1. General Information General Safety 14 Model Identification 13 Specifications 14 | Torque Values ata 1.47 |_ Toots General Safety Carbon Monoxide I the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an en: closed area + The exhaust contains poisonous earbon monoxide gat that can cause loss of consciousness and may lead ta death. Run the engine in an open atea or with an exhaust evacua- tion system in an enclosed area Gasoline Work in 2 well ventilated area. Keep cigarettes. flames or sparks away fram the work area or where gasoline is stored + Gasoline is extremely flammable and is explosive un- der certain conditions. KEEP OUT OF REACH OF CHILDREN. Hot Components. + Engine and exhaust system parts become very hot and remain hot for some time after the engine is tun. Wear insulated gloves of wait until the engine and exhaust system have cooled before handling these parts. Lubrication & Seal Points 1.19 Cable & Harness Routing 1-21 ion Control Systems 4-27 1 Control Information Labels 1-30 (U.S.A. Only) Used Engine/Transmission Oil [4 wanwnc A + Used engine oil (or transmission oil in two-strokes) | 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 still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil, KEEP OUT REACH OF CHILDREN. Brake Dust Never use an air hose or dry brush to clean brake assem blies: Use sn OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the haz ard caused by airborne asbestos fibers. + Inhaled asbestos fibers have been found to cause respiratory dise: Brake Fluid CAUTION + Spilling fluid on painted, plastic or rubber parts | 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 Nitrogen Pressure For shock abverbers with a gas-lilled reservoir nom ar * Use only nitrogen to prassurize the shack absorber The use of an unstable gas can cause a fire or explo sion resulting in serious injury +The shock absorber contains nitrogen under high pres: sure. Allowing fire or heat near the shock absorber could lead to an explosion that could result in serious injury Failure to release the pressure from a shock absorber befor disposing of it may lead to a possible explosion and serious injury if itis heated or pierced. To prevent the possibility of an explosion, release the nitro~ gen by pressing the valve core, Then remove the valve stem from the shock absorber reservoir Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock adsorber, Battery Hydrogen Gas & Electrolyte | Mn da protective clothing and a face shield. | 1-2General Information Model Identification (3) VEHICLE IDENTIFICATION NUMBER The Vehicie Identification Number {VIN} is located on the Safety Certification Label on the left side of the steering head. POT CR aN (WY Vers, (2) ENGINE SERIAL NUMBER. ‘The engine seria! number is stamped on the lower left side of the crankcase. (9) FRAME SERIAL NUMBER ‘The frame serial number is stamped on the right side of the steering head. [4) CARBURETOR IDENTIFICATION NUMBER. The carburetor identification number is stamped on the left side of the carburetor body, (5) COLOR LABEL The color label is attached to the left rear frame tube 3s shown. When ordering color-coded parts, always specify the designated color coe, 1-3.General Information Specifications Unit: mm tin} — General | tem Specifications Dimensions | Overall length 2.185 (86.0) Overall width 855 (33.7) Overall height 1,285 (49.0) | Whee! base 1,485 157.3) Seat height 950 (37.4) | Foot peg hei 415 (16.3) Ground clearance 330 (13.0) Dry weight | 147 kg 1324 Wo) Curb weight 157 kg (346 Ib) Maximum weight capacity 149 kg (328 fb) Frame Frame type Semi-double cradle with steel pipe Front suspension Air asist Telescopic fork Fork inner tube diameter 43.0 (1.69) Fork fluid capacity (per leg) 564 cm? (19.1 US oz, 19.8 Imp oz) Front whee! travel 295 (11.8) Steering heed bearing Tapered roller bearings Rear suspension Proslink with mono strut swingarm Rear wheel travel 280 (11.0), Rear damper Reserve tenk type Damper/Reservoir gas pressure 1471 kPa (15 kgiem?, 213 psi) Pressurized gas material Nitrogen Front tire size 3,00-21 51S tube type Rear tire size 4.60-18 63S tube type Tire tread coad (Dunlop) —_-FR/RR, K850/K850_ Tire tread coad (Bridgestone) FR/RR, —— Tite treed coad (Metzler) FRVRR. — Tire tread coad (Pirelli) FR/RR — Front brake Hydraulic single dise Rear brake Hydraulic single dise Caster angle 63°35" Trail 97 (3.8) Fuel tank capacity 10.5 liter (2.77 US gal, 2.31 Imp gal) Fuel tank reserve capacity 2.3 titer(0.61 US gal, 0.51 Imp gal) _| Engine Bore and stroke 100 x 82 (3.9 x 3.2) Displacement 644 cm? (39.3 cu-in) Compression ratio 83:1 Valve train Silent multilink chain driven and OHC with rocker Intake valve opens 5° BTDC. Intake valve closes 40° ABDC: : Exhaust valve opens 45° BaDC——@* 1M (0.04 in) lift Exhaust valve closes 5° ATOC- Lubrication system Forced pressure and dry sump ll pump type Trochoid Cooling system ~ Air filtration Paper filter (Wet type) Crankshaft type Assembled type 2 main journals Engine weight 81.1 kg (113 Ib} Firing order Cylinder arrangement Cylinder number Single cylinder, 18° inclined from verti 1-4General (Cont'd - a I carburetor Electrical tem Carburetor type Throttle bore Cluteh system Clutch oper Transmission Primary reduction n system Final reduction Gear ratio 1st Gear ratio 2nd Gear ratio 3rd Gear ratio ath Gear ratio Sth Gearshift pattern Tgnition system Starting system Charging system Alternator capacity Regulatorirectifier type Lighting system Fuel reserve warning system General Information Unit: nm (in ‘Specifications Constant Velocity single carburetor 42.5 (1.67 _ Multi-plate, wet Cable operating 5 speeds constant mesh 2.029 (69/34) 3.000 145/15) 2.666 (32/12) 4.647 (28/17) 1.250 (25/20) 1.000 123/23) 0.840 121/28) Left foot operated return system [1-N-2-3-4-5) CDI unit including the side stand inhibiting and igni- | tion cut out circuits. Electric starter with one-way clutch Triple phase output alternator 186 W/5,000 rpm SCR shorted triple phase, full-wave rectification Battery 1-5General Information Lubrication rem Engine oll capacity at draining at disassembly at oil fiter change Recommended engine ail ssure at oil pressure switch (BO°C/176°F) Jump rotor tip clearance ® boay clearance @ I end clearance @ Oil p oi Standard 1.9 lt (20 US qt, 1.7 Imp. ad 2.3 it 12.4 US qt. 2.0 Imp, at 1.95 lit (2.06 US at, 1.72 Imp. at) Use Honda GN4 4-stroke oll or equivalent API Service Classification: SE or SG viseasity: SAE 10W-40 Other viscosity shown in the chart may be Used when the average temperature in your riding area is within the indicated range. 0.15 (0.008) 0.18-0.21 (0.008-0.008) 0,020.08 (0.001 0.003) Unit: mm tn) Service Limit 0.20 10.008) 0.25 10.010) 0.42 10.005) Fuel System Carburetor identification number EBSA — (California mode | VEBEA Main jet | Type Frame Serial Number Main Jet/(High Altitude) so sien 000001" "PM-O00958™ #155/(# 152) “ Alter “PM-000958"" #152/(# 150) cain | =PM-000001""—""PM-000078" | #1552 152) aitoria L L ‘ter "PM-000078"" #152i(# 150) Canada I All products # 152/(# 150) 23) — — | 114) — a | (Front) — | (Peer) — — Siow jot #50 — { Jet needle clip position — | Plot screw initial opening See nage 5-10 \ (California model) — Pilot serew high altitude adjustment See page 5-11 — Pilot screw final opening Air screw initial opening | (California model) Air screw high altitude adjustment See page 5-10 1-6General Information Units mm find Fuel System (cont'd) oe vem Standard Service Limit | carburetor vacuum citference | Base carburetor For carburetor synchronization) — | ile spees 1,300 = 100 rpm Throttle grip tree play 26118-1181 Accelerator pump clearance 0 Secondary air supply system Air injection control valve vacuum pressure 330 mmiig (19.0 in [Cylinder Head % b.1gs0.00 aos 0 001 = camsnat nou ® te” esvacon ® | an T Oo ajhonhb © | Camstet jours 0. _— — @ | cohes = ave nem O84 6:575-6.500 (0.2569-0.2594 2.36 0.280 x 8805-0878 0 2888 0.28891 8.58 0228 Vee aide 10. Siooceersioseer—asee | Ses 020m sterto-gulde eiesance IN b.er0=0020 1.0008 0 00%6) bios 2002) & $.930~.038 1.0002 0.0022) O18 (003 & |= - Before guide installation: | 1g Sst ee s0DeR & Tart Boscoee 210081 outer EX seo una sSo uae anh 38 a1 seo ae 9 £K 11.800—11.518 (0.4528—0.4535) 11.55 (0.4551 | pecker sm shalt 015° ieee tase paceceasen | fen taees) Sub-rocker arm-to-rocker arm shaft clearance 0.028—0.046 {0.001 1—0.0018) [0.10 (0.0041 1-7General Information CylingeriPiston ——— Unit: mm tin) Main journal oil clearance ‘tem Stondara Service Limit F eviinder 10 100.00 100.010 (8.9870-3.987a) | 100.12 18.982 | Cylinder out of round pee 0.08 (0.602) Cylinder taper : 0.08 (0.002) Cylinder warpage |— 0.10 10.008) Piston mark deetion IN mark facing toward the intake side Piston 0.0. (D1 99.960-99.980 (3. 9354-3.93621 | 99.85 (9.931) Piston ©.D. measurement point (H) 28 11.0) from the bottom — Piston pin hole LD. 1) 24,002--24.008 (0,9450-0.9452) 24.03 (0.986) Coy}. pL | Co D Cyiinder-to piston clearance 0.020-0.050 (0.0008 -0.00201 0.12 (0.005) Piston pin 0.0. 23.952--23,996 (0.9446-0.9447) 23.96 (0.942) Piston-to-piston pin clearance 0.008 ~0.016 (0.0002 0.0006) 0.07 (0.003) Connecting rod-to-p'ston pin clearance 0.024-0.049 (0.0008 0.0019) 24.07 (0.948) Top ring to-ing groove clearance 0.018--0.045 (0.0008 0.0018) 0.12 (0.008) Second ring-to-8 groove clearance 0.018 -0.048 (0.0006-0.0018) 0.12 (0.008) Top ring end gp 0.20--0.40 (0.008 0.016) Second ring end 969 0.35-0.55 10.014-0.022) — iting {side rail end gap 0.2-0.7 10.01 0.03) — Top ring mark Install with the marked side Up j= Second ving matk L install with the marked side UP | — F—_ Crankshatt = Connecting red small end 1.0. 24,020~24.041 (0.9487 -0.9465) 24.07 (0.948) Connecting rod big end side clearence 0,050--0.480 (0.002~-0.0177) 0.60 10.024) radial civarance 0,006-0.018 (0.0002-0.0007) 0.08 10.002) Crankshaft runout — J 9.10 10.004) Sm H | 2 eke | (0.24 79) poug'-) foup (0-24 int | Crankpin oil clearance — - Granksin bearing selection — |— | Main journal bearing selection 1-8General Information L Unit; mm fin Transmission = tem a es ‘ & 3 is 0 ci 5 S g ) Gear-to-bushing clearance at M5 gear a Shift fork shaft 0.0. at Ma, C2 gear Mainshatt 0.0. at M4 gear Countershaft 0.0. at C1 gear at C2 gear at C3 gear cs ca c2 = — Gear-to-shaft clearance Gear bushing-to-shaft clearance at C1 gear at M4, C2, C3, gear Shift fork claw thickness : L BO Shift fork 1.0. bor Standard 28.020- 28.041 (1.1031—1. 1040) 28.000~ 28.021 (1.1024—1.1032) 25.020- 25.041 (0.9860-0.9858) 28.020~28 043 (1.1031~1.10401 28.020~28.041 (1.1031—1.1040) 27.979 28,000 (1.1015~ 1.10241 27.949 27.980 {1.1004~ 1.1016) 24.984~ 25,005 (0.9836-0.9844) 27.979 28.000 (1.1015— 1.1024) 27.979 28.000 {1.1015—1.1024) 28.020- 25.041 (0.9850-0.9859) | 20.020- 20.041 (0.7882-0.7890) 25.020- 25.041 (0.9850-—0.9859) | 25.020 25.041 (0, 9850—0.9859) 0.020-0.072 (0.0008-0.0028) 0.015-0.087 (0.0006~ 0.0022) 0.020--0.082 (0.0008—0.0024) 24.972~24.993 (0.9831 ~0.9840) 19.980- 19,993 10.7866—0.7871) 24.972—24,993 (0.9831 0.9840) 24.959~24.980 |0.9826—0.9835) 0.027—0.081 {0.0011 ~0.0024) 0.027—0.069 {0.0011 ~0.0027) 4.930~5,000 (0.194—0.197) 4.930—5,000 (0.194—0.197) 4.930—5.000 (0.194—0.197) 14.000~ 14.018 (0.5512—0.5519) 14,000-14.015 (0.5512~0.5518) 14,000~14.018 (0.5512—0.5519) 13.966-13.984 (0.5498~-0.5506) 13,966— 13.984 (0.5498 0.5506) 13.966~ 13.984 (0.5498—0.5506) Service Limit 28.10(1.108) | 28.08 (1.106) 25.10 (0.988) 28.10 (1.106) 28.10 (1.106) 27.93 (1.100) 27.90 (1.088) 24.93 (0.981) 27.93 (1.100) 27.93 11.100) 25.10 10-988) 20.01 (0.788) 25.10 (0.988) 25.10 (0.988) 0.10 10.004) 0.10 (0.004) 0.11 10.004) 24.92 (0.981) 19.94 (0.788) 24.92 (0.981) 24.92 (0.981) 10 (0.004) 0 (0.004) 18) (0.18) 4.5 (0.18) 14.05 (0.553) 14.08 (0.553) 14.05 (0.55: 13.90 (0.547) 13.90 (0.547) [13.90 (0.547) ot ot jas 45 1-9General Information Units mm tind = Clutch System - - them Standard Service Limit | Clutch lever free play 10-20 13/8374) Recommended clutch uid — Clutch master cylinder 1.0, — Clutch master piston 0.0. — Cluteh outer 1.0 27.000~27.021 {1.0630— 1.0838) 27.08 (1.065) Clutch outer guide 0.0. 26.959 26.980 (1.0614 1.0622) 28.91 (1.059) 0. 21,980- 22.040 (0.8657~0.8677) 22.05 (0.868) Mainshaft 0.0. at clutch outer guide 21.967— 21.980 (0.8648~0.8654) 21.83 (0.863) Oil pump drive sprocket 1.0. — Clutch spring free height Clutch spring free length 44.7 (1.76) 43.1 (1.70) Clutch disc thickness 2.92-9.08 (0.115-0.121) 2.6 (0.10) Clutch plate warpage | — 0.15 (0,008) Centrifugal clutch drum 1.0 | | bushing 0.0. = '— | Centrifugal clutch center guide 1.0. — 0.0. | — Centrifugal clutch center guide collar height — | Centrifugal clutch weight lining thickness Centrifugal clutch spring free length — Clutch fining thickness — Crankshatt 0.0. at clutch center = Drive Train 1 Recommended final drive oil — Final drive gear oll capacity st disassembly — at draining — Final drive gear backlash — Ring gear-to-stop pin clearance (Al = Stop pin shim —_ Bing gear spacer — Pinion spacer — Output gear backlash Output gear 1.0. — Output gear bushing 0.0. — if LD. — Output drive shaft 0.0. — —_ Output gear damper spring free length — Output shaft adjustment shim — Countershaft drive shaft adjustment shim —_ 1-10veneral intormation Unit: mm tint Wheels/Tires tem Standard Service Limit F Minimum tire thread depth (FAD 301012) 3 ‘RR 3.010.121 | Cols tire pressure Up 10 90 kg {200 1b) load (FR) | *150 kPa (1.50 kg/em? — | Up 10 90 kg (200 1b) load (RA) _—_—_-150 KPa (7.80 kavem? Up to maximum went capacity (FR) 150 kPa (1.50 kalem? — Up to maximum weight capacty (RR) 150 kPa (1.50 kgiem?, 2 Front and rear axle tunout | 021000 @ | For: 8 coor wet rm runout Rasa — 2.0 (0.08) (axial - | 2.0 (0.08) Front wheel hub-to-rim distance 20.25 (0.797) — Front wheel hub standard surface i= Rear whee! hub-to-rim distance 9.0 10.78) — Rear whee! hud standard surface Wheel balance weight Front ear ] Drive chain slack | 38-45 11-3/8—1.3/4) — Drive chain sizefing (DID) Dios20ver110L€ (RI RKS2OMOZO/10LE ~ Front Suspension ————_— Fork spring free length 576.0 (22.68) 870 (22.49 Fork spring free length A - - 3 = = Fork spring direction With the taper end facing down Fork tube runout — 0.21001) Recommended fork oll Fork Fluid Fork oi level 145 (6.7) Fork ol level (R) — — a) — — | Fork oit capacity (A) — = w — — Fork sir pressure okPa Steering bearing preload 111.6 kg — — Rear Suspension - ‘Shock absorber spring free fength 225.3 (8.87) 223.1 (8.78) Shack absorber spring free length (Al — — ‘8 Damper gas pressure 1471 kPa (15 kofom?, 213 psi) — Damper compressed gas Nitrogen — Damper rod compressed force at 10 mm (0.4 in compressed 25.5 kg (56.22 1b) Damper driling point — | — (Standerd) 200.3 (7.89) - OARS Gack ma \ { = Adjustable range) 195-205 (7.7—8.1) — out yh With the taper end facing down ae Recommended shock absorber ol = Shock absorber ol capacity | air pressure 1-11General Information Brakes — —— _ Unit: me (nt tem Standard Service Limit Front brake fluid [bors _ brake lever free ploy — broke pad wear indicator — to the groove ® | | | brake dise thickness 4.0 (0.161 3.5 (0.14) brake dise runout — 0.3 (0.01) master cylinder I.D. 12.700~ 12.743 {0.5000-0.5017) 12.78 (0.502) master piston 0.0. 12.657 12.684 (0.4983-0.4994) 12.64 (0.498) caliper eylinder 1. 27.000-27.060 |1.0630— 1.0650) 27.06 (1.085) caliper cylinder LD. (Upper) — — Lower) caliger piston 0.0, 26 900- 26.950 (1.0591 ~1.0610) caliper piston 0.0. (Upper) (Lower) brake dum 1.0. brake lining thickness Rear brake fluid brake pedal height brake pedal free play brake pad wear indicator brake dise thickness master cylinder I.D. master piston 0.0. coliper cylinder 1.0. caliper piston 0.0. brake drum 1.0. brake lining thickness 5.0 (0.20) 12,700~12.743 (0.5000—0.5017} 12.657—12.684 (0.4983—-0.4994) 27.000—27.050 {(1.0630— 1.0650) 26.935~ 26.968 (1.0604—1.0617) 26.85 (1.057) to the groove @ 4.0 (0.16) 0.4 (0.02) 12,76 (0,502) 12.63 (0.497), 27.08 (1.085) 26.91 (1.053), [— BatteryiCharging System Alternator tated output Alternator charging coil resistance (At 20°C/68°F) Regulatorirectifier regulated voltage/amperage Battery capacity Battery specific gravity (Fully charging) (Needs charging) Battery charging rate (Normal) (Quick) Battery voltage (Fully charged 20°C/68°F) (Needs charging 20°C/68°F) ator lighting coil resistance (At 20°C/68°F) AC reguleter regulated voltage IWith analog type) {With digital type 4.86 WIS,000 rpm 02-129 44.7-18.5 V/13 A at 5,000 rom 12V-8 Ab 0.9 Ax5~10h 4.0 A1.0 b 13.0-13.2 V Below 12.3 V 1-12General Information Unit: ma fin) [— Starting System a Starter driven gear 0.0. 57.788--67.768 (2.2738~ 2.2743) 57.66 (2.270) Starter clutch outer 1.0 74.414—74.440 [2.9297 ~2 9307) 74,46 (2.931), eo Starter moter brush spring tension 920 & 140 9 (32.4 + 4.9 021 ~ rush length 42.5 (0.49) 6.5 (0.26) Ignition System item sandra Service Limi @ [Seow DPAGEAS GR = X2aE>RUS (NFPONDENSO) | (For cold cimatofblow 5°c/412F1 paves 9 Gk) = XazeF8 U9 NIPFONDENSO} For extended igh speed riding pasa Wek) — X27EPR a IIFPONBENSO) Spar pus 09 @.e-09 10021-0035 = D | eter tite rm | Searbert,300 2 100 rpm = Ravence son 2/2200 ior sp 28/4009 pm = rut advonce 28°B7DC at 4,000 rom = htenatorexcter coll resistance (At 20°CI68°°1 = Ignton sal vesstonce (hima: at 20°C188"F) 0.190.290 (Secondary with plug cap) | 688.740 = (Secondary wiinot plug cop) | 2.884 Ko = Pulse generate resistance tA 20°C758°F1 iassi7n Lights/Meters/Switches License light — Position light bulb — Front turn signal/running light —_ Front turn signal light 12. V-32 CP x2 —_ Rear turn signal light 12 V-32 CP x2 Instrument lights 12Vv-2cP — il pressure warning indicator — Tailfbrakelight warning indicator — a Side stand warning indicator 12 V—1 cP — Low fuel indicator — Coolant temperature indicator — a Gil temperature indicator — — High beam indicator 12V-1P — Turn signal indicator 12-2 CP - Neutral indicator 12V-2P —_ Reverse indicator — Overdrive indicator — - Oil temperature sensor resistance —_— Fuel unit resistance (at full level) — — fat low levell - 9 | pump flow capacity (min./minute) Coolant temperature sensor resistance Fan motar switch Starts to close (ON) — Stops to open {OFF — 1-13General Information Torque Values Standars Fasteneis Type Torave_ Nem (kg-m, ft-lb) ut 5 (0.5, 4) Fasteners Type Torque Nem tkg-m, ft-lb) 5 mm hex bolt ané 5 mm screw 410.4, 3 | coma weet [Sue se cia Beet, [ER amm | IEF Viewers, | ELS [tmicentrmot | SES teemmmnndnn | seein |Pimammminenn | 3242.39 mmmgemenss, | pane | ~ ope nan ga ne : Sie epee nen wm ss a Se 2 ne as TT: a ot te te OSS rs 5 unt msn Uevantanins CERSSIOS tg a fletruecu cease Soe ae 1 Shoe oot i 7 eee trem Oty gia. mm) | Nem tkg-m, fetb) Remarks nn oe ; 04,0 rasan : uate cristae |e | igs lca | g | saey ots i | & | sees Oo ie a |G | Biss oan i | = | Skse ode ee woe 93.19 Cae no BEE |e te ' | aes fem | | Biss Rocker arm shaft 2 | 27121720) | Note 2 te en : See |tce2 % 2 | Bane [m2 Valve adjusting screw lock nut 4 | 25 (2.5,18) coogi Li BER (ames cd i | Bagi acre Sioa tre Sin : | BEES nee oh ee 1 Right crankcase cover b Jou 6 12:(1.2,9) So "| & | Biifn mune a P| od | BEES Gearshift cam bolt \ 1 6 12:{1.2,9) Note 2 ones i |g | gies ESTE hana i]s | Bee ja 1-14 @ 6General Information = Engine (cont'd) — | Nem any dia. (mm) Nem (kg-m, ft-lb) Remarks: 9 Left crankcase cover belt 7 6 wos | Flywheel bolt 1 12 125 (12.5,90) | Note 6 Starter one-way clutch torx bolt 6 8 1 30 (3.0.22) | Note 2 Dd — rome em oy dia. (mm) N-m (kg-m, ft-lb) Remarks | Framerbody panels: i 1 3 Exhaust pipe protector bolt 2 | 6 18 (1.8,13) Engine mounting: | Fork top bridge 4 8 | 28 (2.8,20) Front ane holder nut i © | tzi2s) Noe 11 9 1-15General laformation ~ Frame (cont'd) —- Rear suspension’ ‘Swingarm pivot nut Shock absorber mounting bolt: Upper Lower Shock absorber spring adjuster lock nut Shock atm bolt: Swingarm side Shock tink: Frame side Shock arm side Brakes: Front caliper bracket mounting bolt Brake hose oil bolt Caliper pin bolt: Flange bott (front) Socket bolt (rea! Inside hex head bolt Brake pad pin Brake pad pin plug Brake caliper bleed valve Brake disc bolt: Front Rear Brake lever pivot nut/bolt Front master cylinder holder bolt Front master cylinder reservoir cap screw Rear master eylinder mounting bolt Reer brake disc cover bolt Rear brake hase guide screw Teas Torque dia. (mm) Nem (kg-m, ft-lb) Remarks 1 90 18.0651 ‘0 Beees) Now 1 3 S355 8 20 13068) ° 7017080 10 ses e00 10 45 (4.5,33) | 8 a1a..20 10 353328 $ 223 3 2282 8 31133) to fener 10 310922) 3 sioeast 3 Sra 27 | Now 12 : wtegoo | Now 12 $ Sioa) | 6 42 44.2,91 { : Tetra é 1s ott 5 Bae 3 bloaze) 1-16General Information Tools + Refer to section 1, Ball Bearing Replacement, of the Common Service Manual d | Description Tool Number Alternate Too! Too! Number one | Float tevel gauge (07401-0010 5 Clutch center holder 077240050001 7 Gear holder 07724—0010100 7 D | wsserment, 20 x 30 mm | 07986-1870100 \ 7 Pilot, 12 mm 077460040200 7 Cam chain tensioner holder 07973-mG30003 | 8 Valve spring compressor 077870010000 8 Valve guide remover, 6.6 mm 077420010200 8 Valve guide reomer 07984~2£20001 | Vaive guide reamer | 07984-2620008 8 Valve guide cutter holder D [oem 07781~0010201 8 Valve seat cutter IN 40,0 mm (45%) | 07780-0010800 8 EX 35.0 mm (45°) | 07780—0010400 | oa | Fiat cutter: IN 38.5 mm (32°) | 07780—0012400 8 €x 35 mm (32°) | 07780—0012300 a Interior cutter } IN/EX 37.5 mm (60°) | 07780-01410 8 Universal bearing puller | 076310010000 10 Bearing puller ciow 77931 —MK20100 10 Bearing remover shaft 07746—0060100 10 Needle race remover O7GMC—MK50100 10 Bearing remover 07836-MK50100 19 Remover handle 07836~-KC10100 10 Remover siding weight 07741—0010201 10 Driver 077490010000 7,10 Attachment, 72 x 75 mm 07746—0010600 10 Pitot, 38 mm 077480040800 10 Attachment, 62 x 68 mm 07746~0010500 10 Attachment, 52 x 55 mm 077460010400 10 Pilot, 25 mm 077460040600 10 Attachment, 42 47 mm 077480010300 10 Pilot, 20 min 07746-0040500 to Attachment, 78 « 80 mm 07GA0—sD40101 10 Pilot, 40 mmm 077460040800 10 Attachment, 92 35 mm 07746-00100 10 Crankcase assembly tool | 07931—KF00000 10, ~puller shaft 07931 —me40000 10 assembly collar 07931 —KF00100 | 40 Drees caster 07931—KF00200 10 Astachment |.D., 35 mm 077460030400 10 1-17General Information Description Tool Number Alternate Too! Too! Number |g "et Spanner €. 58x 6.1 mm 07010020300 112 Bearing remover shalt 077480050100 nae Bearing remover heas, 17mm | 077460050500 nia Driver 007490010000 nae Attachment. 42 x 47 mm 077460010300 112 Attachment, 32 x 38 mm 077460010100 nite Pilot, 17 mm 07746 -0040400 1442 Retainer wiench 076MA~KS70100 in Seal driver attachment 07947 —KFOO100 n Slider weight 07847 —KASO100 n | extension bar 077160020500 { n | Steering stem mut wrenen 07816 -KAs0100 fon Ball race remover 07953—MA00000 aw | Stccrng stem aver 7461300101 n 1@ Retainer wrench A 077100010100 12 Retainer wrench body 077100010401 | oe rachment, 37 x 40 mm 077460010200 ; 32 tachment, 24 x 26 fam | 077460010700 | Pot, 20 mm 077460040500 2 Needle bearing remover 07931 -MA70000 | Bearing remover set [07996-3710001| 12, Driver shaft 07946—MJ00100 12 Spherical bearing driver 07946~KA30200 12 Bearing driver base O7HMF—KS60100 12 Snap ing pliers 079143230001 13 Flywheel holder 077250040000 14,16 Rotor puller 07733 0020001 14,46 Tor bit (740) 077030010100 is Digital multimeter (KOWA) 077410020000 | -KS~AHM~—32—003 14, 15, 16 4 (U.S.A. only) Analogue tester [SANWA) 07308—0020001 14, 15, 3 Analogue tester (KOWA) TH-5H 14,15, 16 1-18Lubrication & Seal points General Information — Engine Location Valve stem (valve guide siding surface) Rocker arm slipper surface Sub-rocker arm slipper surface Camshaft journals and cam lobes Clutch outer guide inner/outer surface Piston pin outer surface Transmission C3, Md gear inner surface ‘Cam chain Rocker arm shaft hole inner surface Sub-rocker arm shaft hole inner surface Piston pin hole inner surface Connecting rod small end Piston round surface Piston ring Shift fork shaft sliding surface Shih fork claw Shifter gear for groove Shift drum groove Connecting rod big end side surface Cylinder head bolt/washer Cylinder bolt/washer Clutch dise Clutch lifter arm shaft surface Threads: Flywhee! bolt Primary drive gear nut Clutch lock nut Each bearing Oil seal lips O-rings Rocker arm shaft threads Sub-rocker arm shaft threads Cam sprocket bolt ‘Cam chain tensioner bolt Gearshift carn bolt Pulse generator bolt Starter one way clutch torx bolt Drive sprocket cover bolt Remarks Material Molybdenum disulfide oll solution (a mixture of engine oil and molybdenum disulfide grease in a 43 1 ratiod Recormended engine oil Locking agent 1-19General Information Frame - Location Romarks Materia Drive chain Te ow _ = Suspension linkage spherical bearing seal ips Molybdenum disulfide past Shock absorber upper spherical bearing rangmission oll # 60-90 ‘Shock absorber bearing seal lips Molybdenum disulfide grease Shock linkage dust seal cap lips Swing arm dust seal cap lips and co! | Side stand pivot siding surface Multi-purpose grease Suspension linkage bearing and collat Steering head bearing and cone race Swingarm pivot beating Speedometer gear box Throttle grip ‘Throttle cable slider sliding surtace Cluteh lever and brake lever pivot bolt Rear brake pedal pivot sliding surface Fach dust seal lips and dust see! cap lips Caliper piston sliding surface DOT 4 brake fluid Caliper seal Master cvlinder piston cup Master cylinder inner surface Rear brake reservoir joint hose O-ring | Handlebar grip rubbers Honda Bond A or an equivalent | Fork leg Fork fluid Fork dust seal lips Fork oil seai lips Fork cap bolt O-ring Brake caliper pin bolt sliding surface Silicone grease Brake caliper pin bolt boot insides Fork bottom bolt Locking agent Side stand switch mounting bolt Ignition switch mounting bolt | 1-20General Information Cable & Harness Routing (1) FRONT BRAKE HOSE (2) CHOKE CABLE 14) SPEEDOMETER CABLE (6) HEADLIGHT CONNECTOR (5) MAIN WiRE HARNESS (11) SPEEDOMETER CABLE (10) CHOKE CABLE (12) THROTTLE CABLE (9) CLUTCH CABLE (14) LEFT HANDLEBAR SWITCH (13) RIGHT HANDLEBAR WIRE HARNESS SWITCH WIRE HARNESS. 1-21General information (2) CYLINDER HEAD BREATHER TUBE (1) THROTTLE CABLE (9) FRONT BRAKE HOSE (8) CLUTCH CABLE 1-22 (7) MAIN WIRE HARNESSGeneral Information a (1) ACV VACUUM TUBE Canada type a (4) AIR SUCTION (3) ALTERNATOR WIRE ATS ws. oon wn sear Stee —[] (tel TET (11) REAR BRAKE , RESERVOIR HOSE > (10) REAR BRAKE LIGHT SWITCH WIRE (9) GROUND CABLE 1-23General information (2) MAIN WIRE HARNESS (3) RIGHT TURN SIGNAL WIRE 4-24General Information 11) REAR BRAKE HOSE Canada type 49 State type Californis type (5) To PCV (No, 5)" thereof: (1) The removal er rendering inoperative by any person, other than for purposes of maintenance, repair or replace ment, of any device or element of design incorporated into any new vehicle for the purposes of noise control prior to its sale or delivery to the ultimate purchaser or while itis in use: or (2) has been removed or rendered inoperative by any person. @ use tf the vehicle after such device or element of design AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, er puncturing the muffier, baffles, header pines ar any other compenent which conducts exhaust gases. > 2. Removal of. oF puncturing of any par of the intake system: 3. Lack of proper maintenance 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 1-29General Information Emission Control Information Labels (U.S.A. Only) An Emission Control Information Label is located on the insicie tf the lett side cover. The side cover must be removed to read it, t gives basic tune-up specifications. Vehicle Emission Control Information Update Label After making a high altitude carburetor adjustment, attach an, update label on the inside of the left side cover Be sure to remove the label after adjusting for low altitude use. Vacuum Hose Routing Diagram Label (California type only) ‘The Vacuum Hose Routing Diagram Label is on the inside of the left side cover. (1) VACUUM Hose ROUTING DIAGRAM LABEL (California type only) (2) EMISSION CONTROL (3) UPDATE LABEL INFORMATION LABEL VACUUM HOSE. ROUTING DIAGRAM Evasoperive Fas CatiFomila VEHICLE 1-30 6 0