CB110O0SFyIMPORTANT SAFETY NOTICE Indicates a strong possibilty of severe personal injury or death instructions are not followed. | cauTion: indicates apossbitty of equipment damage instructions are not followed. Note: Gives helpful information Dotailod descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to nate that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or rander it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or nat recommended by Honda, must ‘satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tole selected TYPE CODE ‘Throughout this manual, the following abbreviations are used to identify individual model ‘CODE AREA TYPE ‘cope AREA TYPE EUROPEAN DIRECT SALES. E UK (Austria, Netherlands, Spain, Switzerland, £D | Portugal, Belgium, Canary lands, Hungary, | F FRANCE ‘Sweden, Finland, Denmark, Norway)HOW TO USE THIS MANUAL This service manual describes the service procedures for the CB11008F. Follow the Maintenance Schadule (Section 3) recom ‘mendations to ensute thet the vehicle is in peak oper: ating condition, Performing the first scheduled maintenance is very important. It compensates for the initial wear that ‘occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removall installation of components that may be required to perform service deseribed in the following sections. Sections 4 through 20 describe parts of the ‘motorcycle, grouped according to location, Find the section you want on this page, then turn to the table of contents on the first page of the section. ‘Most sections start with an assembly or system illustration, service information and troubleshooting forthe section, The subsequent pages give detailed procedure, If you don't know the source of the trouble, go to section 22 Troubleshooting. ALL INFORMATION, ILLUSTRATIONS, DIREC TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE | TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO | MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO 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 ENGINE AND DRIVE TRAIN CONTENTS GENERAL INFORMATION En FRAME/BODY PANELS/EXHAUST EE SYSTEM sat MAINTENANCE Em LUBRICATION SYSTEM Em FUEL SYSTEM. Programmed Fuel Injection] COOLING SYSTEM ka ENGINE REMOVAL/INSTALLATION Ea CYLINDER HEAD/VALVES En CLUTCH/GEARSHIFT LINKAGE En ALTERNATOR/STARTER CLUTCH Em CRANKCASE/PISTON/CYLINDER CRANKSHAFT/TRANSMISSION/ __|_ BALANCER, CHASSIS FRONT WHEEL/SUSPENSIONT Em STEERING ie eee REAR WHEEL/SUSPENSION Ea HYORAULIC BRAKE ys _| ELECTRICAL BATTERY/CHARGING SYSTEM Ea IGNITION SYSTEM Ea ELECTRIC STARTER jis | LIGHTS/METERS/SWITCHES [19 | IMMOBILIZER SYSTEM (HISS) Eq | wirie DIAGRAM. En TROUBLESHOOTING Date offesus: Juno, 1909 © HONDA MOTOR CO.,LTD.SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required Pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease {containing more than 3 % molybdenum disulfide, NLGI #2 or ‘equivalent Example: Molykote® 8R-2 plus manufactured by Dow Corning, U. S. A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan me ie Use molybdenum disulfide paste (containing more than 40 % molybdenum disulfide, NLGI #2 or equivalent) iu Example: Molykote® G-n paste, manufac Honda Moly 60(U. S. A. only) Rocol ASP manufactured by Rocol Limited, U. K Rocol Paste manufactured by Sumico Lubricant, Japan 1d by Dow Corning, U. S.A. Use silicone grease, Apply a locking agent, Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid, Use the recommended brake fluid unless otherwise specified Use Fork or Suspension Fluid.1. GENERAL INFORMATION GENERAL SAFETY 11 TOOLS 1-18 ‘SERVICE RULES 1-2 LUBRICATION & SEAL POINTS MODEL IDENTIFICATION 13 CABLE & HARNESS ROUTING 1:24 ‘SPECIFICATIONS 1-4 EMISSION CONTROL SYSTEMS 1:36 ‘TORQUE VALUES 1.13 GENERAL SAFETY ‘CARBON MONOXIDE USED ENGINE OIL If the engine must be running to do some work, make sure the atea is well ventilated, Never run the engine in an tnclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Gum Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this, is unlikely unless you handle used oll on a daily basis, it is: stil advisable to thoroughly wash your hands with soap ‘and water as soon as possible after handling used oil. KEEP (OUT OF REACH OF CHILDREN. Fun the engine in an open area or with an exhaust ‘evacuation system in an enclosed area. GASOLINE Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is sotred. mg 2 Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS: Ia eee Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust ‘system have cooled before handling these part. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. BRAKE FLUID CAUTION: Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts, whenever the system is serviced. KEEP OUT OF REACH OF ‘CHILDREN, 1-1 ~~GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned. ooo * Avoid spilling engine coolant on the exhaust system or engine ports. They may be hot enough to cause the coolant to ignite and burn without a visible flame. * Coolant (ethylene glycol) can cause some skin irritation {and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN. ‘Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. * Keep hands and clothing away from the cooling fan, as it starts automatically. CAUTION: Using coolant with silicate inhibitors may cause premature water of water pump seals or brockage of radiator ‘passages. Using tap water may cause engine damage. SERVICE RULES BATTERY HYDROGEN GAS & ELECTROLYTE ie eae ‘+The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. ‘The battery contains sulturic acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protec- tive clothing and a face shield. Ifelectrolyte gets on your skin, lush with water. =I electrolyte gets in your eyes, flush with water for at least 15 minutos and calla physician immodiataly. + Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN. 1.Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA's design specifications may cause damage to the motorcycle, 2. Use the spacial tools designed for this product to avoid damage and incorrect assembly. 43. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling, 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified, 6.Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8 Route all electrical wires as show on pages 1-24 through 1-38, Cable and Harness Routing,GENERAL INFORMATION MODEL IDENTIFICATION (1) The frame serial number is stamped on the right side of the steering head, THROTTLE BODY IDENTIFICATION NUMBER | uaa ‘i (2) The engine serial number is stamped on the right, side of the upper crankcase. COLOR LABEL 1G) The throttle body identification number is stamped on the intake side of the throttle body as shown, [@) ‘The color label is attached as shown, When ordering color-coded parts, always specify the designated color code. 1-3GENERAL INFORMATION SPECIFICATIONS GENERAL " DINENSIONS | Ovoralllenath 2,145 mm (440) gaat oem mt, ae cee aoe some ere ree ell ate Fue! tank capacity 22 8 (5.8 US gal, 4.8 Imp gal) HH Sen BiG | eee a rt 1-4;~ GENERAL (Cont'd) Tem CARBURETION | Type | Throttle bore | DRIVETRAIN | Clutch system ELECTRICAL | Clutch operation system Transmission Primary reduction Final reduction Gear ratio shift pattern Ignition system Starting system Charging system Regulatorirectifier Lighting system 1st 2nd 3rd ath 5th _| 42 mm(1.7 in) Loft foot operated return system, GENERAL INFORMATION SPECIFICATIONS PGNCFI (Programmed Fuel Injection) Multi-plate, wet Cable operated type Constant mesh, 5-speed 1,571 (88/56) 2.529 (43/17) 2.769 (36/13) 1.938 (31/16) 1.856 28/18) 1.316 25/19) 1.167 (28/24) Computer-controled digital transistorized with electric advance Electric starter motor Triple phase output alternator SCR shorteditriple phase, full wave rectification BatteryGENERAL INFORMATION | Engine oil capacity ~[Atdraining ‘Atdisassembly _ ‘Atoll filter change | Recommended engine oil Oil pressure atoll pressure switch [> UBRICATION SYSTEM eT STANDARD 380(40USqt,33impqi 46.(49US gt, 4.0 Imp qtl 73.9 (4.1 US qt, 3.41mp qu) HONDA 4-stroke oll or equivalent motor oll API service classification SE, SF or SG Viscosity: SAE 10W-40 “490 kPa (6.0 kgllem@, 71 psidat 5,400 min” (rpmy(@0 °C/176 °F) Unit: mm {in} ‘SERVICE LIMIT Oil pumprotor | Feed pump | Tipdearance | 0.16 (0.006)max. 0.3010.008) | Body eiesrance | 0.15 -0.21 0.006=0.0081 0.35 (0.014) : 0.08 0.090.002 ~0.004) 0.12 (0.008) Cooler 0.15 (0.0061 max. - 0.20 (0.008) pump Body clearance | 0.15-0.21 (0.006 0.008) 035 (0.014) Side clearance 0.120.006) [~ FUEL SYSTEM (Programmed Fuel Injection) "fen SPECIFICATIONS “Throtl body ideniicaion number z cana : Sater valve vacuum diference = 20 min Base trol valve for synchronization No.3 = idle speed 7,700 + 100 min” (rpm) “Throttle grip free ploy Intake air temperature sensor resistance (at 20°C168 °F) Engine coolant temperature sens Fuel injector resistance (at 20 PAIR solenoid valve resistance (at 20 °Ci68, [Cam pulse generator peak voltage {at 20 °C/68°F) Ignition pulse generator peak voltage (at 20 °Ci68 ‘Manifold absolute pressure at ile 2-6 mm (V/16— Vin} akg 26k 20-24 0 0.7 V minimum 0.7 minimum: 200-250 mmHg) 130-1449 Fuel pressure at ile Fuel pump flow (at 12V) 298 KPa (3.0 kgf/cm? 43 psi) 220 em? (7.4 US 02, 7.7 Imp oz] minimum/10 secondsGENERAL INFORMATION ;- COOLING SYSTEM ITEM SPECIFICATIONS Radiator and Roserve tank Coolant capacity “3.26 (3.4 US qt, 28 imp qt) 10.5 £(0.5 US qt 0.4 Imp qt) Radiator cap relief pressure 08 137 kPa (1.11.4 kgllem?, 16 ~20 psi) ‘Thermostat [Begin to open 80-84 °C (176~183°F) Fully open 95°C 20°F) Valve if ‘mm (0.3 in) minimum Recommended anifresze High quality etylene glycol antifreeze containing corrosion B protection inhibitors. Suandard coolant consenraton I 50% raiture wth sof water (— CYLINDER HEAD/VALVES Let mm i} ITEM ‘STANDARD SERVICE LIMIT Cylinder compression T76ia(SOkglen® 165A) | —— —— | ___at 350 min" rpm) Cylinder head warpage {-9.3070.008) Valve, Valve clearance iN 046 = 0.030006 = 0007 = valve guide EX 072 + 0.03(0.009 + 0.00%) = Valve stem 0.D. IN 4.975 ~ 4.990 (0.1969— 0.1965) 4,965 (0.1955) EX | 4960-4975 0.1969-0.1959) 4.950 (0.1949) Valve guide LD. IN 5.000 5012 0.1969 0.1975) 5.040 (0.1884) EX 5.000 — 5.012 (0.1969— 0.1973) ‘Stem‘o-guide clearance |_IN 0,010 0,037 (0.004.001) — [Bx 0.0250.082 0.0010 ~0.0020) Valve gue projecion [IN | 163-165 (0640.65) above cylinder head €X—163 165 10.64—0.65) Walve seat width TINIEX” 0,801.10 (0.038 -0.083) 75 (006) Vale spring Inner Liwex a7ac.a7 35.4 (1.39 freelength [Outer TINEX—a0-6 (7.60) eT Valve lifter | Valve liter 0.0. [iwex 26.978 25.993 1.0208 1.0283) 25.97 (1.022) Walve lifter bore. IWEX [26.010 26,026 (1.0240—1,0248) 26.04 (1.025), Camshaft "Cam tobe height IN] 36:32—38.40(1,509—1.512) 38.02 1.497) le ex | ea gas sit 1514) 38.08 1.499), Runout a 005 (0.602) Oil closrance 01920—0.074 (0.0008 0.0029) 0.100.004)GENERAL INFORMATION p- CLUTCH/GEARSHIFT LINKAGE TEM Chui ever tree play ‘STANDARD Unit: me (in SERVICE LIMIT Cluteh spring free iengih 7 5522.21) Cluteh disc thickness 372-388 (0.146 0.153) 3500.14) Brown color | 3.72 ~3.86 (0.146 0.1591 3510.14) Clutch plate warpage a 0.30 (0.012) | Clutch outer guide 1D. 28,000 26,021 (1.1024 1.1032) 28.031 (1.1086) oo 34975~34:991 (1 970-1.3776) 34.965 (1.766) Mainshaft 01D. at clutch outer guide 27,980 27.993 (1.1016 1.1021) 27.970 (1.1012) Shiftfork, |. Fork 1D. 42.000 12.021 (0.4724 ~0.4733) 12.05 (0.474) fork shat Claw thickness | 6.95~600 (0.233 0.236) 5.9 (023) Fork shaft 0.0, 11,957 —11,986 (0.4707— 0.4719) 14.5 (0.470) ;~ ALTERNATOR/STARTER CLUTCH ————— saan eM ‘STANDARD SERVICE LIMIT Starter driven gear boss 0.0. 3.699 —51,718 (2,0354— 2.0361) 55,6 (20388) [> CRANKCASE/PISTON/CYLINDER bait TEM STANDARD SERVICE LIMIT cylinder 900079035 [3.1107 -3.1108) wera | — (0.004) a a0 (0.004), 105 (0.002) Fiston, piston rings 72.80 8.108) 79.03 (0.749) Piston pin 0. "1.984 (0.7478) Piston-to-piston pin clearance i Piston sing-to-ring | Top 0.030 0.065 (0.00120.0026) {9.08 (0.003) groove clearance | Second (0.015 ~0.045 0.0006 0.0018) 0.06 (0.002) Piston ring end gap | Top 0200.95 0.000.018) |0.8 (0.02), Second ‘0.a0- 0.55 (0.016 0.022) [0.7 0.03) saat Oil{side rail) | 02-08 (0.01~0.63) 010.04) | Gylinder-to-piston clearar ‘0.010 --0.045 (0,0004— 0.0018) as Connecting rod smell end LD- 19.030 19.051 (0.7492—0.7500) 79.061 (0.7504) Connecting rod-o-piston pin clearance 0.030 0.057 (0.0012 -0.0022) Crankpin oll clearance 0.030 —0.052 (0.0012 0.0020) 0.062 (0.0038)GENERAL INFORMATION [— CRANKSHAFT/TRANSMISSION/BALANCER it. men inh TEM STANDARD seavice unit | Crankshaft | Side clearance 0.05—0.20(0.002—0.006) 10.30 (0.012) | Runout __/ 0.30 (0.012) ‘Main journal ol learance 0.017 0.03 (0.0007 —0.0014) (0.045 (0.0018) Transmission | Gear 0. Ma, MS '31.000—31.025 (1.2205~ 1.2216) 31.04(1.222) — C1 26,000 26.021 (1.0236 — 1.0244) 26,08 (1.025) C23 33.000 — 33.025 (1.2992 — 1.3002) 33.04 (1.301) a Ms '30,95030.975 (1.2185~1.2195) 30.93 (1.218) ce 32.985 — 32.980 (1.2974 1.2984) 32.95 (1.296) (C3, distance collar 32.950 32.975 (7.2972 1.2882) 32.93 (1.296) Bashing iD. ma 27.985 28.006 (7.1018 1.1026) 28.02 (1.103) ce 28,985 ~30.006 (1.1805 ~1.1813) 30.02 (1.182) Ma, MS 0.020. 01062 (0.0008 - 0.002) 0.10 0.004) | clearance [ee 0.020—=0.070 (0.0008 -0.0028} 0.11 (0.004 cs 0.026 ~0.075 (0.0010 ~ 0.0030) (0.110.004) MainshaR 0.0. Ma 27,967—27.980 (1.1071 1.1016) ___|_27.967(1.1007) | fase |_Clutch outer guide | 27.980 27.993 (1.1016 1.1021}. 27.970.(1.101 Countersha OD. C2 28,967 ~ 29.980 (1.1798 ~ 1.1803} 27.967 (11007) Bushingto-shatt Ma 10.008 ~ 0.039 (0.0002~0.0018) (0.08 (0.003) clearance c2 0.005 _0.039/(0.0002 0.0015) 6.08 (0.003)GENERAL INFORMATION 15.7 + 0.09 imp 02) [- FRONT WHEEL/SUSPENSION/STEERING Late: mm tinh TEM. STANDARD SERVICE LIMIT Minimum tre read depth = — 75 (0.08) Cold tire pressure Drive only 250 kPa (2.50 kgf/cm? , 36 psi) = | Driver and passenger 250 Pa (2.50 kgflem?, 36 psi) : ‘Axle runout I — 0.20 (0.008) _ Wheel im ranout | Radial - | 20008) [ise ‘Axial t a 2.00.08) Fork Spring fre length 320.5 (12.62) 3 314.1 (1237) Spring direction {Lith the tapered end fecing down | “Tube runout [9207010087 Recommended fork fuld | Fork fuid { = Fluidlevel 168165) Fluid capacity 446 = 250m (18.1 © 00B8US 02, - Steering head bearing pre-load 1015 N(1.0—1.5 kal ~ REAR WHEEL/SUSPENSION an TEM STANDARD SERVICE LIMIT Minimum tire tread depth so 2.0 (0.08) Coldtire pressure | Driver only — "290 era (2 90 katfem?, 42 psi pee Driver and passenger 290 kPa (2.90 kgficm®, 42 psi) — ‘Axle runout 1 : 0.20 (0.008) Wheel rim runout [Radial 2.0 (0.08), ‘Axial = 7201008) Drive chain Sizeslink bio | DiDsOZv-T70LE saat [kk | -aKS0LFO-110LE Slack 2535 (1.0 1.4) 5012.0) Shock absork Spring adjuster standard position| 3rd groove 1-10GENERAL INFORMATION | HYDRAULIC BRAKE aay TEM STANDARD SERVICE LIMIT Front | Specified brake ora 1 Brake dis thickness 4510.18 350.14) Brake dise runout 0:30 (0.012) |"-Master cylinder 112.700 12.743 (0.8000-0.5017) 12.76 (0.502) Master piston 0.0. 121657 — 12.684 (0.4983 0.4594) 1265 (0.498) Secondary master cylinder. 14.000 14.049 (0.55120 5529) 14.055 (0.5533) Secondary master piston 0.0. 13.957—13.984 (0.6495—0.5508) 13.945 (0.5490) Caliper cylinder | Right Upper | 27,000 27.050 (1,0690 1.0650), 77-060 (1.0654), 10. Middle | 22.650 22.700 (0.8917—0.8937) 22.710 (0.8941) 25.400 26.460 (1.0000 1.0020) 25.469 (1.0024) 25,400 26,450 (1.0000 1.0020) 25.460 (1.0024), 22.650 22.700 0.8917—0.8937) | 22.710(0.8941), 22.650—22.700 (0.8917 —0.8937) 22'710 0.8981) Caliper piston 26.916 26,968 (1.0597 1.0617) 910 (1.0584) on) 22.585 — 22.616 (0.8892—0.8908) | Lower | 25.318—25,368 (0.9968 0.9987) Upper_|_ 25.318 25.268 (0.9968 0.9987) 25.310 (0.9965) ‘Middle | 22.585 22.618 (0.8802 0.6905) 72.560/(0.8882) | Lower | 22.585~22.618(0.8602—0.8905) | 22.560 (0.888 Rear Specified brake fluid ora Brake pedal height 85 (2.6) Brake disc thickness 5.0 (0.20) z 40016 Brake aise runout 0.30 0.012) Master cylinder LD. W7aB0— 17.503 0.6874—06887) 17.515 0.6888) Master piston 0. 17.417— 17.444 (0.6857 ~0,6868) 17.405 0.6852), Caliper eylinder 0. | Front 22.650—22.700/0.8917-0.8937) __|_22.710 0.8941), anter_ 25.400 26.460 1.0000 — 1.0020), 25.460 (1.0024) Rear 22.650 22.700 0.8917 0.8937) 710 (0.8981) Caliper piston 0.0. [Front 72.585 72.618 /0.6892—0.6905) 22.560 (0.8862) Center 26.318 -25.368 0.9968—0.9987) | 965)__| Rear 22.585 ~22.618 (0.8892 0.6905) 72.560 (08882) [~ BATTERY/CHARGING SYSTEM TEM ‘SPECIFICATIONS: j Battory Capacity s 12V-10AH [Current eakage 0.2mAmax. Voltage Fully chargod 130-1320 Needs charging : : iat | Normal Ouick A Aiemator Capacity 0.46 KW/5,000 min fepm) | i Cherging coll resistance @0°CI68"F) | 01-109 1-11GENERAL INFORMATION -— IGNITION SYSTEM. ITEM SPECIFICATIONS ‘Spark plug stati (CREEHVX— (NGK) — Ignition pulse generator peak voltage (0.7 minimum (Clgnition timing (""* mark) 12" BTDC atidle Spark pug gep. ~080=0.90 mm (0.931 0.035 in) | | lgnition col peak vottage ——+ = “100 minimum, z [~ ELECTRIC STARTER Late mn} TEM. STANDARD SERVICE LIMIT [Starter moterbrushlengih | 120-730 (047 081) Taso) [— LIGHTS/METERS/SWITCHES TEM SPECIFICATIONS Bulbs eadligh (Lo) | 13V-S055W eS Position light E Sng =a | Brakeltal tight : Ta 2BW a Front turn signal ight 12V=2iW 2 Rear turn signal ight av at aaa ‘instrument ight L 1V—17W x8 aa Turn signal indicator 1V=3aWx 2 [High beam indicator ATW | Neural indistor z 12V=1.7W Oil pressure indicator 121.7 PGM-FI warning indicator Fuel reserve indicator Immobilizer indicator Main fuse. [CPGM-Fi fuse ‘Sub fuse “Tachomeier peak voltage Thermo sensor resistance | Fuse 47.5—56.8 k 149-1 Fanmotor | Starttoclose (ON) ~ 98-102 °C (208-216) switch | Stop to open, 93-97 °C (199-207 °F) 1-12GENERAL INFORMATION TORQUE VALUES | eens ee ‘Nem (kgt-m,Ibttt) saree eeaetet ‘Nem (kgf-m, Ib) 8mm hex bolt and nut. 222.2, 16) | 6mm flange bolt (8 mm head) 910.9, 6.5) | 10 mm flange bolt and nut | 39%40,29) ae -— ENGINE ee i tse oT aes Te oe ee omoaieas 1-13GENERAL INFORMATION (— ENGINE (Cont'd) THREAD TORQUE a | ony DIA. (mm) Nem (kgf, Ibf-ft) eee ENGINE MOUNTING: Drive sprocket cover bolt 2 6 12112,9) Drive sprocket special bolt 1 10 54155, 40) CYLINDER HEAD/VALVES: Cylinder head cover bolt 8 6 10(1.0,7) Breathor plat lange bolt 5 6 12(42,9)|-NOTE2,9 Camshaft holder flange bolt 10 6 12(12,9) | NOTES Cylinder head sealing bolt 1 8 22(93.24 | NOTE2 Cylindor head SH bolt 2 6 1011.0, 7) Cylinder head mounting bolvwasher 10 10 67(68,49) | NOTES Cam sprocket bolt 4 7 2010/14 | NOTE2 Cam chain tensioner eap nut 1 6 12112,9) | Cam chain tensioner lifter mounting bolt 2 8 10100,7) Cam chain guide A mounting bolt feeelteeag 1211219) Cylinder head stud bolt exhaust pipe stud bolt) 8 8 See page 1-15 PAIR reed valve cover flange bolt 4 6 13113,9) Cam pulse generator cover SH bolt 3 5 12112,9) CLUTCH/GEARSHIFT LINKAGE: Clute eanter took nut 1 25 1271130,94) NOTE 4.5 Clutch spring bolvwasher 5 6 12,9) Aight crankcase cover SH bolt n 6 nazi | Aight crankcase cover center bolt 1 6 wuz.) | Shift drum center socket bolt 1 8 23(23,17) | NOTE? Shift drum stopper pivot bolt 1 6 12112,9) Gearshift return spring pin 1 8 | 303,17 ALTERNATOR/STARTER CLUTCH: ‘Alternator cover SH bolt 10 6 12(12,9) ‘nternator wire clamp soeker bolt 1 6 909,65) Flyateel flange bolt 1 10 103 (105.76) | NOTES Stator mounting socket bolt 4 6 72012.) Stator one-way clutch socket bolt 6 6 1616.12) NOTE? ‘CRANKCASE/PISTON/CYLINDER: | | Crenkcase bok, 10mm 1 10 39 (40, 29) Sm (main journal bolt wo | 29 37(38,27) NOTES amm %0 8 2525.18) 7mm 7 7 1818, 13) mm 5 6 12(12,9) Connecting rod nut 8 8 41142,30) | NOTES Lower crankcese lange bolt 1 10 29(30,22) | NOTE? Lower erankease sealing bolt, 20 mm 1 2 29(3.0,22) | NOTE2 8mm 1 a | 222/16) NOTE? (CRANKSHAFT/TRANSMISSION/BALANCER: | Mainahaft bearing sot plate flange bolt 2 6 | rata.) | NOTE? Shift drum set plate flange bolt 2 6 12(42,9) NOTE? Balancer shalt holder flange bolt 2 8 728,720) Balancer shat pinch bolt 3 6 12012.9) | 1-14GENERAL INFORMATION — ENGINE (Cont'd) Tem IGNITION SYSTEM: Ignition pulse generator cover SH bolt Ignition pulse generator rotor special bolt LIGHT/METERS/SWITCHES: Neutral switch | THREAD TORQUE OY | DIA tmm) | Nem tkgtm, test) | REMARKS a 6 12(1.2,9) NoTE1 See page 1-20 1 10 59(60,43) | NOTES 1 10 12(12,9) ‘Throttle body insulator clamp: 12. £ 1mm (06 £ 0.04 in) Exhaust pipe stud bolt: 38.5~39.0 mm (1.62—1.54 in} 1-15GENERAL INFORMATION > FRAME T my Teed | TORQUE —. om DIA.(mm) | Nem (kgfem, Ibfft} ene Sie stand pot bot Ja ‘0 wono.n | Side stand pot lok nut fa | 2190.2 Natrstand mounting bok en) Sites a0) | NoTEs Nain stand spring nook i ¢ 212720) | Ban sensor 2 3 e2. 18 Exh! pipe it nt a > att Muffler band bolt 4 8 18 (1.8, 13) Hutter bracket bo 3 a i272 Seat mourting bot i | 0 mates 3) FUEL SYSTEM (Programmed Foe! injection: Fuel tbe sealing mat tote Body sie : 2 22122.16 Fue! tube banjo bolt (fuel tank side) 1 12 22:(2.2, 16) | Senic eec bot ‘ ° isascm Fuel pump mourtng nit 3 3 ha.) | | Fue iter cap bo a ‘ 20219 | Orsensor i | Bios 8) Bankangl sensor mounting sow 2 : 2102, 18 cote svstent Coot fan ut 1 5 21027,20 Fen motornat 3 8 310838) ENGINE MOUNTING: Side stand chet ot 2 | w oa (55,40 Engine hanger nut (reariupper) 1 12 6416.5 ,47) Enrine hanger nu ealower 18 saiossan Enoine hanger bot > ‘olan, 30 Engine hanger ajustng bok 2 2 Thae Enine hanger adjusting bat lock nit 2) 2 snes, LUTOH/GEARSHT LINKAGE | Gearhi pods ok : ‘ 10119, FONT WHEE 'SUSPENSION/STEERING: Vener stopper bok a 8 25108, 19) Manlabr weigh mounting sew A é ‘o110,7)—_| Noves Siocrmgstcm eu FE] ae sasti08 ey | Se tege rose Toptnead i | @ seta 30) — Toptveed® i | 3 4 Fork ton rte pinch bo 2 © | aaa,in Fort boro idge inch bot 2 ‘160,30 Frontera bo i ow steo.an Font ol holder bot 4 ° 202.10 Fon brat ie mounting Bol 2 | s mio.) | Nove rowcan > |» Bean For sorket bot > 2 poleo.%) | Nove? Fork dmper ock nt 2 | | aol 1-16GENERAL INFORMATION FRAME (Cont'd) 7 ] THREAD TORQUE aoe TY IA (mm) em (kgm, torte) | REMARKS REAR WHEEL/SUSPENSION: Rear axle nut 1 1 118(120,87) | NOTE? Rear brake dise mounting bolt 6 8 42(43,31) NOTES Driven sprocket nut | s 2 108(11.0,80) | NOTE7 Rear shock absorber mounting nut 2 10 42(43,31) | NOTE? Swingarm pivot nut 1 18 93(9.5,69) | NOTE7 Footpeg holder socket bolt 2 10 39140, 29), Drive chain slider bolt 2 6 910.9,65) NOTES HYDRAULIC BRAKE: | Front brake master cylinder holder bolt 2 6 1201.2,9) Front brake master cylinder cap screw 2 4 110.18, 1.4) Brake lever pivot bolt 1 6 10.1, 0.2) Brake lover pivot nut 1 6 6106.43) Brake lever adjuster fee 5 4104/29) Front brake switch serew 1 4 110.12.0.9) Right front brake caliper mounting bolt 2 8 31(32,23) | NOTES Left front brake caliper pivot bolt 1 8 31(32/23) | NOTES Left front brake caliper bolt (second master joint) 1 8 26(27,20) | NOTES Caliper body 8 bolt | 9 8 32(33,24) | NOTES Front brake caliper slide pin (min) 3 2 23(23,17) | NOTE2 Front brake caliper side pin (sub) 3 8 13(1.3, 9} NOTE 2 Pad pin en) 1801.8 13) Brake caliper bleedor 6 8 6108.43) Second master cylinder mounting bolt 2 8 312,23) | NOTES Second master eylinder push rod nut 1 8 1801.8, 13), Second master oylinder connector 2 6 101.0, 7) Rear master cylinder mounting bolt 2 6 1212/9) Roar master evinder reservoir mounting bolt 1 6 1212/9) Rear master cylinder push rod nut ee fe 1801.8,13) Rear master cylinder hose joint screw 1 4 10.15/11) | NOTE? Brake hose oil bolt 2 10 34 (3.5, 25) Brake pipe joint 8 10 wi17112) | NOTES Brake pipe 23 way joint 2 6 12(12, 9) Brake hose clamp bolt 2 6 12(12, 9) Delay valve mounting bolt 2 6 12042'9) PCV (Proportional Control Valve) mounting bolt | 2 6 12(12/9) Right font brake hose clamp bolt 1 6 12(129) IGNITION SYSTEM: Ignition coil mounting nut 4 6 16(1.6, 12) Ignition coil mounting nut 2 6 10(1.0,7) | UGHTS/METERS/SWITCHES: Teilbeake light mounting bolt 2 6 7(07,8:1 Rear turn signal unit mounting nut 2 10 5(05 36) Combination meter mounting bolt 2 4 2102, 1.4) Fan motor switch 1 16 1818.19) NOTEX Ignition switch mounting bolt 2 8 25 (25, 18) Side stand switch mounting bolt 1 6 1WiN0.7) | 1-17GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available, 2. Alternative tool 3. Newiy provided too} 4.Newiy designed tool DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Fucl pressure gauge ‘o7G6-0040002 is Oil pressure gauge set 07506-3000000 4 Oil pressure gauge attachment 07510-4220100 4 Clutch contor holder 07724.0060002 9 Flywheel holder 7725-0040000 | NOTE1 10 Fiyasheel puller 07733.0020001 70 Attachment, 32 * 36 mm 07746-0010100, 14 ‘Attachment, 37% 0 mm 07746-0010200 9 | ‘astachment, 42 * 47 mm 07746-0010300 9.13 Attachment, 52 * 56 mm 07746-0010800 14 | Attachment, 62 * 68 mm 07746-0010500 18 Aitachment, 22. 24 mm 07746-0010800 4 Driver, 40 mm 0 07746-0030100 2 Astachment, 30-mm LD, 97746-0030300 | 2 Pilot 17 mm 7746-0040400 1a Pil, 20 mm 107746-0040500 13,14 Pilot 35 mn 07746-0040800 9 Pilot, 28mm 07746-0041100 14 Bearing remover shatt 07746-0050700 13,18 Bearing remover head, 20 mm 07746-0050600 1314 river 07748-0010000 9,13, 14 Valve spring compressor | 07757-0010000 |e Valve seat cuter NOTE 8 Seat cutter, 29 mm (45° EX) 07780-0010300 Seat cuter, 33 mm (45° IN) 07780-0010800 | Flat cutter, 29 mmm (32° EX) | or7eocoraa00 | NoTE4 Fatoutter, 39 mm (32° IN} | o77a0.0012900 Interior cuter, 30 mm (60° EX) 07780-0014000 Interior exter, 34 mm (60° IN} 07780-0014700 | Cutter holder 5 mm 0778%-0010800 Snap rng pliers o7er4-sasoo0 | NOTE2:07914:3230001 9.15 Stooring stom socket o7e16-3710101 3 Valve guide driver, 8 mm 07942-60000 8 Artachment, 28 % 30 mm 07946-1870100 14 Needle bearing remover 7946.K50000 8 Ball race remover set 07946-KM90001 je Driver attachment, A 07848-KM0100 | Driver attachment, 8 07946-KM90200 | ~ Driver shaft assembly (07946-KM90300 ~ Bearing vemover, A | o7sasKmooaor ~ Bearing remover, 8 07946-KN90500 ~ Assembly bose 07946-K90600 Steering stem driver 07946-800000 13 Driver shaft 07946-00100 14 Oil seal driver o7ea7-KAa0200 3 Slider weight (07947-KAS0100 3 Driver attachment handle 97949-371000 | Valve spring compressor attachment 07959-K1¥30101 8 Driver shat 07964-00200 2 Valve guide roam o798a.Ma6o001 8 Oi fiter wrench G7MAA.PI7O100 | 3 —_— 1-18GENERAL INFORMATION DESCRIPTION TootnumeEn | REMARKS REF. SEC. "Peak voltage edaptor | o7HG,-0020700 NOTE 2: 517,18 ‘| Imrie diagnostic tester (mode! 625) Needle bearing remover, 28 mm ‘o7HMC-MR70100 14 Tappet hole protector 07HMG-MR70002 8 Drive chain tool set (O7HMH-MR10103 3 Compression gauge attachment (OTAM-MY0100 8 Lock nut wrench O7VMA.MATO100 7 Test pin box o7WGz-0010100 | NOTE3 5 ECU test harness o7wMz-MBGo100 | NOTE3 5 Test hamess o7xMz-MBNoI00_| NOTES 20 1-19GENERAL INFORMATION LUBRICATION & SEAL POINTS ;— ENGINE LOCATION ‘Crankease mating surface MATERIAL, 7 Liquid sealant (Thee Bond 12078 or equiv- alent) REMARKS, 5 E (0.40.5 in) Oil pan mating surface Ignition pulse generator cover bot treads (marked | lait il pressure switeh throads Do not apply sealantio the thread __hoad 34mm (0.10.2) ap ‘Thermo unit threads | Knock sensor threads 1-20 | | 10-15 mm (oa08im) ‘9g Coating width: 65 + 1mmy~ ENGINE (Cont'd) — LOCATION Cylinder head semi-circular cut-out "| Sealant (MATERIAL GENERAL INFORMATION REMARKS Camshaft lobesvjournals Valve lifter outer sliding surface Valve stem [valve guide sliding surface) Piston pin sliding surface Main journal bearing surface Connecting rod bearing surface Crankshaft journals (M3,C4, C5 shifter gear (shift fork grooves) Clutch outer/primary driven gear sliding surface Clutch outer guide sliding surface Starter reduction gear outer surface Primary drive gear and sub gear sliding surface a APPLY AREA (nerevanen oe) Molybdenum disul fide oil (2 mixture of 1/2 engine oil and 1/2 molybdenum disul- fide grease Piston ring sliding area Main journal 9 mm bolt threads and seating surface (after removing anti-rust oil additive) Cylinder head special bolt (after removing anti-rust oll additive) Oil strainer packing Ol fter cartridge threads and O-ring Flywheel bolt threads and seating surface Starter one-way clutch sliding surface Connecting rod nut threade Clutch joint piece sliding surface CCluteh lifter rod surface CCluteh center lock nut threads Clutch dise surface Engine oil Each gear teeth and rotating surface Each bearing Each O-ring Other rotating area and sliding surface 1-21GENERAL INFORMATION ENGINE (Cont'd) LOCATION ‘Timing hole cap threads Balancer damper rubber fitting area Oil seal lips Cylinder head sealing bolt threads Gylinder head cover breather joint threads Lower crankcase sealing bolt threads Starter one-way clutch outer bolt threads il pump driven sprocket bolt threads Ol pipe mounting bolt threads il Fiter boss threads Shift drum sot plate bolt threads Shift drum center bolt threads Mainchaft boaring set plate bolt threads Cam sprocket bolt threads Gylindor head cover breather plate bolt threads MATERIAL, ‘Multi-purpose grease | Tocking agent REMARKS: Coating width: 6.5 + t mm 1-22GENERAL INFORMATION FRAME LOCATION Front wheel dust seal lips Rear whee! side collar inner surface Footpeg sliding area Passenger footped sliding area Rear brake pedal pivot sliding area Throtle pipe sliding area ‘Soat catch hook Steering head bearing sliding surface Steering head dust seal lips ‘Swingarm pivot bearing ‘Swingarm pivot dust seal lips Shock absorber needle bearing ‘Shock absorber dust seal lips Left front brake caliper pivot bearing sliding surface Left front brake caliper pivot oil seal sliding surface Left fork needle bearing sliding surface Loft fork dust seal sliding surface: ‘Side stand pivot surface Main stand pivot surface Throttle pipe cable sliding surface ‘Shock absorber spring adjuster cam surface Steering stem top thread Throtle cable casing inner Brake pipe joint threads ‘ Throttle cable A, B casing innor Choke cable casing inner Clutch eable casing inner ~Piteiyidenum pasie MATERIAL Muti-purpose grease | “Multi-purpose grease (Sholl Alvania EP2 or equivalent) Molybdenum disul- fide grease Cable lubricant REMARKS: Rear wheel dust seal lips Brake master cylinder cups Brake caliper piston seals DOT 4 brake fiuid Brake caliper dust seals, Front brake lever pivot and piston tips ‘Second master cylinder boot inside and push rod tips Rear master cylinder boot inside and push rod tips Brake caliper slide pin surface Silicone grease Fork oll soa lips Brake caliper slide pin threads Locking agent Rear mastor cylinder hose joint serew threads Fork socket bolt threads Driven sprocket stud bolt threads. _ Handle grip rubber inside Honda Bond A Fork cap O-ring Fork fluid 1-23GENERAL INFORMATION CABLE & HARNESS ROUTING COMBINATION METER 9° (NATURAL) CONNECTOR or LEFT HANDLEBAR ‘SWITCH 6P (BLUE) CONNECTOR POSITION LIGHT 2P (NATURAL) CONNECTOR ~~ RIGHT TURN SIGNAL CONNECTOR: IGNITION SWITCH 4P [NATURAL] CONNECTOR LEFT TURN SIGNAL CONNECTOR MAIN WIRE HARNESS \ HEADLIGHT SOCKET HORN WIRE 1-24GENERAL INFORMATION COMBINATION METER WIRE THROTTLE CABLES CLUTCH CABLE ~ RIGHT TURN SIGNAL WIRE SIGNAL Wine LErrHaNDLEBAR SwireA Wik RIGHT HANDLEBAR "| WITCH WIRE IGNITION SWITCH WIRE IMMOBILIZER WIRE 1-25GENERAL INFORMATION CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE OIL COOLER HOSE 9\\ rom oacese \ an THROTTLE CABLES /} Ne Dy; | DD sap : RIGHT HANDLEBAR Z eee ‘SWITCH WIRE a 1-26GENERAL INFORMATION THROTTLE CABLES PAIR CONTROL SOLENOID VALVE _/ _ CRANKCASE BREATHER TUBE _F. No. 2/3 IGNITION COIL iz : Ss No 1/4 IGNITION Coit IATSENSOR Turorme __- SENSOR MAP SENSOR ~ pRessuRE Swaree ECT SENSOR “ kwock SENSOR IGNITION PULSE GENERATOR WiRE ALTERNATOR WIRE } CAM PULSE GENERATOR ware ENGINE SUB-HARNESS STARTER MOTOR CABLE \ VEHICLE SPEED SENSOR ‘STARTER MOTOR GROUND CABLE 1-27GENERAL INFORMATION No, 2/3 IGNITION COIL MAIN WIRE HARNESS \ PAIR CONTROL SOLENOID \ ‘VALVE 2P (NATURAL) / CONNECTOR / | cwroncasie STARTER MOTOR CABLE FAN MOTOR SWITCH WIRE \ ALTERNATOR WIRE SIDE STAND SWITCH WIRE 1-28GENERAL INFORMATION No. 1/4 IGNITION COIL, FUEL TANK OVERFLOW TUBE AIR BLEED TUBE FUEL TANK AIR VENT TUBE | ‘ REAR BRAKE HOSE | IL COOLER HOSE BRAKE LIGHT SWITCH WIRE | \ o.sengorwine | siPHON TUBE | UPPER RADIATOR HOSE IGNITION PULSE GENERATOR WIRE 1-29GENERAL INFORMATION MAP SENSOR | 1ar senson \ | KNOCK SENSOR 1-30GENERAL INFORMATIONGENERAL INFORMATION FUEL CUT RELAY BANK ANGLE SENSOR (ENGINE STOP SENSOR} ENGINE STOP RELAY | mamruse Hotoe \ MAIN WIRE HARNESS: / TURN SIGNALRELAY FUSE 80x ‘STARTER RELAY SWITCH 1-32GENERAL INFORMATION MAIN WIRE HARNESS PROPORTIONAL CONTROL VALVE REGULATORVRECTIFIER RESERVOIR HOSE BRAKE LIGHT SWITCH WIRE 1-33GENERAL INFORMATION PROPORTIONAL CONTROL VALVE REAR BRAKE CALIPER REAR MASTER CYLINDER 1-34GENERAL INFORMATION FRONT MASTER CYLINDER RIGHT FRONT BRAKE CALIPER 1-35GENERAL INFORMATION GENERAL INFORMATOR—<—<—_——————————— EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS ‘The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not rogct in the same way, but itis toxic. Honda Motor Co., Ltd utilizes loan injection settings as well as other systems, to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body. AIR CLEANER HOUSING _- THROTTLE BODY <= FresH ain Gem 8.02 casGENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) ‘The exhaust emission contro! system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is seperate from the crankcase emission control system. ‘The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust por. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse Secondary Air Injection) control valve. This charge of fresh air promotes burning of tho unburned exhaust gases and changes 9 considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and weter vapor. ‘The reed valve prevent reverse alr flow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid valve is controlled by the PGM-Fl unit, and the fresh air passage is openediclosed according the running condition {ECTAATITPIMAP sensor and engine revolution) ‘No adjustments ta the secondary air supply system should be made, although periodic inspection of the components is recommended. AIR CLEANER HOUSING se eon ea EXHAUST PORT 1-37GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TEMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing thereof (1) The removal ot rendering in operative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to ‘ts sale or delivery to the ultimate purchaser or while it isin use; (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person, [AMONG THOSE ACTS PRESUMED TO CONSTITUTE TEMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2. Removal of, or puncturing of any part of the intake system, 3. Lack of proper maintenance. 44 Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those specified by the manufacturer. 1-38MEMO,FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS SIDE GRILL 2-02. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS 20 FRONT FENDER 25 | SERVICE INFORMATION 24 REAR FENDER 25 TROUBLESHOOTING 24 SEAT RAIL 28 | 2 | SEAT 2-2 MUFFLER/EXHAUST PIPE 240 REAR COWL 22 FOOTPEG 216 | RADIATOR GRILL 24 | SERVICE INFORMATION GENERAL EOE Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF + Serious burns may result if the exhaust system is not allowed to cool before components \CH OF CHILDREN. removed or serviced. * Work in a well ventilated area. Smoking or allowing flares or sparks in the work area or where gasoline is stored can cause a fire or explosion. * This section covers removal and installation of the body panels and exhaust system, * Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. * When installing the exhaust system, loosely install all of the exhaust pipe fasteners, Always tighten the exhaust pipe ‘lamps first, then tighten the mounting fasteners. if you tighten the mounting fasteners first, the exhaust pipe may not seat propery. ‘+ Always inspect the exhaust system for leaks after installation. TORQUE VALUES Bank sensor 22.Nim (2.2 kgm , 16 IDF) Exhaust pipe joint nut 21 Nem (2.1 kgm, 15 tht) Muffler band bolt 18N-m (1.8 kam, 13 IF) ‘Muffier bracket bolt 26 Nim (2.7 kof 20 loft Seat rail mounting bolt 444 Nem (4.5 kar, 33 tt) TROUBLESHOOTING Excessive exhaust noise roken exhaust system * Exhaust gas leak Poor performance * Deformed exhaust system ‘+ Exhaust gas leak * Clogged mutflerFRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Unlock the seat using the ignition key. Remove the seat backward, INSTALLATION Align the seat hooks with the frame brackets and instal the seat Push the rear end of the seat and lock it REAR COWL REAR GRAB RAIL RUBBER PLUGS. ] REMOVAL / Remove the seat see ebove) Remove the rear grab rail mounting bolt rubber plugs Remove the mounting bolts and rear grab ral Remove the two tim clips under the rear cowl TRIM CLIPS.FRAME/BODY PANELS/EXHAUST SYSTEM Remove the four rear cowl mounting special bolts. SPECIAL BOLT Romove the rear cowl backwerd. INSTALLATION Installation isin the reverse order of removel REAR COWLFRAME/BODY PANELS/EXHAUST SYSTEM RADIATOR GRILL REMOVAL Remove the six radiator grilliside grill mounting special bolts. Ramove the radiator gril forward. Remove the side grill mounting bolt and mounting fi rubber, then remove the side grill. INSTALLATION Installation isin the reverse order of removal. RIGHT SIDE GRILL — LEFT SIDE GRILL 8 RADIATOR GRILL 2-4FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL FRONT FENDER ) Remove the front fender mounting special bolts, Remove the front fender forward, INSTALLATION Installation isin the reverse order of removal ENGINE STOP REL SENSOR” REAR FENDER REMOVAL Remove the following Rear cow! (page 2-2) Battery (page 16-5) Fuel cut-off relay Engine stop relay ~Starter relay switch Unhook the retaining tab and remove the fuse box. Unhook the retaining tab and remove the main fuse Disconnect the rear brake light switch connector and engine stop sensor connector. Remove the retaining band and ECM (Engine Control Module), then disconnect the multi connectors.FRAME/BODY PANELS/EXHAUST SYSTEM Disconnect the seat lock cable. [ TAILBRAKE LIGHT ‘SEAT LOCK CABLE CONNECTOR 7 | Disconnect the tail/brake light connector and rear turn signal connectors. Remove the rear fender mounting special bolts. Remove the rear fender mounting bolts, nuts and collars. Remove the rear fonder backward.FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION ENGINE STOP SENSOR s \ MANFUsE SEATLOCK CABLE eve: ese FUSE BOX / STARTER RELAY SwiTch NN \ REAR FENDER BATTERY NOTE: fender, route the wire While installing the harness properly [page Install and tighten the front side mounting special bolts securely. Install the rear mounting collar, bolt and nut Tighten the nuts while holding the bolts, Install the removed parts in the reverse order of removal NOTE: Route the wires property (page 1-24).FRAME/BODY PANELS/EXHAUST SYSTEM. SEAT RAIL Pv "BRAKE RESERVOIR] REMOVAL \ ( | Remove the rear fender (page 2-5). Remove the rear brake hose clamp bolt. Remove the PCV (Proportional Control Valvo) Remove the rear brake reservoir mounting bolt. AZ BRAKE HOSE CLAMP BOLTS. Disconr connector. Remove the bolts and regulator/rectifior. the reguletorirectifier 6P (Black) Remove the turn signal relay from the seal rail bracket. Remove the seat rail mounting bolts, nuts and seat rail 2-8FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION TURN SIGNAL RELAY SEAT * f 44 Nom {4.5 kgf , 33 lot) f y / of 44 Nem (4.5 kam, 33 IDFA) Install the seat rail snd tighten the mounting bolts tothe specified torque, TORQUE: 44.Nim (45 kgm , 33 IDF) Install the turn signal relay onto the seat rail bracket. [—FRAME/BODY PANELS/EXHAUST SYSTEM Install the regulator/rectifier, tighten the bolts. Connect the regulator/rectfier 6P (Black] connector. Install and tighten the PCV (Proportional Control Valve) mounting bolts. Install and tighten the rear brake hose clamp bolt. Install and tighten the rear brake reservoir tank ‘mounting bolt Install the removed parts in the reverse order of removal. MUFFLER/EXHAUST PIPE REMOVAL ET Do not service the exhaust system while its hot. Loosen the exhaust pipe/muffier band bolts. Loosen the muffler front mounting nut, 2-10FRAME/BODY PANELS/EXHAUST SYSTEM Remove the muffler rear mounting boltnut, then remove the muffler Remove the muffler gasket Remove the following: Seat (page 2-2) Radiator grill page 2-4) FUEL TANK Remove the fuel tank mounting bolts, Support the rear end of the fuel tank using @ ‘equipped tool (extension, EQUIPPED TOOL Disconnect the O, sensor 4P (Gray) connector. 5 SENGOR CONNECTION \FRAME/BODY PANELS/EXHAUST SYSTEM Unfasten the tube/wire band. Release the O, sensor wire from the wire clamp. 0; SENSOR WIRE Disconnect th fon motor sub-arnse 2° Nata wasven SOcKEr a0cT comer > Mn \ saree tha eadior upper meuning seta bat |Z srdwosim Remove the radiator from the upper and lower brackets by moving it to the right, then move the rodiator/oil cooler forward as an assembly Remove the exhaust pipe joint nuts. sorter WuTS: 2-12FRAME/BODY PANELS/EXHAUST SYSTEM. Remove the following: Exhaust pipe mounting bolvnut Washer Collar Exhaust pipe ~Exhaust pipe gaskets INSTALLATION LEFT MUFFLER, RIGHT MUFFLER 26 Nm (2.7 kgtin owen) 18 Nem (1.8kgém , 13 oF) \\ 21 Nem (2.1 kate 18 IDF) / 0, SENSOR GUARD EXHAUST PIPE Install the new exhaust pipe gaskets onto the exhaust ports of the cylinder head. NoTe: Always replace the exhaust pipe gaskets with newFRAME/BODY PANELS/EXHAUST SYSTEM Install the exhaust pipe, temporarily install the ‘exhaust pipe joint nuts and mounting bolt. NOTE: install the mounting collars, washer, bolt and nut properly. First tighten the exhaust pipe joint nuts to the specified torque, TORQUE: 21 Nim (2.1 kgf, 15 Ibt th Tighten the exhaust pipe mounting bolvnut. Install the radiator/oil cooler assembly aligning the radiator grommets with the upper and lower brackets. Install the wesher and radiator mounting socket bolt, then tighten the socket bolt. Connect the fan motor sub-harness 2P (Natural) connector. WASHER SOCKET BOLT | 2P (NATURAL) CONNECTOR i 2-14FRAME/BODY PANELS/EXHAUST SYSTEM Route the 0. sensor wire and clamp it with a wire clamp. Fasten the O; sensor wire and fuel tank breather tube and overflow tube with a wire band, Connect the 0, sensor 4P (Gray) connector. 0, SENSOR CONNECTOR Remove the fuel tank support tool and close the fuel tank, Install and tighten the fuel tank mounting bolts! washers, FUEL TANK Install the following: ~Seat (page 2-2) Radiator grill page 2-4) Install the new gasket into the muffler Install the mufflers NOTE: ‘At muftler installation, align the grommet of the muffler with the hook of the muffler bracket as shown,FRAME/BODY PANELS/EXHAUST SYSTEM Temporarily install the muffler mounting bot. => Tighten the muffler bracket nut to the specified torque, TORQUE: 26 N-m (2.7 kgfim, 20 Ibft) Tighten the muffler mounting boltinut to the specified torque. TORQUE: 26 N:m (2.7 kgf , 20 Ibft) ighten to the specified torque. TORQUE: 18N-m(1.8kgfm 13 IbF*t] FOOTPEG REMOVAL Release the retaining clip end from the V-cut groove. Pull out the clip from the footpeg joint pin hole. Remove the washer, joint pin and return spring, then remove the footpes. FOOTPEG. a |FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION CAUTION: Do not reuse the retaining clip. Install the footpeg onto the holder, then install the return spring, joint pin and washer. Push the new retaining clip into the joint pin hole. Turn the retaining clip with the joint pin, then hook the clip end into the V-cut groove of the footpeg holder. JOINT PIN RETURN SPRING FOOTPEG: WASHER p FOOTPEG. 2-17MEMO.3. MAINTENANCE SERVICE INFORMATION 3-1 DRIVE CHAIN. 3-20 MAINTENANCE SCHEDULE 3-3 DRIVE CHAIN SLIDER 3-24 FUEL LINE 34 BRAKE FLUID 3-25 THROTTLE OPERATION 34 BRAKE PAD WEAR, 3-25 El CHOKE OPERATION 35 BRAKE SYSTEM 3-26 AIR CLEANER 3-5 BRAKE LIGHT SWITCH 3-27 SPARK PLUG 3-7 HEADLIGHT AIM. 3-28 VALVE CLEARANCE 3-11 CLUTCH SYSTEM 3-28 ENGINE OIL/OIL FILTER: 3-15, SIDE STAND 3-29 ENGINE IDLE SPEED 3-18 SUSPENSION 3-29 RADIATOR COOLANT 3-18 NUTS, BOLTS, FASTENERS 3-30 COOLING SYSTEM 3-19 WHEELS/TIRES 3-31 SECONDARY AIR SUPPLY SYSTEM 3-19 STEERING HEAD BEARINGS 3-31 SERVICE INFORMATION GENERAL : ‘+ Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. ‘if the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. + Place the motorcycle on @ level ground before starting any work. ‘SPECIFICATIONS - Unit: rom (in Tem ] SPECIFICATIONS ‘Throtile grip free play 2-616 Wa) aan — Bait] ‘Spark plug is CRBEHVX~ 3 (NGK) i Spark plug gap 0.80 0.90 (0.031 — 0.035) | Valve clearance |_IN. 0.16 + 0.03 (0.006 + 0.007) - x [0.22 = 0.03 0.009 + 0.001), 3-1MAINTENANCE MAINTENANCE TEM Engine oil capacity Atdraining | Recommended engine oil Engine idle speed [Drive chain stack [Atoll filter change SPECIFICATIONS, 3802 0US qt, 33 impql 2.94 (4.1 US at, 34 imp at HONDA &-stroke oor equivalent mo {P| serview classification SE, SF or SG Viscosity: SAE 10W— 40 4,100 1100 min ep) 2536 mm (1.01.4) [Recommended brake fi Dora ies za Tire size | Front 1207707817 \s@W)/Radial : _ Rear 180/86 2R17_(73W\Radial i Tire brand Bridgestone Front | BTS7FRADIALG reat sana __ Rear | BTS7A RADIAL F Michelin Front_| MACADAM90XG_— = | Rear | MACADAM 90X MI Tireairpressure _Driveronly 250 kPa (2.50 kgllem?, 36 psi a |_290 kPa 2.90 kgtiom®, 42 psi) eae P iver and passenger 250 kPa (2.50 kgflem®, 36 psi) ae 290 kPa (2.90 kgifom 4 psi) Minimum tire wead depth 45mm (006in) aa 20 mm/0.08 im) z TORQUE VALUES Timing hole cap Spark plug Cylinder head cover bolt Oil drain bolt il fiter cartridge Rearaxle nut Drive sprocket special bolt Driven sprocket nut Rear master cylinder push rod nut TOOLS i fiter wrench Drive chain tool set 1a Nm (1.8kgfim 13 IbFt] 1aNm(12kgtm9 TON-m (1.0 kgf-m, 7 29N-m/(3.0katim, 22 10Nem (1.0kgtm, 7 T1BN-m (12.0 kghim, Apply grease to the threads bff If) It fe ibf ft) Apply clean engine oil to the O-ring 87 Ibf-) Usnut 54 Nem (5.5 kgm , 40 loft) 108 N-mn (11.0 kgfem 80 lb-ft) 18 Nm(18kgtM 13 1bFH O7HAA-PI70100 O7HMH-M10103MAINTENANCE SCHEDULE MAINTENANCE A sw Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period, l:Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A; Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require ‘more technical information and tools. Consult their authorized HONDA dealer, mo FREQUENCY | WHICHEV. ©> ODOMETER READING (NOTE 1) | ~. ER COMES i Fst [Xi00km [1 TS] 1218] 24]30]38) REFER fa ~ } Xig00m'/06) 4's [12] 16/20 24 ToRAGe [ - Months | 6 [12] 18] 24 30-36 | FUELLINE rr pt] 3a 4 THROTTLE OPERATION coor ha CHOKE OPERATION oe = |_AIR CLEANER |_NOTE2 Tat Rk, 3. SPARK PLUG EVERY 12,000 km (72001 3-7 EVERY 24,000 km (14400 mi) 8 % | VALVE CLEARANCE - vf a1 ENGINE OL R[[R| wy pet 3a5 ENGINE OIL FILTER R[iat—ay_[R} 346 # ENGINE IDLE SPEED z Ce sae RADIATOR COOLANT NOTES CL Trp Rt sie % | COOLING SYSTEM COP sa9 + | SECONDARY AiR SUPPLY SYSTEM i rye} 1349 DRIVE CHAIN EVERY 1/000 km (600 mil, | 3-20 DRIVE CHAIN SUDER a iP Ti] 320 BRAKE FLUD “NOTES Tore at— 335 BRAKE PAD WEAR z Serer 325 | [BRAKE SYSTEM L Tp erp 38 [BRAKE Licht SwircH - rtp 327 + | HEADUGHT AIM Ly) 3a8 CLUTCH SYSTEM ry Pry Pra SIDE STAND Sa 2 [5 [SUSPENSION z Cpr | 329 [ok | NUT, BOLTS FASTENERS : Corr a20 WHEELSTIRES = Cpr 331 i+) STEERING HEAD BEARINGS Too tear * Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data and is ‘mechanically qualified. + NOTES: 1. Inthe interest of safety, we recommend these items be serviced only by an authorized HONDA dealer. Athigher odometer reading, repeat atthe frequency interval established here. 2, Service more frequently ifthe motorcycle is ridden in unusually wet or dusty areas. 3, Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires ‘mechanical skil 3-3MAINTENANCE FUEL LINE ‘Support the rear end of the fuel tank (page 2-11) Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. Install the fuel tank in the reverse order of removal. THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is, not smooth. Measure the free play atthe throttle grip flange. FREE PLAY: 2~6 mm (1/16—1/4 in) Throttle grip free play can be adjusted at eithe of the throttle cable. Minor adjustment are made with the uppar adjuster. Adjust the free play by loosening the lock nut and turning the adjuster Major adjustments are made with the lower adjust Remove the air eleaner housing (page 5-60) Adjust the feee play by loosening the lock nut and turning the adjuster. {After adjustment, tighten the lock nut securely. Recheck the throitle operation, Replace any damaged parts, if necessary. 34MAINTENANCE CHOKE OPERATION OFF: on: This motorcycle is equipped with a bypass air volume control choke system, controlled by the starter valve, The starter valve opens a bypass air circuit when the choke knob under the left side of the main frame is pullod ON. Choke lever operation Check for smooth operation of the choke knob. Lubricate the choke cable if the operation is not smooth, Starter valve lever operation Open and support the rear end of the fuel tank (page 2-11). Check for smooth operation of the starter valve lever. There should be no free play. Set the starter valve lever to fully closed so that the lever contacts the throttle stop screw. Check that there is @ maximum of 1-2 mm (0.04 0.08 in} of free play in the inner choke cable with the choke knob set to fully OFF. 12mm Replace the choke cable if the free play is out of (0.04 0.09 ‘specification, Install the removed parts in the reverse order of removal AIR CLEANER Disconnect the fuel pumplreserve sensor 3P (Black) connector.MAINTENANCE Remove the fuel tank rear mounting bolts, RR Pull out the fuel tank front bracket rubbers from the frame. Remove the fuel tank mounting collar, temporarily, install a fuel tank mounting bolts. Support the front end of the fuel tank using a suitable support as shown.MAINTENANCE Disconnect the IAT (Intake Air Temperature} sensor connector SCREWS Romove the screws and air cleaner housing cover. Romove and discard the air cleaner element in accordance with the maintenance schedule (page 3.3) Also replace the air cleaner element any time itis excessively dirty or damage. Install the removed parts in the reverse order of removal SPARK PLUG REMOVAL CAUTION: Be careful not to damage the oil cooler and radiator fins. Remove the radiator grll/side grill mounting bolts and then remove both side gril sockeT BOLT | Disconnect the fan motor sub-harness 2P (Natural) connector. Remove the radiator mounting socket bolt and washer. WASHER 3-7MAINTENANCE 3-8 Remove the radiator from the upper and lower brackets by moving it to the right, then move the radiator/oil cooler forward as an assembly. Disconnect the spark plug caps. NOTE: Cleen around the spark plug bases with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber. Remove the spark plug using 2 equipped spark plug wrench or an equivalent. Inspect or replace as described in the maintenance schedule. INSPECTION Check the following and replace if necessary (recommended spark plug: page 3-1) ‘Insulator for damage ‘Electrodes for wear * Burning condition, coloration Ifthe electrades is contaminated with accumulated ‘objects or dirt, clean the electrode using the spark plug cleaner. CAUTION: = This motoreyele’s spark plug equipped with platinum type electrodes. Do not use wire brush to clean the electrodes. ‘© The plug cleaner should be used with the air pressure of less than 6 kof/ent (85 psi) and for less than 20 seconds.Always use specitieg spark plugs on this mmotoreyele, Replace the plug if the center electrode is rounded {as shown in the illustration, ‘SPECIFIED SPARK PLUG: CRBEHVX~9 (NGK) Check the gap betwoen the center and side electrodes with a wire type feeler gauge, CAUTION: To prevent damaging the platinum coating of the center electrodes, use a wire type feeler gauge to check the spark plug gap. Make sure that the 1.0 mm (0.04 in} plug gauge does not insert between the gap. If the gauge can be inserted into the gap, replace the plug with @ new one. ‘CAUTION: Do not adjust the spark plug gap. Ifthe gap is out of specification, replace with a new one. Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification TORQUE: 12.Nim (1.2 kgm, 9 bf) using the new plug, install as follows: Install and hand tighten the new spark plug, then tighten it about 1/2 turn after the sealing washer tof the plug hole, Install the spark plug caps MAINTENANCE ROUNDED ELECTRODE WIRE TYPE FEELER GAUGE oxMAINTENANCE Install the radiatorfoll cooler assembly onto the upper bracket Install the radiator lower bracket boss to the Y radiator lower bracket, Install the washer and radiator upper mounting [ Saeed Reon ttt SOCMET BOLT GEA) socket bolt, then tighten the socket bolt. cee Connect the fan motor sub-harness 2P (Natural) ‘onnector, | 2 NATURAL) CONNECTOR Install the both side gril, then tighten the radiator [ —_—— Sine GAL arillside grill mounting bolts securely 3-10MAINTENANCE —_. a MINTENANCE VALVE CLEARANCE i eo.r (CAM CHAIN TENSIONER LIFTER INSPECTION \v LOCK NUT Loosen the lock nut and turn the adjusting nut to adjust free play. Hold the adjusting nut securely while tightening the lock nut If proper free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (see section 9) SIDE STAND ‘Support the motorcycle on a lever surface Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stend pivot if necessary. Chock the side stand ignition cutoff system: “Sit astride the motorcycle and raise the side stand. Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squeezed. Move the side stand full down, The engine should stop as the side stand is lowered If there is a problem with the system, check the side stand switch (section 13} SUSPENSION : Loose, worn or damaged suspension parts impair ‘motorcycle stability and control. Repair or replace any damaged components before riding. Riding a ‘motoreyele with faulty suspension inereases your risk of an accident and possible injury. FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension several times, Check the entire assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired, Tighten all nuts and bolts. Refer to saction 13 for fork service.MAINTENANCE REAR SUSPENSION INSPECTION Support the motorcycle on its center stand and raise the rear whee! off the ground, Hold the swingarm and move the rear wheel sideways with force to see if the wheel bearings are Check for worn swingarm bearings by grabbing the rear swingarm and attempting to move the swingarm side to side. Replace the bearings if any are looseness is noted. ‘Check the action of the shock absorber by com: pressing it several times. ‘Cheek the entire shock absorber assembly for sings. ‘of loaks, damage or loose fasteners. Replace damaged components which cannot be repaired, ‘Tighten all nuts end bolts Refer to section 14 for shock absorber service. NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts ere tightened to their correct torque values (page 1-13}. Check that all safety clips, hose clamps and cable stays are in place and property secured. 3-30MAINTENANCE WHEELS/TIRES STEERING HEAD BEARINGS NOTE Tire pressure should be checked when the tires are COLD. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: Front | REAR Tire pressure ~ 260 {2.60 , 36) |290 (2.90, 42) io lester’, pel) Tite sie 12070 ZRI7 | 18055 2RIT | (sew) | (73 fe | Bridgestone| — BT57F BTS7R | blona RADIALG _RADIALF eee Michelin” | MACADAM—-MACADAM [xe soxM Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels for trueness (refer to section 13 and 14) Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH: FRONT: 1.5 mm {0.06 in} REAR: 2.0 mm {0.08 in) NoTE: Check that the control cables do not interfere with handlebar rotation. Support tho motorcycle securely and raise the front whee! off the ground. Check that the handlebar moves freely from side to side. I the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (Section 13) 3-31LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFTS PISTON (CRANKSHAFT BALANCER === — MAINSHAFT i * —<——— 1 COOLER CounreRsHarT | ol PUMP ~ OIL STRAINER OILFILTER CARTRIDGE RELIEF VALVE 4-04. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM. 40 OIL STRAINER/PRESSURE RELIEF VALVE 44 ‘SERVICE INFORMATION 44 OIL PUMP 47 TROUBLESHOOTING 42 | OIL COOLER 4an2 | OIL PRESSURE INSPECTION 43 SERVICE INFORMATION zm GENERAL rw ‘+ When the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an ‘enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death, Run the engine in an open area or with an exhaust evacuation system in an enclosed area. ‘+ Used engine oll may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, itis stil advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. ‘+ The oil pump can be serviced with the engine installed in the frame. ‘+ The service procedures in this section must be performed with the engine oll drained, '* When removing and installing the oil pump, use care not to allow dust or dit to enter the engine, ‘If any portion of the oil pump is worn beyond the specified service limits, replace the oll pump as en assembly. « After the oil pump has been installed, check that there are no oll leaks and that oil pressure is correct, SPECIFICATIONS Uni mm in [ item STANDARD SERVICE UAT | Engine ol eapacity ‘At draining 3.80 (40US qt, 33imp qu) ‘Atdisassembly 4.64 14.9 US qt. 4.0 Imp qt) ee Atoll filter change | 3.94 14.1 US qt, 3.4 Imp qt) Recommended engine oll HONDA 4-stroke oil or equivalent motor oil API service classification SE, SF or SG Viscosity: SAE 10W~40 Gil pressure ail pressure switch 400 kPa (5.0 kgm, 71 pal at 500 min epmt@0 “C176 i! pump rotor | Feed pump — | Tip dlesrance | 0.15 0.006] max, “220 (0.0081 Body cloarance | 0.15.01 (0.006 0008) 0135;0.014) Side clearence — | 004~-0.09(0.002—0.003) 0.120.005) Cooter pump | Tipelearance | 0.15 0.0051 max. F020 (0.008; Body clearance | 0:15-0:21 (0.006-0.008) Side clearance — | 004-0009 (0.002— 0.004) 0.1200LUBRICATION SYSTEM. TORQUE VALUES Oil drain bott Dilfiter boss Oil pump assembly flange bolt Oil pump driven sprocket bolt Gil strainer nut Oil fiter cartridge Oil pressure switch Oil pressure switch wire terminal screw il pipe mounting bolt TOOLS Oil pressure gauge Oil pressure gauge attachment Oil filter wrench TROUBLESHOOTING Engine ol level too low ‘*Oil consumption ‘External oil leak ‘Worn piston ring or * Worn valve guide or seal Low or no oll pressure * Clogged oil orifice * Incorrect ol being used No oil pressure * Oil love! 100 low ‘Oil pump drive sprocket broken + Oil pump damaged ipump shaft) ‘Internal oil leak 42 \correet piston ring installation 29 Nem (3.0 kgf m, 22 Ib 18 Nim (1.8 kgf, 13lbF Fy) 13 Nm (1.3 kgm ,9 bE) 15 Nem (15 kgf 11 bt) 12Nem(1.2 kgm ,9 Ft) AONem (1.0 kgfim , 7 bit) 12Nm(1.2 kgm, 9 bt) 2N-m (0.2 kefm, 1.4 bff) A2Nem (1.2 kgtm , 9 IbF ft (07506-3000000 (07510-4220100 o7HAA-PI70100 Apply @ locking agent to the threads CT bolt Apply @ locking agent to the threads Usnut ‘Apply clean engine oil to the O-ring Apply sealant to the threads Apply @ locking agent to the threads Low oil pressure ‘Clogged oil strainer sereon * Oil pump worn or damaged ‘Internal oil leak * Incorrect oll being used * Low oil level High oil pressure * Plugged oil filter, gallery, or metering oritice * Incorrect oll being usedLUBRICATION SYSTEM. OIL PRESSURE INSPECTION NOTE: If the oil pressure indicator light remains on a few seconds, check the indicator system before check ing the oi! pressure. Check the oil level (page 3-15), Warm up the engine to normal operating tempera: ture {approximately 80 °C176 °F). ‘Stop the engine and disconnect the oil pressure switch wire connector from the switch, Romove the oll pressure switch and connect an oil pressure gauge and attachment to the switch hole. TooLs: Oil pressure gauge 07506-3000000 aivalent commercially available) Oil pressure gauge attachment 07510-4220100 (Equivalent commercially available) Start the engine and inerease the rpm to 5,400 min” oupnessune Bo not apy sean wo te ead] USS EPe eC katon?, 7 psi at 400 in pe Bono poy sealant the reed (80°C/176 °F) ss 7 Stop the engine and remove the tools. Apply sealant to the threads of the oil pressure switch, Install ang tighten itto the specified torque, TORQUE: 12.N-m (1.2 kgf-m ,9 IDF cauTION To prevent crankcase damage, do not overtighten © the switch. Connect the oil pressure switch connector, tighten the terminal serew to the specified torque TORQUE: 2 Nim (0.2 kgm, 1.4 Ib OIL PRESSURE SWITCH a3LUBRICATION SYSTEM OIL STRAINER/PRESSURE RELIEF VALVE REMOVAL Drain the engine oil (page 3-16) Remove the exhaust pipe (page 2-10). Remove the oil pan flange bolts. Disconnect the oil return pipe from the lower crankcase and remove the ol pan. Remove the pressure relief valve and O-ring Remove the oil strainer and oll pipe set plate nut ‘and plate. Fomove the oil strainer and gasket. Clean the ol strainer sereen, 4-4LUBRICATION SYSTEM. Remove the bolts, cil pipe A, B and O-rings. INSPECTION Check the operation of the pressure relief valve by pushing on the piston. Disassemble the relief valve by removing the snap ring & WASHER Inspect the piston for wear, sticking or damage. ts / Inspect the spring for weakness or damage. Oe / RELIEFVALVEBODY t Assemble the reli valve in the reverse order of / 65 disassembly, | / | | SPRING SNAP RING INSTALLATION Apply oil to the new O-rings and install them onto. the oll pipe A and 8. Install the ol pipe A and B into the crankcase. Apply a locking agent to the oil pipe mounting bolt threads. Install and tighten the oil pipe mounting bolts to the specified torque. TORQUE: 12.Nim/(1.2 kof'm, SbF)LUBRICATION SYSTEM Apply oto the new gasket and install it onto the oil strainer. Install the oil strainer into the crankcase while aligning its grooves with the boss and stud bolt in the oll pump body. Install the oil strainer set plate aligning its cut-outs with the oil pipes, Tighten the nut to the specified torque. TORQUE: 12.Nim (1.2 kgfm 9 Ibfft) Apply oil to the new O-ring and install it onto the roliof valve. Install the relief valve into the crankcase. Clean the oil pan mating surtace thoroughly. Apply Three Bond 12078 or an equivalent to the mating surface. CAUTION: Do not apply sealant more than necessary.LUBRICATION SYSTEM Install the oil pan onto the lower crankcase Temporarily tighten the two bolts first, then tighten the all bolts ina crisscross pattern in 2~3 stops. Install the exhaust pipe (page 2-13). Fill the crankease with recommended ail (page 3.16} NOTE: ‘After installation, check that there are no oil leaks. OIL PUMP REMOVAL Remove the following Clutch assembly [page 9-4) Oil strainer and oil pipes [page 4-4) Remove the bolvwasher, then remove the cil pump driveldriven sprocket, clutch outer guide and drive chain as an assembly. Remove the three flange bolts and oil pump assem: by. DISASSEMBLY NoTE: If any portion of the oll pump is worn beyond the specified service limit, replace the oil pump as an ‘assembly. Straighten and remove the cotter pin, Remove the valve seat, spring and pressure relief valve. Chock the pressure relief valve for wear or damage,LUBRICATION SYSTEM 48 Remove the oil pump assembly bolt, ASSEMBLY BOLT Remove the oil pump cover and dowel pins. COSTER pons Sine DOWEL PINS. Remove the cooler pump outer rotor and ianer Gyre ROTOR | Remove the drive pin. Gi _ INNER ROTOR x \ lL PUMP COVER DRIVE PIN Remove the oil pump spacer and dowel pins. HWS es ae Dowel PINs outer rotor and inner rotor from the oll pump body. oavérn | \ WASHER IL PUMP SPACER INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. ‘Measure the tip clearance for the feed and cooler 9% pump. 1 ‘SERVICE LIMITS: » Feed pump: 0.20 mm (0.008 in} Cooler pump: 0.20 mm {0.008 in}LUBRICATION SYSTEM. Measure the pump body clearance for the feed and cooler pump. ‘SERVICE LIMITS: Foed pump: 0.35 mm (0.014 in) Cooler pump: 0.35 mm (0.014 in) ‘Measure the side clearance for the feed and cooler pump using a straight edge and feeler gauge. ‘SERVICE LIMITS: Feed pump: 0.12 mm (0.005 in} Cooler pump: 0.12 mm (0.008 in} ASSEMBLY COOLER PUMP OUTER ROTOR \ COOLER PUMP INNER ROTOR DOWEL PINS | VAY / / SWI A, SS / O» On DRIVE PIN CO RELIEF VALVE Dor \ ° 3 / reeopume ft ue SERRATOn |G OIL PUMP SHAFT jones | awe PIN \ ‘ OIL PUMP COVER DOWEL PINS OIL PUMP SPACER 49LUBRICATION SYSTEM Install the feed pump outer and inner rotors into the EEED PUMP SIDE: cil pump body, Dowel PINS. Install the oil pump shaft through the oil pump body and inner rotor. Install the drive pin into the hole in the pump shaft and align the pin with the groove in the inner rotor as shown, ‘ Install the thrust washer a Install the dowel pins and oil pump spacer DRIVE PIN WASHER OIL PUMP SPACER Install the drive pin into the hole inthe pump shaft. ¢goLER PUMP SIDE. Pin Install the cooler pump outer and Inner rotor into On EEE nS the oil pump cover. ourenaciod Install the dowel pins. Install the oil pump cover assembly onto the oll pump body. G INNER ROTOR \ OIL PUMP COVER, ORIVE PIN Install and tighten the assembly bolt to the spect SSaAORSOE fied torque. TORQUE: 13.N-m (1.3 kgfm 9 IbEft) Check the oil pump operation by turning the pump shaft. necessary, reassemble the oil pump. Install the oil pressure rolief valve with its small .D. side facing the spring, Intall the spring and spring seat. SPRING SEAT RELIEF VALVE 4-10LUBRICATION SYSTEM Hold the spring seat and install a now cotter pin, Bend the cotter pin securely as indicated in the ‘llustation, INSTALLATION Install the oll pump into the crankcase while aligning the pump shaft lug with the water pump shaft groove. Install and tighten the three flange bolt seaurely, Apply oil to the clutch outer guide, oll pump drive sprocket, driven sprocket and drive chain, ‘nstai! the oi! pump Inetall the clutch outer guide, drive‘dtriven sprocket riven sprocket and drive chain as an assembly, with ts “OUT! mark facingLUBRICATION SYSTEM Apply @ locking agent to the oil pump driven sprocket bolt threads. Install and tighten the driven sprocket boltwasher tothe specified torque TORQUE: 15 Nim (1.5 kgm 17 Ibtt) Install the following: Oil strainer/oil pipe and oil pan (page 45) Clutch assembly (page 2-3} ‘After installation, fill the erankease with recom: ‘mended oll and check that there is no oil leaks. Check the oil pressure (page 4-3) OIL COOLER aw REMOVAL Drain the engine oll (page 3-16) Remove the radiator grill (page 2-4) Remove the oil cooler hose joint mounting bolts, and cooler hoses. Remove the oil cooler mounting bolts and oil cooler. Remave the oil pipe guide mounting bolt BOLTS 4-12LUBRICATION SYSTEM Remove the SH bolts and oil cooler pipes and O- fF rings. INSPECTION Check the oil cooler air passage for clogging or damage. Straighten bent fins with a small, flat blade screw- driver and remove insects, mud or other obstructions with compressed air. Check for any oil leakage from the oil cooler and hose. INSTALLATION lL COOLER. 4-13LUBRICATION SYSTEM Apply clean engine oil to the new O-rings, and install them onto the oil cooler pipes. Install the oil cooler pipes into the lower crankcase install and tighten the SH bolts, Install the oil pipe guide to the eylinder block, and tighten the bolt Install the oil cooler onto the radiator brackets. Install and tighten the oil cooler mounting bolts. CAUTION: Do not cross thread or overtighten the oil cooler ‘mounting bolts. 4-14LUBRICATION SYSTEM Apply clean engine oil to the new O-rings and install them onto the oll cooler hose joint fiango. Install the oll hose joints to the oll cooler and tighten the bolts securely Pee Fill the crankcase with recommended engine oll (page 3-18), and check for ol leaks. Install the radiator grill (page 2-4). 4-15FUEL SYSTEM (Programmed Fuel Injectioin) i Bs evote na ‘ 15. Nem (1.5 kgm, 11 Ibfft) / 22.Nem (2.2 kgf-m , 16 IDF) 5-05.FUEL SYSTEM (Programmed Fuel Injection) SERVICE INFORMATION 54 STARTER VALVE 5-70 ‘TROUBLESHOOTING 53 STARTER VALVE SYNCHRONIZATION 5-75 SYSTEM LOCATION 54 MAP SENSOR 577 ‘SYSTEM DIAGRAM 55 IAT SENSOR 577 PGM-FI (PROGRAMMED FUEL INJECTION) SYSTEM 56 ECTSENSOR 5-78 PGM-FI SELF-DIAGNOSIS MALFUNC- CAM PULSE GENERATOR 5-78 TION INDICATOR FAILURE CODES 5-10 ‘TP SENSOR 5-80 FUEL LINE INSPECTION 5-51 BANK ANGLE SENSOR 5-81 FUEL PUMP 5.54 ENGINE STOP RELAY 5-82 FUEL CUT RELAY 5-55 KNOCK SENSOR 5-83 FUEL TANK 5-56 ECM(ENGINE CONTROL MODULE) 5-83 AIR CLEANER HOUSING 5-60 PAIR CONTROL SOLENOID VALVE 5-84 THROTTLE BODY 5-63 0, SENSOR 5-85 INJECTOR 5-68 SERVICE INFORMATION GENERAL ‘Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Be sure to relieve the fuel pressure while the engine is OFF. Bending or twisting the contro! cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. ‘* Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can ‘cause a fire or explosion, CAUTION: * Do not apply commercially available carburetor cleaners to the inside of the throttle bore, which is coated with ‘molybdenum. Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle operation. * Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports ‘after the throttle body has bean removed. * Do not damage the throttle body. It may cause incorrect throttle and idle valve synchronization. * Prevent dirt and debris from entering the throttle bore, fuel tube and return tube, clean them using compressed air. * The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual. * Do not loosen or tighten the white painted bolts and screws of the throttle body. Loosening or tightening them can cause throttle and idle valve synchronization failure. ‘Tighten the yellow painted bolts and screw of the throttle body to the specified torque. Yellow painted parts of the throttle body not shown in this manual should not be disassembled. ‘+ Do not push the fue! pump base under the fuel tank when the fue! tank is stored. + Always replace the O-ring when the fuel pump is removed.