROUTING FRONT COWL
LEFT INNER PANEL RIGHT INNER PANEL
LEFT FRONT TURN

SIGNAL LIGHT WIRE
RIGHT FRONT TURN
SIGNAL LIGHT WIRE
HEADLIGHT/FRONT TURN
SIGNAL LIGHT WIRE
23-20
LEFT HANDLEBAR
SWITCH WIRE
BRAKE HOSE
THROTTLE
CABLE
CLUTCH CABLE
RIGHT HANDLEBAR
SWITCH WIRE
PASSING
CHOKE CABLE
RELAY
IGNITION
SWITCH WIRE
LEFT HANDLEBAR
SWITCH 9P (BLACK
SPEEDOMETER CONNECTOR)
CABLE
LEFT HANDLEBAR
SWITCH WIRE
COMBINATION METER CONNECTORS
9P CONNECTOR
TECHOMETER WIRE
CONNECTOR

CONNECTOR
23-21
FRAME
CLUTCH CABLE
HORN WIRE
CHOKE CABLE
CHOKE CABLE
SPEEDOMETER
CABLE
23-22
RIGHT HANDLEBAR
SWITCH WIRE BRAKE HOSE
FRAME
MAIN WIRE
HARNESS
THROTTLE
CABEL
THROTTLE
CABLE
MAIN WIRE THROTTLE

HARNESS CABLE
HT LEAD
BRAKE HOSE
CLUTCH CABLE
23-23
THROTTLE
MAIN WIRE CHOKE CABLE
HARNESS CABLE
HT LEAD
AIR VENT
HOSE
WINKER
RELAY
CLUTCH
CABLE
SWITCH ASSY.
STARTER RR. STOP
RELAY
0o - 10o
FUEL TANK
OVER FLOW HOSE BATTERY DRAIN
FUEL TANK
HOSE
BREATHER HOSE
23-24
IGNITION
CONTROL
MODULE
(ICM)
RIGHT REAR TURN

REGULATROR/
SIGNAL LIGHT WIRE
RECTIFIER
SUB FUSE (15A)
MAIN WIRE HARNESS
MAIN FUSE (20A)
23-25
FRONT COWL
FRONT
COWL SCREWS
Remove the front cowl mounting screws and bolt.
Remove the front cowl and disconnect the head-
light/turn signal light 6P (Black) connector.
Remove the bolts and number stay from the front
cowl.
Installation is in the reverse order of removal.
STAY
6P CONNECTOR
BOLTS BOLT
WIND SCREEN SCREWS
Remove the front cowl.
Remove the screws and wind screen.
23-26
SCREW B
RIGHT SIDE COVER SCREW A
REMOVAL/INSTALLATION A B
Remove the seat.

Remove the right side cover mounting screws.
Release the side cover bosses from the fuel tank.
Remove the right side cover.
Installation is in the reverse order of removal. LUG
RIGHT SIDE COVER SCREW
LEFT SIDE COVER

LEFT SIDE
REMOVAL/INSTALLATION COVER A B
Remove the seat.

Remove the right side cover mounting screws.
Release the side cover bosses from the fuel tank.
Remove the left side cover.
SCREW B
LUG
SCREW SCREW A
23-27
HANDLE BAR
UPPER HOLDERS
Loosen the handlebar lower holder nuts.
LOWER HOLDERS LOWER NUT
Remove the four caps
CAP
Remove allenkey bolts, handlebar upper holders and

handlebar from the top bridge.
ALLEN BOLTS
Temporarily tighten the handlebar lower holder nuts.

Place the handlebar to the top bridge.
Place the handlebar holders with the punch marks facing
forwards and install the holder bolts.
Align the punch mark on the handlebar with the mating
surface of the lower holder.
Tighten the forward allenkey bolts then the rear bolts.
TORQUE : 26 N.m (2.7 kgf.m, 19 lbf.ft)
Tighten the handlebar lower holder nuts.
TORQUE : 26 N.m (2.7 kgf.m, 19 lbf.ft)
23-28
FRONT WHEEL
REMOVAL SPEEDOMETER CABLE
Raise and support the motorcycle using safety stand or
a box.
Remove the speedometer cable while pushing the cable
tab.
Remove axle nut, U, 19 mm.
Remove the axle and front wheel. NUT
TAB
Remove the side collar.

SIDE COLLAR
Remove the speedometer gear box.
SPEEDOMETER
GEAR BOX
INSPECTION
Place the axle in V-blocks and measure the runout with
a dial indicator.
23-29

Service Limit
Limit:: 0.2 mm (0.01 in)
Check the wheel rim runout by placing the wheel in a
turning stand. Spin the wheel by hand and read the
runout using a dial indicator.
SERVICE LIMIT:
RADIAL
Axial: 1.0 mm (0.04 in) READING
AXIAL
READING
Replace the Turn the inner race of each bearing with your finger,
bearings in pairs. the bearing should turn smoothly and quietly
Also check that the bearing outer race fits tightly in the
hub.
Remove and discard the bearings if the races do not
turn smoothly, quietly, or if they fit loosely in the hub.
DISASSEMBLY
DUST SEAL
Remove the left dust seal from the left side of the front
wheel.
Remove the speedometer gear retainer.

RETAINER
23-30
Remove the right dust seal from the right side of the
front wheel.
DUST SEAL
Remove the hub brake disc assembly mounting nuts

and brake disc allen bolts. BRAKE DISC
ALLEN
BOLTS
Install the bearing remover head into the bearing. From

the opposite side, install the bearing remover shaft and BEARING REMOVER SHAFT
drive the bearing out of the wheel hub.
bearing.
TOOLS:
REMOVER HEAD
23-31
ASSEMBLY
SIDE COLLAR
BRAKE DISC
○
BEARING (6301)
○
RETAINER
○
ALLEN BOLT
○
42 N.m (4.3 kgf.m, 31 lbf.ft) ○
○
DUST SEAL
○
DUST SEAL
○
DISTANCE COLLAR ○
SPEEDOMETER
BEARING (6301) GEAR BOX
Never install the WHEEL ASSEMBLY DRIVER

old bearing, once
Fully seated
the bearing has Pack all bearing cavities with grease.
been removed,
Drive in a new right bearing squarely with its sealed
the bearing must
be replaced with side facing up until it is fully seated.
new ones. Apply a thin coat of grease to the distance collar and
COLLAR
Drive in a new left bearing squarely with its sealed side
facing up.
TOOLS:
Attachment, 37 x 40 mm 070GD-002I150 ATTACHMENT PILOT
Pilot, 12 mm 070GD-004I130 BEARINGS
Do not get Install and tighten the allen bolts in a crisscross pattern
grease on the in 2 or 3 steps. BRAKE DISC
brake disc or
stopping power TORQUE: 42 N.m (4.3 kgf.m, 32 lbf.ft)
will be reduced.
ALLEN
BOLTS
23-32

Install the dust seal to the right wheel hub.
DUST SEAL
Install the speedometer gear retainer to the wheel hub,

RETAINER
while aligning the tabs on the retainer with the slots on
the hub.
SPEEDOMETER
GEAR BOX

DUST SEAL
Install the dust seal to the left wheel hub.
23-33
INSTALLATION
Install the speedometer gear box into the left wheel
hub, while aligning the tabs with the slots.
Align
SPEEDOMETER
GEAR BOX
Install the side collar into the right wheel hub. SIDE COLLAR
Be careful not to Install the front wheel between the fork legs, while
damage the aligning the speedometer gear box groove with the boss
pads. on the fork leg so that the brake disc is positioned
between the pads.
FRONT AXLE
Install and tighten the axle nut to the specified torque.

Install the speedometer cable to the speedometer gear SPEEDOMETER CABLE
box.
NUT
TAB
23-34
REAR WHEEL COTTER PIN
REMOVAL CUSHION STOPPER

Raise the rear wheel off the ground by placing a work RUBBER ARM
stand or box under the frame.
- Cotter pin
- Joint nut
- Washer
- Cushion rubber BOLT
- Joint bolt
- Brake panel stopper arm NUT
WASHER
Disconnect the brake rod by removing the adjusting

nut, and remove the spring and joint pin. AXLE NUT
Remove the axle nut. ADJUSTING
NUT
ROD
JOINT PIN SPRING
Remove the axle, collar and right side adjusting plate.

COLLAR AXLE
ADJUSTING
PLATE
Remove the damper rubber and O-ring

DAMPER RUBBERS
O-RING
23-35
Remove the brake panel.
BRAKE PANEL
INSPECTION
AXLE
Set the axle in V-blocks. Turn the axle and measure the
runout using a dial indicator.
Actual runout is 1/2 the total indicator reading.
Replace the WHEEL BEARING

bearings in pairs.
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the hub.
Remove and discard the bearings if they do not turn
smoothly, quietly, or if they fit loosely in the hub.
WHEEL RIM
Check the rim runout by placing the wheel in a turning
stand.
Spin the wheel by hand, and read the runout using a
dial indicator.
SERVICE LIMIT:
Radial:1.0 mm (0.04 in)
Axial: 1.0 mm (0.04 in)
23-36
DISASSEMBLY BEARING
WHEEL BEARING REMOVER SHAFT
Install the remover head into the bearing.
From the opposite side of the wheel, install the bearing
remover shaft and drive the bearing out of the wheel
hub.
bearing.
TOOLS:
Bearing remover head,15mm 070SRTKSP012
ASSEMBLY
BEARING (6302)
DAMPER RUBBER
BEARING (6302)
DISTANCE COLLAR
O-RING
WHEEL BEARING DRIVER

Fully seated
Pack new bearing cavities with grease.
Drive in a new right side bearing squarely with the sealed
side facing up until it is fully seated.
Apply a thin coat of grease to the distance collar and
COLLAR
Drive in a new left side bearing with the sealed side
facing up.
TOOLS:
Attachment, 42 x 47 mm 070GD-002I160 ATTACHMENT PILOT
Pilot, 15 mm 07746-0040300 BEARINGS
23-37
Do not get grease INSTALLATION

on the brake drum BRAKE PANEL
and shoe linings.
Install the brake panel.
Apply grease to a new O-ring.

Install the O-ring and damper rubbers. DAMPER RUBBERS
O-RING
Apply a thin coat of grease to the axle outer surface. COLLAR AXLE
Insert the axle from the left side through the adjusting
plate, swingarm, rear wheel and collar.
ADJUSTING
PLATE
Install the axle nut.

Tighten the axle nut to the specified torque. AXLE NUT
ADJUSTING
NUT
Install the spring onto the brake rod and the joint pin
into the brake arm. Connect the brake rod to the brake
arm with the adjusting nut.
ROD
JOINT PIN SPRING
23-38

- joint bolt COTTER PIN
- brake panel stopper arm
- cushion rubber CUSHION STOPPER
- washer RUBBER ARM
Install and tighten the rear brake stopper arm joint nut.
Install the new cotter pin.
Adjust the brake pedal free play.
BOLT
NUT
WASHER
23-39

HONDA - CBF 150 - Taller

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@&'! IBUU! 41! XBUU=<! &%! F=?B;SFU@

SERVICE RULES ············································ 1-2 REAR WHEEL/ BRAKE/ SUSPENSION

FUEL SYSTEM SPECIFICATIONS················· 1-5 IGNITION SYSTEM SPECIFICATIONS ··········1-9

CYLINDER HEAD/ VALVES LIGHTS/ M ETER/ SWITCHES

CYLINDER/ PISTON SPECIFICATIONS ········· 1-6 STANDARD TORQUE VALUES ···················1-10

CLUTCH/ GEARSHIFT LINKAGE/ ENGINE & FRAM E TORQUE VALUES ········1-10

FRONT WHEEL/ SUSPENSION/ EM ISSION CONTROL SYSTEM S ················1-25

FRAM E SERIAL NUM BER

CARBURETOR IDENTIFICATION NUM BER

FUEL SYSTEM SPECIFICATIONS

CYLINDER HEAD/ VALVES SPECIFICATIONS

CLUTCH/ GEARSHIFT LINKAGE/ KICKSTARTER SPECIFICATIONS

REAR WHEEL/ BRAKE/ SUSPENSION SPECIFICATIONS

HYDRAULIC BRAKE SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

LIGHTS/ M ETER/ SWITCHES SPECIFICATIONS

ENGINE & FRAM E TORQUE VALUES

1. Apply engine oil to the threads and seating surface.

Em bed to incom plete thread

CYLINDER STUD BOLT:

Em bed to incom plete thread

FRONT WHEEL/ BRAKE/ SUSPENSION/ STEERING

LIGHTS/ M ETER/ SWITCHES

Alternator w ire grom m et seating surface

RIGHT FRONT TURN

Clam p the w hite

TACHOM ETER WIRE

RIGHT HANDLEBAR HEADLIGHT/FRONT TURN

M AIN WIRE THROTTLE

AIR CLEANER HOUSING

Slant cut open

SUB FUSE (10A)

M AIN WIRE HARNESS

M AIN FUSE (15A)

TURN SIGNAL BATTERY (-) WIRE BATTERY (+) WIRE

LEFT REAR TURN

PAIR CONTROL RESONATOR

SERVICE INFORM ATION ······························ 2-2 FUEL TANK·····················································2-4

TROUBLESHOOTING ···································· 2-2 FRONT FENDER··············································2-5

FRONT COWL ················································ 2-3 REAR GRIP······················································2-6

WIND SCREEN ··············································· 2-3 REAR COWL····················································2-6

SEAT······························································· 2-3 REAR FENDER ················································2-8

RIGHT SIDE COVER······································· 2-4 SAREE GUARD ···············································2-8

LEFT SIDE COVER ········································· 2-4 EXHAUST PIPE/ M UFFLER·····························2-9

RIGHT SIDE COVER SCREW

LEFT SIDE COVER

Rem ove the nuts, w ashers and brake/tail light unit.

RIGHT REAR SCREWS

Alw ays inspect the Tighten the m uffler m ounting bolt.

STUD BOLT REPLACEM ENT

SERVICE INFORM ATION ······························ 3-2 DRIVE CHAIN ················································3-15

M AINTENANCE SCHEDULE························· 3-4 BATTERY·······················································3-19

FUEL LINE ······················································ 3-5 BRAKE FLUID················································3-20

THROTTLE OPERATION································ 3-6 BRAKE SYSTEM ···········································3-21

CHOKE OPERATION ······································ 3-6 BRAKE LIGHT SWITCHES····························3-22

AIR CLEANER················································· 3-7 HEADLIGHT AIM ··········································3-22

CRANKCASE BREATHER······························ 3-8 CLUTCH SYSTEM ·········································3-22

SPARK PLUG ················································· 3-8 SIDE STAND ·················································3-23

VALVE CLEARANCE······································ 3-9 SUSPENSION ···············································3-23

ENGINE OIL·················································· 3-11 NUTS, BOLTS, FASTENERS························3-24

ENGINE OIL CENTRIFUGAL FILTER··········· 3-13 WHEELS/ TIRES ············································3-24

ENGINE IDLE SPEED ··································· 3-14 STEERING HEAD BEARINGS ······················3-25