HOW TO USE THIS MANUAL CONTENTS

Thos MMCe manual desalbes the S8fVlO8 procedur8$ !Of the CAI25H

Follow me Maonlenance Schedulll (SectIOf1 3) reeommendatlOtlS 10

_ur, that 1he vehICle fs If1 peak opera~ng con<IiIoon
Per10fming the first scheduled maintenance IS very Important. II
compeoS81es lor the inotlal W1l8r H'lat oocurs durong the break·ln period
MAINTENANCE
Sectoons 1 and 3 apply 10 the whOle motorcycle 5ecliOrl 2 ~lustral&5
proeedu'8$ for removaVIJlStallabon 01 ~lS !hat may be requIred
10 perIotm sefVICG described in the /oIIoww'Ig secloons
SeI;bon 4 rtvough 14 desaibe pans 01 the motorcycle. grouped
8OOOf'dor'Ig 10 ~bOn

Fond !he sectIOn you warn on thIS page. then turn 10 the table 01 conlents
.
<;
a:
0-
FUEL SYSTEM

COOLING SYSTEM
on !he fil$l page oIlhe sectIOI"I W
ENGINE REMOVAUINSTALLATION
~
Most sectlOrlli stan WIth an IIssembly Of IySIem ~1U$tratJon, serVUI a:
Inbmatoon and UoubIeshoollOg for 1he MCbOf'I The SUb$aquent p8I1t'S o CYLINDER HEAD/C YLINDER/PISTON
\IMI detailed procedures.

II you doIl~ know the source 01 the trouble, go to S&cttOO 16

TroubJeshoot'ng
.
o
z
W
z
RC VALVE

az CLUTCHIKICKSTARTER/GEARSHIFT LINKAGE
W
CRANKCASEICRANKSHAFTITRANSMISSION
Your S8/ety and the salety 01 ~_ is 'o'8<y omportanl To help you
rnaII.e II'IIormed duosoons _ have pl'OVl<led safety messages and
FRONT WHEEUSUSPENSIONISTEERING
other II\b'mallOn Ihroughoul ItuS mar'IlIIIIl 04 00\.IfSe, it is not !1l
practl(:lolOf possible 10 warn you about aH !he hazards iISSOCIiIted
WIth tIef'I/ICIrIQ !his \IehicIe
Voo must '*' your own good jUdogement
'(QI,j will fond omportant salety onfofmallon on a I'8nety 01 lorms
..
U)
U)

:z:
u
REAR WHEEUSUSPENSION

Includtng HYDRAULIC BRAKE

• Satety Labels - on the vehICle
• Satety Massages - preceOad by a salaly alert symbol J arid
one 01 three S'9f\1I1words, DANGER. WARNING. Of CAUTION IGNITION SYSTEM/ALTERNATOR
These SIQIl3I worUs mean

iH'@d3aii ~RT~I~:n.~=~~~USLY WIRING DIAGRAMS

MWiW mm.
You CAN be KILLED or SERIOUSLY HURT TROUBLESHOOTING
~ you dorn IoIIow IflSlI\lCtlOn5.

eMi,U.g ::~ be HURT ~ you don1 IoIIow INDEX

• IllStn.ICtIOnS - how to servICe tl'lil vehICle (:Offaetly and salely

As you read thiS manua l. yoo will lind inlormatlO/1 thai is prec&ded by a
MOTICt symtJoj The purpose 01 thIS meS$ll{le IS to help prevent
damage to your vehICle. other property. or the efMlonment
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols. it will be explained specifically in the 18)(1 wilhoullhe use 01 the symbols.

111 Replace the part(s) with new ona(s) before assembly.

r--
-, t"
,
'acommaodad ",loa oil, oo'a" olh.",I," ,p"dlled.

78 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease In a ratio of 1 : 1).

-
f--
•..um.. Use multi-purpose grease (lithium based mUlti-purpose grease NLGI #2 or equivalent) .

....i-s
-
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent) .
Example: Molykole® BR-2 plus manufactured by Dow Corning U.S.A.
MUIlI-p"'po,. M-2 maouract"ed by M,"ubl,hi Oil, Japao
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Motykot~ G-n Paste manufactured by Dow Corning U.S.A.
~ Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Aocol Limited, U.K.
Aocol Paste manufactured by Sumico lubricant, Japan
-

..-'iiSioI Use silicone grease.

L1m:J Apply a lockIng agent. Use a mIddle strength locking agent unless otherwise speCIfied .

t.
.,('ft1Il Apply sealant.

I DOT 4 br.lk" lIuld Usa the recommended brake flUId unless otherwIse specifIed

-
.. Use Fork or SuspenSIon FlUId
 1. GENERAL INFORMATION

SERVICE RULES ............. ............................... ' -2 FRONT WHEEL/ SUSPENSION/ STEERING

SPECiFiCATIONS············································ ' -9
MODEL IDENTIFICATION······························ ' -2
REAR WHEEL/SUSPENSION
GENERAL SPECiFiCATIONS ························· ' -4 SPECiFiCATIONS··············· ····························· ' -9

LUBRICATION SYSTEM SPECIFICATIONS · '-6 HYDRAULIC BRAKE SPECIFICATIONS ······· , -,O

FUEL SYSTEM SPECiFiCATIONS ················· ' -6 IGNITION SYSTEM / ALTERNATOR

SPECiFiCATIONS·········································· ' -'0
COOLING SYSTEM SPECIFICATIONS ......... ' -6 STANDARD TORQUE VAlUES ··················· , -"
CYLINDER HEAD/ CYLINDER/PISTON
SPECiFiCATIONS ········································ ... ' -7 ENGINE & FRAME TORQUE VAlUES ········ , -"

CLUTCH/KICKSTARTER/GEARSHIFT LUBRICATION & SEAL POINTS ·················· ' -' 6

LINKAGE SPECiFiCATIONS ·························· ' -7
CABLE & HARNESS ROUTING ··················· ' -'8
CRANKCASE/ CRANKSHAFT/
TRANSMISSION SPECiFiCATIONS·············· '-8 OPTIONAL PARTS ········································ ' -2S

1-1
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants o r thei r equivalents. Parts that don 't meet Honda 's
design specifications may cause damage to the motorcycle.
2. Use the special tools designed fo r this product to avoid damage and incorrect assembly.
3. 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. colter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diamet er or inner bolt first. Then lighten 10 the specified torque
diagonally in incremental sleps 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 shown on page 1-18, Cable and Harness Routing .

MODEL IDENTIFICATION
'04 model shown:

1-2
 GENERAL INFORMATION
The Vehicle Identification Number (VIN) is stamped on the right side of
the steering head.

The engine serial number is stamped on the left side of the crankcase.

The carburetor identification number is stamped on the right side of

the carburetor body.

1-3

-
GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
fENSIONS Overall length '04: 2,157 mm (84.9 in)
After '04: 2,163 mm (85.2 in)
1 Overall width 821 mm (32.3 in)
Overall height '04: 1,280 mm (50.4 in)
After '04: 1,282 mm (50.5 in)
Wheelbase '04: 1,466 mm (57.7 in)
After '04: 1,470 mm (57.9 in)
Seat height '04: 952 mm (37.5 in)
After '04: 954 mm (37.6 in)
Foolpeg height '04: 436 mm (17.2 in)
After '04: 439 mm (17.3 in)
Ground clearance '04: 349 mm (13.7 in)
After '04: 352 mm (13.8 in)
Dry weight 87.5 kg (192.9Ibs) _ _ __ _
FRAME Frame type Twin-tube
Front suspension Telescopic fork
Front wheel axle travel 275 mm (10.8 in)
Front suspension cushion stroke 305 mm (12.0 in)
Rear suspension SwingarmlPro-link
Rear wheel axle travel '04: 325 mm (12.8 in)
After '04: 320 mm (12.6 in)
Rear damper Decarbon type with nitrogen gas filled
damper
Front lire size 80/100-21 MIC 51M
Rear tire size 100/90-19 M /C 57M
Tire brand Front D742F (Dunlop)
Rear 0756 (Dunlop)
Front brake Hydraulic single disc
Front brake swept area 334.5 cm 2 (51,8 in 2)
Rear brake Hydraulic single disc
Rear brake swept area 391.1 cm 2 (60.6 in 2 )
Caster angle '04: 25°39'
After '04: 25°45'
Trail length 100 mm (3.9 in )
Fuel tank capacity 7.7 liter (2.0 US gal, 1.7 Imp gal)
I ENGINE Bore and stroke 54.0 x 54.5 mm (2.13 x 2.15 in)
Displacement 124.8 cm 3 17.6 cu ·in)
Compression ratio '04: 9.1 : 1
After '04: 8.6: 1
lubrication system Fuel/oil mix
Cooling system Liquid cooled
Air filtration Oiled polyurethane foam
Crankshaft type Assemble type
Engine dry weight 18.5 kg (40.8 Ibs) ~
Cylinder arrangement Single cylinder, inclined 18.5° from vertical
CARBURETOR Carburetor type Piston valve type
Venturi diameter 38 mm (1.5 in)

1-4
 GENERAL INFORMATION

DRIVE TRAIN Clutch system

ITEM I SPECIACATION
Multi-plate, wet
Clutch operation system Cable operated
Transmission Constant mesh, 5-speeds
Primary reduction 3.150 (63120)
Final reduction '04: 4.077 (53113)
After '04: 4.000 (52/13)
Gear ralio 1st 2.307 (30113)
2nd 1.867 (28/15)
3,d 1.529 (26117)
4th 1.294 (22117)
5th 1. 130 (26/23)

r-ELECTRICAL =-l
Gearshift panern

Ignition system
1 Left foot operated return system,
,-N·2·3·4·5
_ _~C~D~I (Capa;;'d"tiv:Ce~
DC;;s:;''''''':::
~~~__
rge Igni'.c';",on",I_ _-.J

1-5
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS

i i

i
GN4 4-stroke oil (U.S.A. and Canada)
or equivalent motor oil
API service classification: SG or higher
JASO T 903 standard: MA

FUEL SYSTEM SPECIFICATIONS

ITEM SPECIRCATIONS
Carburetor identification number '04: TMX04A
After '04: TMX05A
Main jet '04: #420
After '04: #430
Slow jet '04: #40
After '04: #55
Jet needle '04: 6DGY26-69
After '04: 6DGY28-68
Jet needle clip position 3rd groove from lop
Air screw initial opening '04: 2 turns oul
After '04: 1·314 turns out
Float level 7.5 mm (0.30 in
Throttle grip free play 3 5 mm (118 1/4 in)
Reed valve clearance service limit 0.2 mm (0.01 inl

COOLING SYSTEM SPECIFICATIONS

oran
ene glycol antifreeze containing silica-free corrosion

1-6
 GENERAL INFORMATION
CYLINDER HEAD/CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)

Cylinder head warpage

ITEM STANDARD --==:::::'::S~E
~R~VICE LlMIU ~
Cylinder f LO. ----:t~5~3~.9~7~6" 53.983 (2.1250
53.968 53.976 (2. 1247
2.1253)
2.1250)
0.05 (0.002) ,
54.013 (2.1265)
54.006 (2.1262)
Out of round 0.05 (0.002)
, Taper 0.05 (o.002H
Warpage 0.05 (0.002)
Piston, pisto~Piston mark directioec". :,--.-_ __ "IN" mark facing toward the intake"s"id""-t--,o, - ~
ring Piston 0.0. Ai 53.933 - 53.940 (2.1233 - 2.1236) 53.883 (2.1214)
B 53.925 53.933 (2. 1230 - 2.1233) 53.875 (2. 12'1 )
Piston 0.0. mea- '04: 10 mm (0.39 In) from the bottom of skirt
surement point Aher '04: 11 mm (0.43 in) from the bottom of sk"irt;;----
Piston pin bore 1.0. 15.002 - 15.015 (0.5906 0.5911) 15.022 (O.59 14r
Piston pin 0.0. 14-:-994 - 15.000 (0.5903 0.5906) 14.980 (0.5900)
Piston-Io-piston pin clearance 0.002 - 0.021 (0.0001 0.0008) 0.03 (0.00': 1
Piston ring·to -ring groove clear· 0.045 - 0.080 (0.0018 0.0031) 0.09 (0.004)
ance ('04 model)
Piston ring end gai,po.:===-- 0.40 - 0.55 (0.016 - 0.022) 0.65 (0.026)
Cylinder·lo·piston clearance 0.035 - 0.050 (0.001 4 - 0.0020) 0.07 (0.003)
Connecting rod small end 1.0. 19.002 19.014 (0.748 1 - 0.7486) 19.022 (0.7489)

CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD R VICE LlM'I'fl
_==~S~E~
Clutch lever free play -~'10 - 20 (318 - 31~4~'~"",,=--
-----]-36.1 (142) 35.4 (1.39)
Clutch spring fre:;e~'~'Q"9~t~h==­
Clutch outer gu~e 1.0. 20.000 20.021 (0.7874 0.7882) 20.05 (0.789)
Clutch disc thicknc:e~,,~;:;;:::::_ 2.92 3.08 (0.114~:~O.~'i21~'g~f 2.85 (0.008)
(0.006)
I warpage 0.15
gear 1.0. _t--c',,60.5~1616.534 --+-<:'6".5",5 (0.652)
i spindle0.0. 16.466-16.484 16.45 (0.648)
Kickstarter idle gear 1.0. 17.016 17.034 ~'if.:~;:, 17.0510.671 -' - -
Countershah 0.0. at kickstilrter idle gear 16.983 16.994 6 _ _~_'",6.97 (0.668)

1-7
GENERAL INFORMATION
CRANKCASE/CRANKSHAFT/TRANSMISSION SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Runout 0.05 (0.002)
~=oo=<=C~o:-+-.
Connecting rod big end side clear- 0.4 - 0.8 (0.02 - 0.03) 0.9 (0.04)
aoce
Connecting rod big end radial clear- 0.010 - 0.022 (0.0004 - 0.0009) 0.032 (0.0013)

T""mi"ion I ,nee
Gear 1.0.

-~'
C2
M4, M5
- I
23.02

23'04':i.~~~~~;;~c2~3~'O!6jI0~'9!0~81
20.02 0-20.041
o-
27.02 0-27.041
, C3 25.020-25.041
Busing 0.0. M4, M5 22.979- 23,000 I
~
19.979 - 20.000
C2 - 26.97 9 - 27.000 (1.0622 - 1.0630) ----=h~~~
, •
C3
M5
24.97 9 - 25.000 (0.9834 - 0.9845)
(O.7874_-00.:6'7i7~8~2~1_=+~~~~
Busing 1.0. 20.00
C' 0- 20.021
17.00 0-17.018 (0.6693,-
C2
~!f.~f.~~==±Ji~o:
24.00
C3 - _~2.00 0- 24.021
22.021 ~\
Gear-to- M4, C1, C2, C3 0.020 - 0.062 (0.0008 - 0.0024) -~~~"'---1
bushing M5 0.040 - 0.082 (0.0016 - 0.00321
clearance
l
Mainshaft M5 19.959 - 19.980 (0.7858 - 0.7866) 19.94
0.0.
Counter- Ct bushing 16.98 3 -16.994 (0.6686- 0.6691) 16.97
shaft 0.0. I C2 bushing 23.959 - 23.980 (0.9433 - 0.9441) 23.94 (0.943)
C3 bushing --->--21.959 - 21.980 (0.8645 - 0.8651) 2 1.94 (0.864) I

~ Shih fork,
Sianer idle gear 16.983 - 16.994 (0.6686 - 0.6691)

~FO~'~k~'~"~w~tfh~iC;';k~nooe:':':C_"_"___-==::t=4~'9~3~-
16.97 (O.668 ~

(0. ';.94~-~0~,'::97jl~~~==:j::~4r,8~(~O,~'~91~~,
shift fork shaft ~hift fork 1.0. 11.035 5.00
- 11.056.~0.4344 - 0.4353) 11 .065 (0.4356i
Fork shaft 0.0. __ --'-_',,0"',9"'83 - 10.994 (0.4324 -0.4328) 10.973 (0.4320)

1-8
 GENERAL INFORMATION
FRONT WHEEl/SUSPENSION/STEERING SPECIFICATIONS
Unit" mm (in)
ITEM STANDARD SERVICE lIMIT-----
r--cow tire pressure 100 kPa (1.0 kgf/cm , 14 psi) ~
-
-
Axle funout 0.20 (0.008)
Wheel rim runout Radial
~

f- 2.0 (0.08)
Axial 2.0 (0.08)
27.25 (t073)
-
Wheel hub-Ie-rim distance
_~pring free length 476.0 (18.74)
r Fork
Tube runout
Recommended fork fluid
~

Pro Honda HP Fork Oil 5W or equiva-

473 (18.6)
0.2 (0.01)

I lent
-
Fluid level
Fluid capacity
, 71 (2.8)
462 ±4cm J
,
-

(15.6 ± 0.14 US OZ, 16.3 ± O.141mp azl

--= -.
Compression damping adjuster standard position
I
15 clicks out from full In
Rebound damping adjuster standard position 6 clicks oul from full in

REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit· mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire pressure lOa kPa (1.0 kgf/cm . 14 psi)
Axle runout 0.20 (0.008)
Wheel rim run out Radial 2.0 (0.08)
Axial 2.0 (0.08)
_~heel hub-to-rim distance 48.00 (1.89)
Drive chain slack 25 35 (1 1-3/8)
Drive chain size/link DID 520DMA2 116
- 5 (o .i)
Drive chain slider thickness
Drive chain ten- Upper r '04, 35 (1.4)
sioner roller 0 .0. After '04: 39 (1.5)
Lower '04: 25 (1.0)

~ Shock absorber Damper gas pressure

After '04:

Damper compressed gas

981 kPa (10.0 kgf.cm , 142 psi)
Nitrogen gas
31 ( 1.2)

Damper rod compressed force 18.1 22.1 kg (39.90 48.72 Ibf)

_ !t 10 mm compressed
Spring direction Narrow wound end of coil facing down
Spring installed ~~4: 266.5 (10.49)
length After '04: 266.0 (10.47)
- -
f High speed compression damping adjuster standard
position
I Low speed compression damping
1-1 /6 1-1 /2 turns out from full in -
'04: 7 " clicks out from full in
- - -
adjuster standard position After '04: 8 12 clicks out from full in -

Rebound damping adjuster standard '04: 18 22 clicks out from full in -

position -L After '04: 20 24 clicks out from full in

1-9
GENERAL INFORMATION
HYDRAULIC BRAKE SPECIFICATIONS

Front
ITEM
Specified brake fluid
Brake pad wear indicator
:-+ STANDARD
"'0"'OT'-24_ _ __
Unit: mm (in)
SERVICE LIMIT

1.0 (0.04)
Brake disc thickness 3.0 (O.1'122!I====- 2.5 (0.10)
Brake disc runout 0.15 (0.006)
Master cylinder 1.0. 11.00 (0.'"43"3"1- - -
Caliper cylinder 1.0. 27.00 (1,063)
Rear Specified brake fluid 00T,,4'-_ _ __ _
Brake pad wear indicator _ _ __ ~1.0 10,041
Brake disc thickness 4 .0 (0.16) 3.5 (0. 14)
Brake disc funout _ _-,0""'"5,,,(0.006)
Master cylinder 1.0. 9.52 (0.375)
Caliper cylinder 1.0. --r-;22.65 (1.892)

IGNITION SYSTEM/ALTERNATOR SPECIFICATIONS

ITEM SPECIFICATION
Spark plu~9--"S"'-;;-,";;;'dard --i==--~B~R~9~EG~(NGK) W27ESR-V (DENSO)
OPtion_,'~-=====:-_ BR9EV (NGK) W27ESR-G (DENSO)
S"p::,:O,''"'p''lu''9;;-;09''''PO -- -;; 0.5 - 0.6 mm (0.020 - 0.024 in)
Ignition coil
resistance
Primary
Secondary with plug cap
Qc.-----
0.4 - 0.6
15 - 22 kO
(at 20 cCf6S OF) Secondary without plug cap 10 _ 17 kn
Ignition coil peak-voltage 100 V minimum
Ignition pulse generator resis tance (al 20 °C/68 OF) 180 - 280 n
Ignition pulse generator peak voltage 0.7 V minimum
Alternator charging coil resistance
(at 20 °C/68 OF) .
'04: I 0.5 - 4.0:~n~'----

Alternator exciter coil resistance -t--AAkft"e';C'' '04;C'c - - - - + - - Yellow - Blue: Blue White:
(at 20 C/68 F) 120 - 180 n 24 - 44 n
Alternator exciter coil peak voltage After '04: - - + - -'20 V m inimum (Yellow -:-Slue and Blue While)
Ignition timing (nF" mark)F-'~:jb'04~,~~=_-~+~-~"."""=~30~±~2~'BlDC/3,000 rpm
After '04: ..L.. 33.7 ± 2 8TDG/4,000 rpm

1-10
 GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N 'm Ikgf·m. Ibf.ft) N'm Ikgf·m, IbUt)
5 mm hex bolt and nul 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm hex bolt and nut 10 (lO, 7) 6 mm screw 9 (0.9, 6.5)
8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9, 6.5)
10 mm hex bolt and nul 34 (3.5, 25) 6 mm flange bolt (10 mm head) 12 (l2, 9)
12 mm hex bolt and nut 54 (5.5, 40) and nut
8 mm flange bolt and nut 26 (2.7, 20)
_ _~~I,,-
O mm flange bolt and nut ~----,,3,,9",(
4.0,29)

ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners .
• Others should be tightened to standard torque values listed above.
NOTE
1. Apply a locking agent to the threads.
2. Apply oil to the threads and seating surface.
3. Stake.
4. U-nul.
5. UBS bolt/nut.
ENGINE
MAINTENANCE
TORQUE- - '--- -
ITEM N 'm (kgf.m, Ibf.ft) REMARKS
Oil drain bolt 29 (3.0, 2 2 f T
Spark plug 18 (l8, 13)
Oil check bolt (clutch cover side) 9.8 (1.0, 7)

FUEL SYSTEM

ITEM Q'TY
THREAD TORQUE 1 REMARKS
DIA.lmmJ N'm Ikgf·m, Ibf·ft) 1
Reed valve mounting screw 6 3 1.0(0.1,0.7) NOTE 1
Throttle cable holder 10 2.9 (0.3, 2.2)
Float pin set screw 4 2.0 (0.2, 1.4)
Carburetor air filter bolt 4 2.0 (0.2, 14)
Main jet 5.3 2.0 (0.2, 1.4)
Slow jet 1 4 1.0 (0.1, 0.7)
Carbu retor top screw 3 4 2.0 (0.2,14)
Throttle stop screw lock nut 1 5 2.0 (0.2, 14)
Float chamber screw 3 4 3.9 (0.4, 2.9)
Carburetor drain plug 22 3.9 (0.4, 2.9)
Choke knob lock nut 3.9 (0.4, 2.9)
Float valve seat set screw 3 1.0(0.1,0.7) NOTE 1
Insulator band screw 4 _ _~---"S"e"e page 1-13

COOLING SYSTEM
THREAD TORQUE
ITEM Q'TV
DIA.(mm) N·m (kgf.m, Ibf·ft)
Water pump impeller 7 12 (1.2, 9)
Water pump cover bolt '04: 4 6 12 (1.2, 9)

Coolant drain bolt

After '04:
t 5 6
6
12 (1.2, 9)
9.8 (lO, 7)

1-11
 +
GENERAL INFORMATION
CYLINDER HEAD/ CYLINDER / PISTON

ITEM a 'TV THREAD TORQUE REMARKS

_ ___ CIA. (mm ) N'm (kgf 'm , l;"bfC'ft" I--+_

11
r-cylinder stud bolr - -- - 5 8 12(12,9) NOTE 1
Cylinder head nut 5 B 27 (2 8, 20)
Cylinder mounting nut 4 8 27 (2 8, 20) I
Cylinder sealing boll , 6 L 9.8 (1.0, 7) ----L
RC VALVE
THREAD TORQUE

~c :t mo'de~I;rI--- ~-;" ,,
l E REMARKS
DIA.lmm) N·m (kgf'm , IbUtl
valve shaft pulley n {:4 8.8 (0.9, 6.5)

,,,
~n~~d_ _ , 8.8 (0.9, 6.5)
After '04: 2 8.8 (0.9, 6.5)
AC valve shaft stopper plale bolt ('04 model) 1 9.8 (1.0, 7)
AC valve shaft collar stopper plate bolt (After '04)
Pinion gear/tie rod retaining screw (Aher '04) , 9.8(1.0,7)
8.8 (0.9, 6.5)
Left RC valve cover bolt '04:
After '04:
4
4 ,
5 4.9 (0.5, 3.6)
12 (1.2, 9)
Right AC valve cover bolt '04:
After '04:
4
4 ,
5 4.9 (0.5, 3.6)
12 (1.2, 9)
Right RC valve cover screw
L Blow-by oil drain bolt ('04 model) ,
5
J 2.9 (0.3, 2.2)
9.8 (1.0, 7)

CLUTCH/ KICKSTARTER / GEARSHIFT LINKAGE

ITEM
Right crankcase cover bolt ---~ ~
a 'TV
10
- - ' -' TH
"'"READ
OIA. lmm l
6
nN,m TORaUE-~

Ikgf·m, IbHt)
9.8 (la, 7)
REMARKS

Clutch cover bolt 5 6 9.8 (1.0, 7)

Gearshift drum center pin 8 22 (2.2, 16) NOTE 1
Gearshift drum stopper arm bolt 6 12(1 .2,9)
Clutch spring boll 5 6 9.8(1.0,7)
Clutch center lock"n"u,-,-'_~ _ ---"'8" - 69 (7.0, 51) _ - - ' - _
CAANKCASE/ CRANKSHAFTfTAANSMISSION

ITEM
--,-~

THREAD -,-- -T"O"'RauE'--,----

a 'TV N.m (kgf'm, Ibf.tt) REMARKS
OIA.(mm )
EXhaust pipe joint bo~l"t--~ 9.8 (1.0, 7)

I!I 1
Primary drive gear boll 64 (6.5, 47 )
Countershah bearing set plate screw 9.8 (1.0, 7) NOTE 1
Gearshift drum bearing set plate bolt 9.8(1.0,7)U NOTE I
Drive sprocket bolt 31 (3.2, 23) NOTE 5
Crankcase stud bolt ~~~5~e~ec,page 1- 13

ALTERNATOR

F~YWheel
THREAD TORaUE-~ ~
ITEM a 'TV
DIA . (mm) N·m (kgf'm, ;<
lb"f,:"ft'CI--j~ REMARKS
+~;--+--""'12 '--+-"~54 (5.5, 40)
~'ternator cover bolt
[ nut
4 - ' - _--",_ 2.0 (0.2, 1.4)

1-12
 GENERAL INFORMATION
Insulator band screw

3-4mm
(O. 12-0.1Sin)

Crankcase stud bolt

1-13
GENERAL INFORMATION
FRAME
FRAME/ BODY PANELS/ EXHAUST SYSTEM
~-
THAEAD
~
TORQUE

t
ITEM REMARKS
DIA.( mm) N'm (kgf'm, I~~
-----seat mounting bolt 2 8 2612.7, 20)
Seat front hook screw 5 5.9 (0.6, 4.3)
Sub-frame mounting bolt (upper) 1 8 29 (3.0, 22)
Sub-frame mounting bolt (lower) 2 8 29 (3.0, 22)
Rear fender mounting bolt 4 6 13(1.3,9)
Footpeg bracket upper bolt 2 12 54 (5.5, 40)
Footpeg bracket lower bolt 2 8 29 (3.0, 22)
Expansion chamber front mounting bolt 2 6 12 (1.2, 9)
Silencer case bolt 2 5 4.9 (0.5,3.6) ~

MAINTENANCE

I
ITEM
""_==---=
I Drive chain ad"ju","t"';o"g'b"olt lock nut
= - +Q'TV
2
THREAD
DIA. ~1,m~m
8_
::1::r:~N,,'m
TORQUE
'j (kgf'm, l_bf" .ft.,I_ 1-
26 (2.7, 20)
REMARr i S
NOTE 5
ENGINE MOUNTING
~
THRE~
D TORQUE
I ITEM G'TV
DIA. (mm) N ·m (kgf'm , Ibf·tt)
REMARKS
t Engine hanger plate nut
~gine mounting nut

CLUTCH / KICKSTARTEA/GEAASHIFT LINKAGE

I 3 8
2 _ - 1 - _ 10
34 (3.5, 25)
54 (5.5, 40), _ _ _

---,
ITEM G'TV THRE~
D TORQUE REMARKS
DIA. (mml N ·m (kgf'm , Ibf·tt)
Gearshift pedal pinch bolt 6 12(1.2,9)
Kickstaner pedal bolt -'-~_ 8 37 13,8, 2,~7,-1_~

FRONT WHEEL/ SUSPENSION/STEERING

ITEM
Front brake hose guide bolt
--
t Q'TV
l '
I THREAD
DIA .( mml
6
TORQUE
N·m (kgf'm, Ibf·tt)
4.9 (0.5, 3.6)
88 (9.0, 65)
REMARKS
-
Front axle nut 1 16
Front axle holder bolt 4 8 20 (2.0, 14)
Front spoke nipple 36 BC 3.5 3.9 (OA, 2.9)
Front rim lock 1 8 13 (1.3, 9)
Front brake disc nut 6 6 16 (1.6,12) NOTE 4
Handlebar upper holder bolt 4 8 22 (2.2,16)
Handlebar lower holder nut 2 10 44 (4.5, 33) NOTe 4
Steering stem nut 26 108 (11.0, 80)
Steering stem adjusting nut 30 6.9 (0.7, 5.1)
Fork tube top pinch bolt 4 8 23 (2.3, 17)
Fork tube bottom pinch bolt 4 8 20 (2.0, 14)
Fork cap 2 48 29 (3.0, 22)
Fork cap lock nut 2 t2 28 (2.9, 21)
Fork center bolt 2 30 54 (5.5, 40) NOTe 1
Fork protector mounting bolt 6 6 6.9 (0.7, 5.1) NOTe 1
Front brake disc cover bolt 2 6 13 (1.3, 9)
Fork air pressure release screw 2 5 1.2 (0.12, 0.9)
Clutch lever pivot bolt 1 6 2.0 (0.2, 1.4)
Clutch lever pivot nut 1 6 9.8 (1.0, 7)
Clutch lever bracket holder bolt 2 6 8.8 (0.9, 6.5)
Front master cylinder holder bolt 2 6 9.8 (10, 7)
Throttle housing cover screw 2 4~ 2,010.2,1.41
Throttle housing mounting bolt 2 6 8.8 (0.9. 6.5)
Engine stop button screw 4 2.0 (0.2, 1.4)

1-14
 GENERAL INFORMATION
REAR WHEEUBRAKE /S USPENSION
THREAD TORQUE
ITEM REMARKS

If,,
OI A.( mm j N'm (kgf ·m . Ibf·ft )
Rear axle nut 22 127 (13.0, 94) NOTE 4
Rear spoke nipple 32 4.5 3.9 (0.4, 2.9)
Rear rim lock 8 13 (1.3, 9)
Rear brake disc bolt/nut 4 6 16 (1.6.12) NOTE 4
Final driven sprocket nut 6 8 32 (3.3, 24) NOTE 4
Rear wheel bearing retainer 50 44 (4.5, 33)
Swingarm pivot nut '4 88 (9.0, 65) NOTE 4

,,
Shock arm nut (swingarm side) '2 52 (5.3, 38) NOTE 2, 4
Shock arm nut (shock link side) '2 52 (5.3. 38) NOTE 2,4
Shock link nut (frame side) '2 52 (5.3, 38) NOTE 2, 4
Shock absorber mounting nul 2 10 44 (4.5, 33) NOTE 4
Shock absorber spring lock nut 56 29 (3.0, 22)
Drive chain roller bolt 8 12 (1.2, 9)
Drive chain rolter nut '04: 8 12 (1.2, 9) NOTE 4
After '04: 6 12 (1.2, 9)
Drive chain guide mounting bolt/nut 112 6 12 (1.2, 9) NOTE 2
Drive chain slider screw 3 5 3.9 (0.4, 2.9) NOTE 1
Rear brake hose guide screw 2 5 1.2 (0.12, 0.9)
Shock absorber damper rod end nut 12 26 (2.7, 20) NOTE 3
Shock absorber damping adjuster 28 29 (3.0, 22) NOTE 3

HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA.( mm ) N·m (kgf 'm , Ibf.ft)
~
Brake hose oil bolt 4 10 34 (3.5, 22)
Brake lever pivot bolt 6 5.9 (0.6, 4.3)
Brake lever pivot nut 6 5.9 (0.6, 4.3)
Brake lever adjuster lock nut 5 5.9 (0.6, 4.3)
Front master cylinder reservoir cover screw 2 4 1.5 (0.15,1.1)
Rear master cylinder reservoir cover bolt 2 4 1.5 (0.15, 1.1 )
Front master cylinder holder bolt 2 6 9.8 (1.0, 7)
Front caliper mounting bolt 2 8 30 (3.1, 22) NOTE 1
Caliper bleeder valve 2 8 5.9 (0.6, 4.3)
Rear master cylinder mounting bolt 2 6 13 (1.3, 9)
Front caliper pin boh 8 23 (2.3, 17) NOTE 1
Front caliper bracket pin bolt 1 8 23 (2.3, 17) NOTE 1
Brake caliper pad pin 2 10 18 (1.8,13)
Brake caliper pad pin plug 10 2.010,2, 1.4)
Rear caliper pin bolt '2 27/2.8,20)
Rear caliper bracket pin bolt 8 13 (1.3, 9) NOTE 1

L
Brake pedal pivot bolt '04: 8 25 (2.6, 19)
After '04: 10 36 (3.7, 27)
Rear master cylinder joint lock nut 6 5.9 (0,6, 4.3)

1-15
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
LOCATION MATERIAL REMARKS
Connecting rod big end, small end and journal area Pro Honda HP2 2-stroke -1-
Piston outer surface and cylinder inner surface Oil or equivalent
Piston pin outer surface
Piston ring end gap and outer surface
Crankshaft big end Molybdenum oil solution
Flap valve shaft rolling area and sliding surface (mixture of the transmis -
Flap valves (shaft hole inner surface) sion oil and molybdenum
Mainshaftlcountershaft spline and gear rolling area grease in a ratio of 1 : 1)
Kickstarter spindle spline and pinion sliding surface
Kickstarter bearing rolling area (right crankcase)
Gearshift spindle spline
Gearshift drum guide groove
Shift fork claw
Shift fork shaft outer surface
Water pump bearing rolling area (right crankcase)
Valve shaft arm (tie rod joint pin surface) After '04
Governor steel ball surface After '04
Governor shaft bearing rolling area After '04
Tie rod joint area After '04
Clutch lifter cam area Molybdenum paste ,
Ta~smission gear teeth, rolling are and contact area Transmission oil -t-
Right and left crankshaft bearing rolling area (Pro Honda HP Trans Oil,
Main and countershaft bearing rolling area Pro Honda GN4, HP4 4~
Gearshift drum bearing rolling area stroke oil or equivalent
Clutch outer needle bearing rolling area motor oil)
Clutch outer guide whole surface
Clutch lifter needle bearing rolling area
Governor sliding surface and beari ng rolling area After '04
Clutch lifter piece steel ball contact area Multi-purpose grease I
Right and left crankshaft oil seal lips
Counters haft oil seal lips
Counters haft collar i nner surface and O-ring
Water pump shaft oil seal lips
Water seal lips
Kickstarter spindle oil seal lips
Gearshift spindle oil seal lips
Clutch lifter oil seal lips
, Exhaust pipe joint O-ring outer surface
Cylinder stud bolt threadS(a mm stud side) Pro Honda Anaerobic
Countershaft bearing set plate bolt screw threads Thread lock or equivalent Coating width: 6.5 ± 1.0 mm
Gearshift drum bearing set plate bolt threads Coating width : 6.5 ± 1.0 mm
Guide plate bolt threads Coating width: 6.5 ± 1.0 mm
Reed valve screw ,

1-16
 GENERAL INFORMATION
FRAME
, LOCATION MATERIAL REMARKS
Shock arm-tO-$wingarm nut threads and seating sur- Pro Honda GN4 4-stroke
face Oil or equivalent
Shock arm-ta-shock link nut threads and seating sur-
face
Shock link-ta-frame nut threads and seating surface
Thronle pipe inside and cable sliding surface
Steering head bearing rolling areaand oil seal lips Urea based multi.purpose Apply 3 9

r Steering head upper and lower oil seal lips grease for extreme pres-
sure (example: EXCELITE
EP2 manufactured by
KYODO YUSHI, Japan) or
equivalent
Swingarm pivot needle bearing rolling area Multi-purpose grease Apply 3 9
Swingarm pivot thrust bearing rolling area (Shell alvania EP2 or
Swingarm pivot dust seal lips equivalent)
Shock arm/shock link needle bea ring rolling area
Shock arm/ shock link side collar (bearing side)
Shock arm/shock link dust seal lips
Clutch lever cable adjust dial
Rear brake pedal pivot bolt sliding surface
Wheel bearing dust seal lips Multi-purpose grease
i Throttle cable roller inner and outer surface
Kickstarter pedal joint shaft sliding surface
~Ge"'hift ped., pio ,lidi09 ""'"
Brake caliper pin boltfpin bolt A Silicone grease
Brake caliper dust seals
Brake lever pivot bolt sliding surface
1
I.
Brake lever adjusting bolt tip
Rear master cylinder push rod sliding su rface
Rear master cylinder boot fitting area 1
•
Brake caliper slide pin threads Pro Honda Anaerobic
Drive chain slider mounting screw threads Thread Lock or equivalent
Front brake caliper mounting bolt threads
Fork protecto r bolt threads

::=t.
I
Brake caliper piston seal lips DOT 4 brake fl u id
Master cylinder inner surface
Master piston outer sliding surface
Fork cap O-ring
Fa,k fI"id
Fork oil seal lips and dust seal lips
Handlebar grip rubber inner surface Honda Bond A or Pro
Honda Hand Grip Cement
(U.SA only) J

1-17
GENERAL INFORMATION
CABLE & HARNESS ROUTING
'041 After '04:

THROTTLE CABLE CLUTCH CABLE

ENGINE STOP
FRONT
BUTTON WIRE
BRAKE HOSE

A •_ _ MAIN WIRE HARNESS

THROTTLE CABLE

'04:

CONDENSER

RADIATOR
REGULATOR/RECTIFIER OVERFLOW HOSE

IGNITION COIL _ _-\,~~~~

SPARK PLUG WIRE

CLUTCH CABLE

THROTTLE CABLE
THROTTLE POSITION
SENSOR WIRE

1-18
 GENERAL INFORMATION
'04:

ENGINE STOP BUTTON WIRE CONNECTORS

CLUTCH CABLE

THROTTLE CABLE

ALTERNATOR WIRE

'04:

CLUTCH

THROTTLE

REAR BRAKE HOSE('~~~

1-19
GENERAL INFORMATION
'04:

ALTERNATOR WIRE THROTTLE CABLE

CLUTCH CABLE

RADIATOR OVERFLOW HOSE CARBURETOR AIR VENT HOSES

'041Afte r '04:

THROTTLE POSITION

THROTTLE CABLE II SENSOR WIRE

CRANKCASE BREATHER HOSE

CARBURETOR DRAIN HOSE CARBURETOR AIR VENT HOSES

1-20
 GENERAL INFORMATION
Afte r '04:

THAOTIlE CABLE ~~:~~~~~~=

ENGINE STOP SUnON WIRE
CONNECTORS

CLUTCH CABLE

CLAMP
lri?r~'r~~I+~~\--- MAIN WIRE HARNESS

VENT HOSES

Aft er '04:

THROTILE CABLE

CLUTCH CABLE RADIATOR

v.----,..r OVERFLOW HOSE

REAR BRAKE HOSE

WAin HOSE

T~::~~~L~ POSITION
SWIRE

1-21
GENERAL INFORMATION
After '04:

THROTTLE CABLE ----~~ I \'1-_------ CLUTCH CABLE

LEFT UPPER
RADIATOR HOSE
~le- RADIATOR
OVERFLOW HOSE

RIGHT UPPER
HlU-!---- RADIATOR HOSE

MAIN WIRE HARNESS _.JiMt-V-&~~~~~~~~~f~~~_

r- IGNITION COIL PRIMARY
WIRE CONNECTOR

IGNITION PULSE GENERATOR ALTERNATOR 3P (BLACK)

2P (BLACK) CONNECTOR CONNECTOR

SPARK PLUG CAP THROTTLE POSITION

SENSOR WIRE

IGNITION COIL
\,------

After '04:
THROTTLE POSITION
SENSOR 3P CONNECTOR CLUTCH CABLE

~ "

\ IGNITION COIL PRIMARY

ALTERNATOR 3P (BLACK) WIRE CONNECTOR
CONNECTOR

\
CLAMP

IGNITION PULSE GENERATOR

2P(BLACK) CONNECTOR THROTTLE CABLE

1-22
 GENERAL INFORMATION
Aft er '04:

SPARK PLUG WIRE

CLUTCH CABLE

THROTILE CABLE

RADIATOR HOSE

ALTERNATOR WIRE

'"
II I
CARBURETOR AIR VENT HOSES
After '04:
THROTILE CABLE

A LTERNATOR W IRE ~::pc:-:;::j-ffr

WIRE BANDS

RADIATOR OVERFLOW HOSE CARBURETOR AIR VENT HOSES

1-23
GENERAL INFORMATION
After '04:

THROTTLE POSITION SENSOR

GROUND WIRE 3P CONNECTOR

WIRE BAND
. THROTTLE POSITION SENSOR WIRE
. IGNlTION COIL PRIMARY WIRE

1-24
 GENERAL INFORMATION

OPTIONAL PARTS
CARBURETOR SETTING PARTS
MAIN JET

I Optional
M ain jet number

SLOW JET

ITEM STANDARD
Standard '04: #40
After '04: # 55
Optional '04: # 35, # 37.5, # 40, # 45, # 50
f--After '04: # 45 65 (in increments of 5)

1-25
GENERAL INFORMATION
JET NEEDLE
'04:
Jet Needle Number
Spec ific Flow Characteristics at 1/16 Jet Needle Number
(112 clip position lower than standard series;
to 11 8 throttle (Standard Series)
Richer only at 1/8 to 3/4 throttlel
Rich 6DGY26-66 (Q2.66 mm) 6DGY27·66 (02.66 mm)
r-~DGY26-67 (Q2.67 mm) 60GY27-67 (02.67 mm)
1 BOGY26-68 (02.68 mm) SOGY27-68 (02.68 mm)
Gene tal Flow Characteristics At 1'16 6DGY26-69 (02.69 mm) BOGY27-69 (02.69 mm)
To 118 Throttle (Standard)
6DGY26·70 (02.70 mm) 6DGY27-70 (02.70 mm)
J 6DGY26-71 {(l2.7 1 mm) SDGY27-71 (02.71 mm)
Lean 6DGY26-72 (Q2.72 mm) 6DGY27-72 (02.72 mm)

After '04:
Jet Needle Number
Specific Flo w Characteristics at 1"6 Jet Needle Number
(1/2 clip position lower than standard series;
to 1/8 thrott I. (Standard Series)
Richer only at 118 to 3/4 throttle)
6DGY29-65 (Q2.65 mm)
I
Rich 6DGY28-65 ($2.65 mm)
6DGY28·66 ($2.66 mm) 6DGY29-66 (Q2.66 mm)
1 ~~Y28.67 (¢2.67 mm) 6DGY29-67 (Q2.67 mm)
I

General Flow Characteristics At 1/16 6DGY28·68 (¢2.68 mm) 6DGY29-68 (Q2.68 mm)
To 1/8 Thrott I, (Standard)
6DGY28·69 1$2.69 mm) 6DGY29-69 (¢2.69 mm)
J I
6DGY28-70 (4)2.70 mm) 6DGY29·70 (Q2.70 mm)
Lean 6DGY28-71 ($2.71 mm) 6DGY29·71 ($2.71 mm)

Jet needle nurn be<

NEEDLE NUMBER

\
[JIll i + ,
.' .. _-
f
O.D.

1-26
 GENERAL INFORMATION
MAINTENANCE EQUIPMENT

Work stand
ITEM - -" RO
For maintenance
E'MARKS
1

Air pressure gauge For checking tire a-ir pressure

Pin spanner Pin spanner A x 2
For shock absorber spring installed length (preload)
..I..-adjustment (two required) J
DRIVE CHAIN & SPROCKET
DRIVEN SPROCKET TEETH (M aterial)
Standard 52T (Aluminium)
n RIVE CHAIN LINK
11Slink
Optional 51T (Aluminium) '1Sl;;n;', -_ _
53T (Aluminium) 116 link J

HANDLEBAR LOWER HOLDER

---.=H :;;A
~N;;;DlEBAR LOWER HOLDER , - - - -REMARK"'
S- -
- Standard 3 mm (0.12 in) offset J
Optional No offset -----.J

1-27
GENERAL INFORMATION
20 INCH FRONT WHEEL
CO NSTRUCTION
• Front wheel assembly
- Rim (20 x 1.85)
- Spoke
- Hub
- Distance coliar
- Wheel bearing
- Dust seal
• Rim lock ( 1.85)
• Tire (Dunlop 0739FA 901100-20, 90/100-20 M/C)
• Tire flap
• Tire tube
See page' '·9 for front wheel assembly.

OPTIONAL WHEEL SPECIFICATION

Unit: mm (in)
ITEM T
STANDAR"O- - I SERVlCE lIM~

~
Wheel rim L Rad,,';C
" '--_ .O(O.08} -!
runout L-Axial 2.0 (0.08)
Wheel hub-la-rim distance 23 (0.9) ,
Specifications above are when using original brake disc, disc bolts and
side collars.
When using the optional 20 inch wheel, align the top surface of the top
'04 MODEL SHOWN:
bridge with the top surface of the outer tube.

rJ

~
~

1-28
 GENERAL INFORMATION
FORK SPRING
• The standard fork spring mounted on the motorcycle when it leaves the factory are not marked. Before replacing the
springs, be sure to mark them so they are distinguished from the other optional springs.

TYPE
Light
I
I
IDENTIFICATION MARK
, scribe mark
SPRING RATE
0.42 kgf/mm (23.52 Ibf/in)
FLUID lEVEL/ CAPACITY
Standard: 1
67 mm (2.6 in )1

~
--i~6 em] (15.8 US OZ, 16.41mp oz)
Maximum:
33 mm (1.3 in)1
505 em] (17.1 US OZ, 17.8 Imp oz)
Minimum:
I 108 mm (4.3 in)/
, 425 em] (14.4 US OZ, 15.0 Imp oz)
0.44 kgf/mm (24.64 Ibf/in)
-
Standard No mark Standard:
71 mm (2.8 in)/

~
462 em] (15.6 US OZ, 16.31mp oz)
, Maximum:
37 mm (1.5 in}1
499 em 3 (16.9 US OZ,
I Minimum:
17.6 Imp oz)

113 mm (4.4 in)1

L Heavy 2 sCribe marks 0.46 kgf/mm (25.76 Ibf/m)

420 em] (14.2 US oz,
Standard.
75 mm (3.0 in)1
14.8 Imp oz)

458 cm 3 (15.5 US OZ, 16.1 Imp ozl

Maximum:
41 mm (1.6 in)1
493 cm 3 (16.7 US OZ, 17.4 Imp ozl
Minimum:
117 mm (4.6 in)!
416 cm 3 (14.1 US OZ, 14.6 Imp ozl

SHOCK ABSORBER SPRING

• The standard fork spring mounted on the motorcycle when it leaves the factory are not marked. Before replacing the
springs, be sure to mark them so they are distinguished from the other optional springs.

r.~TY~P~E~=4~~ID~E~N~n~F~IC~A~'~IO
~ N~M~A~R~K~~~~=':~S~P~RI~
NGR'AT E'------l'
Light ! Green paint 4.4 kgf! mm (246.4 Ibflin) -j

~
Standard No mark (factory prod· 4.6 kgf/mm (257.6 Ibflin)
ucts) or White paint (after
market parts)

Heavy Blue paint 4.8 kgf/mm (268.8 Ibf/in)

~
P
I I_R
_,_d__'_;"_t____________"--_5>_o_' _g f/mm (280.0 Ibflin)

1-29
MEMO
 2. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION .............................. 2-2 NUMBER PLATE ·············································2-4

TROUBLESHOOTING ........ ............................ 2-2 SUB-FRAME····················································2-5

SEAT ······· ·· ······················································ 2-3 FUEL TANK ····················································· 2-6

SIDE COVERS ................................................ 2-3 EXHAUST PIPE ·· ·············································2-7

RADIATOR SHROUD .... ····························· ··· · 2-4

2-1
FRAME / BODY PANELS / EXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
• 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.
• This section covers removal and installation of the body panels. fuel tank and exhaust system.
• Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.
• Always inspect the exhaust system for leaks after installation.

TORQUE VALUES
Seat mounting bolt 26 N·m (2.7 kgf·m, 20 Ibf.ft)
Seat front hook screw 5.9 N·m (0.6 kgf·m, 4.3 Ibf·ft)
Sub·frame mounting bolt (upper) 29 N·m (3.0 kgf·m, 22 IbUt)
(lower) 29 N·m (3.0 kgf·m, 22 IbHt)
Rear fender mounting bolt (rear) 13 N'm (l.3 kgf·m, 9Ibf.ft)
Footpeg bracket boh (upper) 54 N'm (5.5 kgf·m, 40 Ibf·ftl
(lower) 29 N·m (3.0 kgf·m, 22 Ibf·ft)
Expansion chamber front mounting bolt 12 N·m (1.2 kgf·m, 9Ibf.ft)
Silencer case bolt 4.9 N·m (0.5 kgf·m,3.6 Ibf.ft)

TROUBLESHOOTING
EKcessive eKhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor perfo rm ance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

2-2
 FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL
Remove the two bolts, collars and seat.

INSTALLATION
A lign the hook of the seat with the mounting screw ,--- - --
on the fue l tank and the seat prongs with the sub-
frame tabs.
Install and tighten the seat mounting bolts to the
specified torque.
TORQUE: 26 N 'm 12.7 kgf·m , 20 IbUt)

BOLT

SIDE COVERS
REMOVAL/INSTALLATION
Remove the seat mounting bolts and collars.
TlCOLLAR I
Remove the flange bolts, collars and side cover.

........--

2-3
FRAME/BODY PANELS/EXHAUST SYSTEM
Be careful nor fa
damage the tabs
Install the side cover in the reve rse o rder of
removal. •
,
Tighten the seat mounting bolts to the s pecified
torque.
TORQUE: 26 N·m (2.7 kgf·m , 20 Ibf.ft )

RADIATOR SHROUD
REMOVAlliNSTAlLA TION
Note that rhe thin- Remove t he bolts, colla rs and radiator sh roud.
ner collars are In
rhe upper boils

Insert Ihe tab inside Installation is in the reverse order of removal.

the seal

NUMBER PLATE
REMOVALIINSTAlLA TION
Remove the number plate tab from t he handlebar.
Remove the bolt and number plate.

2-4
 FRAME/ BODY PANELS / EXHAUST SYSTEM
Inslall the number plate aligning its hole and pin on
the steering stem.
Installation is in the reverse order of removal.

SUB-FRAME
REMOVAL
Remove the seat (page 2-3).
Loosen the air cleaner connecting tube band screw.

Remove the three sub-frame mounting bolts.

Remove the sub-frame by pulling it straight back- SUIS-Fl'A'" •
ward. •

,
INSTALLATION
Loosely attach the upper and lower ends of the sub-
frame to the main-frame while connecting the
expansion chamber to the silencer pipe with the
sealing rubber and the air cleaner connecting tube
to the carburetor.
Tighten the screw on the connecting tube band.

2-5
FRAME/BODY PANELS/EXHAUST SYSTEM
Snug but do not tighten the three mounting bolts.
SUB-FRAME ,.
Tighten the sub-frame upper and lower mounting
bolt to the specified torque. 4 I
TORQUE: 29 N'm (3.0 kgf·m , 22 )bOt)
Install the seat (page 2-3).

....
FUEL TANK
FUEL FILTER MAINTENANCE
Drain the fuel from the fuel tank into an approved
gasoline container.
Disconnect the fuel hose from the fuel valve.
Remove the bolts, collars and fuel valve.

Wash the fuel filter in high flash-point cleaning sol -

vent. o - 0-RING
Check the D-ring is in good condition, install it onto FUEL FILTER
the fuel valve.
After inS/al/allon, Install the fuel valve in the reverse order of removal.
make slire there are
no Ive/leaks.

FUEL VALVE

REMOVAL
Remove the seat (page 2-3).
Remove the radiator shroud (page 2-4),
Turn the fuel valve OFF, and disconnect the fuel
hose.

2-6
 FRAME/BODY PANELS/EXHAUST SYSTEM
After '04 Remove the insulator rubber from the fuel tank
boss.

Remove the fue l tank breather hose from the steer- r::~~
ing stem nut.
Remove the fuel lank mounting bolt, unhook the
band and remove the fuel t ank.

INSTALLATION
After ins talla tion, Inslallation is in the reverse order of removal.
make sure there BREATHER HOSE
Install the breather hose into the stem nut as
are no fvellea ks
shown .

BAND

EXHAUST PIPE
SILENCER REMOVAL/INSTALLATION
Remove the right side cover (page 2-3).
Remove the silencer case mounting boll, silencer
case and sealing rubber.
Check the sealing rubber for wear or damage.
Replace the sealing rubber if necessary.
If necessary, perform glass wool packing mainte-
nance (page 3-20).
Installation is in the reverse order of removal.

2-7
FRAME / BODY PANELS/ EXHAUST SYSTEM
EXPANSION CHAMBER REMOVAL/
INSTALLATION
Loosen the expansion chamber mounting bolt.

Always replace the Unhook and remove the chamber springs.

exhaust pipe 9as - Remove the mounting bolts and expansion cham - EXPANSION CHAMBER SPRINGS

~
i<ers after removing ber.
the exhaust piPe
Inspect the expansion mounting rubbers for dam -
from the engine
age.
Installation is in the reverse order of removal.
Tighten the expansion chamber front mounting bolt
to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m , 9 Ibf·ft )

2-8
 3. MAINTENANCE

SERVICE INFORMATION ···· .. ·················. ······ 3·2 DRIVE/DRIVEN SPROCKET .......... .... .......... ·3·14

MAINTENANCE SCHEDULE · ........ ··.............. 3·4 BRAKE FLUID· .... · ........ · ...... ·.......................... 3.15

THROTILE OPERATION ...................... .......... 3·6 BRAKE PAD WEAR · ........................ .............. 3. 16

AIR CLEANER·· ........ ·· .... ·........... ............. ...... .. 3.6 BRAKE SYSTEM .. · .... ·.. ·· .. ·· .. ·· .. · ...... ·· ·.. ·· ....... 3. 17

SPARK PLUG ................................................. 3.8 CLUTCH SYSTEM .... ............ · ........................ 3.17

RADIATOR COOLANT ................................... 3.9 CONTROL CABLES· .... · .. · .... ·.. ·· .. · .... · ............. 3.19

COOLING SySTEM ............................ ............ 3·9 EXPANSION CHAMBER/SILENCER ............ 3.20

CYLINDER HEAD DECARBONIZING .......... 3·10 SUSPENSION .. · .... · ............ .... · .......... · ........ · .. 3.21

EXHAUST VALVE DECARBONiZiNG ...... · .. 3·10 SWINGARM / SHOCK LINKAGE .................. ·3·22

TRANSMISSION OIL ............................ ....... 3·11 NUTS, BOLTS, FASTENERS .. ...................... 3·22

DRIVE CHAIN .............................................. · 3· 12 WHEELS / TIRES ........ · ...... ·· .. · ............ · .......... ·3·22

DRIVE CHAIN SLIDER ................................. 3·13 STEERING HEAD BEARINGS · .................... ·3·23

DRIVE CHAIN ROLLER ................................ 3·14

3·1
MAINTENANCE

SERVICE INFORMATION
GENERAL
• Place the motorcycle on a level surface before starting any work.
• 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 o r 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 ca rbon monoxide gas thaI may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

SPECIFICATIONS

capac-

TORQUE VALUES
Oil check bolt 9.8 N'm (1.0 kgf'm, 7Ibf.ft)
Oil drain bolt 29 N·m (3.0 kgf·m, 22 Ibf.ft)
Spark plug 18 N·m (1.8 kgf·m, 13 Ibf·ft)
Rear axle nut 127 N'm (13.0 kgf·m, 94lbf.ft)
Drive chain adjusting bolt lock nut 26 N·m (2.7 kgf·m, 20 Ibf·ftl UBS nut
Drive chain roller bolt 12 N·m (1.2 kgf·m, 9Ibf.ft) U·nut
Brake lever adjuster lock nut 5.9 N'm (0.6 kgf·m, 4.3 Ibf·ft)
Front master cylinder reservoir cover bolt 1.5 N'm (0.15 kgf·m, 1.1 Ibf.ft)
Rear master cylinder reservoir cover bolt 1.5 N·m (0. 15 kgf·m, 1.1lbf·ft)
Fork air pressure relea se screw 1.2 N·m (0.12 kgf·m, 0.9 Ibf.ft)
Spoke nipple 3.9 N'm (0.4 kgf·m, 2.9 Ibf·ft)
Aim lock 13 N·m (1.3 kgf·m, 9lbHt)

3-2
 MAINTENANCE
TOOL
Spoke wrench, 6.6 mm
Q70MA-KZ30100

or equivalent commercially avail-

able in U.S.A.

3-3
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period .
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
FREQUENCY I Each Every 3
races or
Every 9
races or
REFER
NOTE race or TO
about about 7.5 about 22.5

, -
PAGE
ITEMS 2.5 hours hours hours
iTHROTILE OPERATION + - f 3-6
-+-i6
AIR CLEANER NOTE 1 C
, +- ~'-
3 -8
SPARK PLUG
RADIATOR COOLANT NOTE 2+ : R
3-9
COOLING SYSTEM
I
~­
CYLINDER HEAD DECARBONIZING
EXHAUST VALVE DECARBONIZATION
-T ~-
C
--,-- c
t-
-> 3-9
-+-3-10
3-10
PISTON AND PISTON RING~-
PISTON PIN AND CONNECTING ROD SMALL END BEAR-
t - R
R
7-13
7-13
i£5 j
I
'NG
REED VALVE ONLY
TRANSMISSION Oil
DRIVE CHAIN
~~ ~~
1 ~-R

R
R
4-21
3-11
3-12

-=l- 3-13

+
DRIVE CHAIN SLIDER
DRIVE CHAIN ROLLER
DAIVE SPROCKET , ~14
3-14
DRIVEN SPAOC~
BRAKE FLUID
BRAKE PADS WEAR
-N-OT
- E- ' t=~~i ~
~_ ~~
~4
3-15
3 - 16

BRAKE SYSTEM~­
==-1 , '3"=17

+- l +
CLUTCH SYSTEM 3-17
CONTROL CABLES 3-19
EXPANSION CHAMBER/SILENCER
SUSPENSION
SWINGARM/5HOCK lINKA~
- - -
+=':l ~~3 - 2'
3-20

3-22
12-28

~-
12-33
IFORKOIL NOTE 3 11 · 12
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
STEERING HEAD BEARIN as--
_ t:-- : ~-
3 - 22

3-22
3·23
This maintenance schedule is based upon average riding conditions. Machines subjected to severe use require more fr e-
quent servicing.
NOTES:
1. Clean after every mota for dusty riding condition.
2. Replace every 3 years. Replacement requires mechanical skill.
3. Replace after the first break-in ride.

3-4
 MAINTENANCE
ADDITIONAL ITEMS REQUIRING FREQUENT REPLACEMENT
ENGINE

-t
~ __ ITEM CAUSE REMARKS
Cylinder head gasket Compression leak Replace whenever disassembled
Clutch disc Wear or discoloration
Cylinder base gasket leakage Replace whenever disassembled
Right crankcase cover gasket
Exhaust valve cover gasket

FRAME
1 Damage
Damage
Replace whenever disassembled

I CAUSE ~MARK~
front/rear tire ~ Wear Minimum cleat height: 8mm (5/16 in)
Front/rear brake pad Wear Minimum thickness: 1mm (0.04 in)
Sub-frame mounting bolt Fatigue or damage
Drive chain guide plale Wear or damage
Side cover Damage
Front number plate Damage
Front/rear fender Damage
Clutch lever/holder Play or damage
Brake lever Play or damage
Handlebar Bent or damage
Throttle housing Damage
Grip rubber Damage
Gearshift pedal Damage
Brake pedal Damage
Drive chain adjuster/boll Damage
Air cleaner Damage
Exhaust chamber spring/ ho~o~k,--_ _~~F~
atigue or damage ----------L...-

These parts and their possible replacement schedule are based upon average riding conditions. Machine subjected to
severe use requi re mo re frequent servicing.

3-5
MAINTENANCE
THROTTLE OPERATION
Check that the throttle grip opens smoothly to full
throttle, and closes fully and automatically in all
steering positions.
Check the throttle cable and replace them if they are 3-5mm(1/8-1I4in)
deteriorated, kinked or damaged.
Lubricate the throttle cables if throttle operation is
not smooth.
Measure the free play at the throttle grip flange.
FREE PLAY: 3 - 5 mm (118 - 1/4 in )

Throttle grip free play can be adjusted at either end

of the throttle cable. LOCK NUT

Minor adjustments are made with the upper

adjuster.
Remove the dust cover from the adjuster
Adjust the free play by loosening the lock nut and
turning the adjuster.
Tighten the lock nut after making the adjustment .
Reinstall the dust cover.

Major adjustments are made with the carbure tor

end of the cable.
Pull the carburetor rubber cap up.
Adjust the free play by loosening the lock nut and
turning the adjuster.
After adjustment, tighten the lock nut securely and
reinstall the rubber cap.
Recheck the throttle operation.

AIR CLEANER
Remove the seat (page 2-3).
Remove the air cleaner retaining bolt.
Remove the air cleaner assembly.

3-6
 MAINTENANCE
Remove fhe 81f Remove the air cleaner from the cleaner holder.
cleaner holder HOLDER
pm{51 from the
hole(s) on tile alf
cleaner tab(s)

AIR CLEANER

Never use gasolme Thoroughly wash the air cleaner in clean non-flam-
or low flash pomt mable or high flash point cleaning solvent.
solvems fOf clean- Then wash the element again in a solution of hot Washin
solvent
mg the alf filter ele- water and dishwashing liquid soap.
menl- A fire or Clean the inside of the air cleaner housing. Squeeze
explOSIOn could out
Aher cleaning. be sure there is no dirt or sand
resuh
trapped between the inner and outer layer of the excess o i l

_~_
-w-~
cleaner.
D",
Wash again if necessary.
Allow the air cleaner to dry thoroughly. 1'.-') , ,
After drying, soak the air cleaner in clean Pro Honda Squeeze P'o
Foam Filter Oil or an equivalent. out solvent Honda
thoroughly Foam
Apply air filter oil to the entire surface of the air Filter Oil
cleaner and rub it with both hands to saturate the L _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _---'
element with oil.
Gently squeeze out excess oil. It is important not to
over-oil, or under-oil the element.
Insert the air cleaner holder center boss to the air
HOLDER
cleaner center hole, and align the air cleaner holder
pin(s) with the hole(s) on the air cleaner tab(s).
Apply a thin coat of Pro Honda Filter Grease to the
sealing surface.
Install the air cleaner rataining bolt through the
j
assembly.

PIN/HOLE (AFTER '04) BOSS

If the air cleaner Insert the pin of the holder in the air cleaner housing , - - - - - - - - - , - - - - - - - - - - - ,
hole and install the assembly into the air cleaner "6" MARK Align
8ssembly IS not
Installed correc/ly. housing while aligning the tab on the air cleaner
dirt and dust may and the " 6· mark on the air cleaner housing.
enter tile engme
Tighten the retaining bolt securely.
resulting wear of
Carefully position the sealing flange of the element
the piston nng and A IR CLEANER
to prevent dirt intrusio n.
cylmder
Install the seat (page 2-3).

HOLE ~-
PIN
HOLDER

3-7
MAINTENANCE
SPARK PLUG
Disconnect the spark plug cap.
Clean around the spa rk plug bases with compressed
air before removing. and be sure that no debris is
allowed to enter the combustion chamber.

Remove the spark plug and inspect it for damage.

Check the following and replace if necessary (rec-

ommended spark plug: page 3-2):
• Insulator for damage
CENTER ELECTRODE l
• Electrodes for wear
• Burning condition, coloration;
- dark to light brown indicates good condition.
- excessive lightness indicates malfunctioning
ignition system or lean mixture.
- wet or black sooty deposit indicates over-rich
mixture.

INSULATOR SIDE ELECTRODE

If necessary. adjust the gap by bending the side

electrode. Then measure the gap again and rein - 0.5-0.Smm J
stalL (0.020 - 0.024 in) .,

SPARK PLUG GAP: 0.5 - 0.6 mm (0.020 - 0.024 in)

~

3-8
 MAINTENANCE
Topreven/damage Reinstall the spark plug in the cylinder head and
to the cylInder hand tighten, then torque to specification .
head. hand /I(}h/en
the spark. plug TORQUE: 18 N·m (1.8 kgf·m , 13 IbUt)
before usmg a
wrench to tIghten
to the specified
torque.

RADIATOR COOLANT
Remove the radiator cap.

Check the coolant level with the engine cold, it

should be up to the filler neck.
Add coolant as required (page 5-8 ).

COOLING SYSTEM
Remove the radiator shroud (page 2-4 ).
Remove the fuel tank (page 2-6).
Check the radiator air passage for clogging or dam-
age.
Inspect the hoses for cracks and deterioration.
Use low pressure water and a soft brush to rinse off
any dirt that may be stuck in the radiator core.
Inspect the hoses for cracks and deterioration.
Replace if necessary.
Check the tightness of the hose clamps and radiator
mounting bolts.

3-9
MAINTENANCE
CYLINDER HEAD DECARBONIZING
Remove the cylinder head (page 7·6).
CYLINDER HEAO
DecarbOnize/he Clean the cylinder head surface of any gasket mate-
cy/mder head every rial.
3 races or SOOtH 75
hou"

Use care not /0 Remove the carbon deposits from the combustion
scratch the com- chamber.
bustton chamber or
the head gasket
surface.

EXHAUST VALVE DECARBONIZING

NOTE '
• Decarbonize the flap valves and valve shaft after
each race.
'04 model Remove the flap valves and valve shaft (page 8-9).
VALVE SHAFT

FLAP VALVES

Afrsr '04 Remove the flap valves and valve shaft (page 8-10).

VALVE SHAFT

L-__________________~F~LA
2PVALVES

Remove the carbon deposits from the flap valves

and valve shaft. AFTER '04 MODEL SHOWN:
Inspect the flap valves and valve shaft for wear or VALVE SHAFT
damage.

FLAP VALV"S

3-10
 MAINTENANCE
TRANSMISSION OIL
OIL lEVEL INSPECTION
1. Slart the engine and let it idle for 2 - 3 minutes.
2. Wail three minutes after shutting off the engine
to allow the oil to properly distribute itself In the
clutch and transmission .
3. Support t he motorcycle in an upright position on
level ground.
4. Remove the oil filler cap from the right crankcase
cover ,

5. Remove the check bolt from the right crankcase

cover. A small amount of oil should flow out of
the check bolt hole. Allow any excess oil to flow
out of the check bol l hole.
6. If no oil flow out of the check boll hole, add oil
slowly through the oil filter hole until oi l starts to
flow out of the check bolt hote. Install the oil
check bolt and filler cap,
7. Repeal step 1 - 6.
8. After checking the oil level or adding oil, tighten
the oil check bolt and filler cap securely.
TORQUE: 9.8 N'm (l .O kgf·m. 7 Ibf.ft)

OIL CHANGE
Transmission oil should be changed at least every 3
races or 7.5 hours of running 10 ensure consistent
performance and maximum service life 01 both
transmission and clutch components.
Warm·up me 1. Stan the engine and let it idle for two or three
engme befOte dram· minutes.
m!} the 011 ThIs WIll
ensures complere
2. Support the motorcycle in an upright positiOn on
level ground.
and fapd drsmmg
3. Remove the oil filler cap from the right crankcase
cover.
4. Place the oil pan under the engine to catch the
oil. then remove the drain boh.
5. After the oil has been drained completely. install
the drain bolt with a new sealing washer.
TORGUE: 29 N 'm (3.0 kgf·m. 22 Ibf.ft )

3-11
MAINTENANCE
6. Add the recommended oil.
OIL FILLER CAP
Oil CAPAC lTV:
0.57 liter (0.60 US qt, 0.50 Imp qt) at draining

RECOMMENDED TRANSMISSION OIL:

Pro Honda HP Trans Oil, Pro Honda GN4 4·stroke
o il (U.S.A. and Canada) or an equivalent motor oil
API service cla ssification: SG or higher
JASO T 903 standard: MA
Viscos ity; SAE 10W- 30
Check the oil level bv following sleps 1 - 6 in oil
level check procedure (page 3· ").

DRIVE CHAIN
N• .,., _ _ " "" CLEANING AND LUBRICATION
adJust the drive For maximum service life, the d rive chain should be ,
cham wIllie rhe cleaned and lubricated after every ride. LINK CliP
engme IS running
Perform the following service with the engine
slopped and the transmission in neutral.
Place a work stand or equivalent under the engine.
Carefully remove the master link clip with pliers.

Remove the masler link, plate and disconnect the , -- - - -- - - - - - - - - - - - - ,

drive chain. liNK

PLATE

Clean the drive chain in non·llammable or high

flash point solvent Bnd wipe it dry.
Inspect the chain for possible wear or damage; SOFT BRUSH
replace any chain that has damaged rollers or loose
fitting links.
Reinstall the drive chain and lubricate it with Pro
Honda Chain Lube o r its equivalent.
WIPE AND DRY
Install the open end of the master link opposite the
direction of chain travel.
LUBRICATE

'CJe;:C-:c:?(=:x::::x::::x::ex::::X::

3·12
 MAINTENANCE
Measure the distance between a span of 17 pins (16
pitches), from pin center to pin center.
SERVICE LIMIT: 258.0 mm (10.16 in)
SERVICE LIMIT: 258.0 mm (10.16 in)
If the measurement exceeds the service limit,
replace the chain.

ADJUSTMENT
Raise the rear wheel off the ground by placing a
workstand under the engine.
Measure the chain slack, on the upper chain run,
midway between the sprockets.
CHAIN SLACK: 2S-35mm(1 .0 - 1.4in)

Raise the rear wheel off the ground by placing a

workstand under the engine,
Check that the chain adjuster index marks are in the
same position on each side, then tighten the axle
nut to the specified torque.
TORQUE: 127 N ·m 113.0 kgf·m, 94Ibf.ft)

After torquing the axle nul, seal the adjusting bolts

snugly agains! the axle adjustment plates and
tighten the adjuster lock nut to the specified torque ....~O
TORQUE: 26 N ·m (2.7 kgf·m , 20 Ibf.tt)

DRIVE CHAIN SLIDER

Inspect the drive chain slider for excessive wear.

SERVICE LIMIT: 5 mm (0.2 in) from upper surface

CHAIN SLIDER

3-13
MAINTENANCE
Check the chain guide and chain guide sl ider for
alignment, wear or damage. CHAIN GUIDE SUDER CHAIN GUIDE
Replace the chain guide jf it is damaged or worn.
Replace the chain guide slider if the chain is visible
through the wear inspection window.

INSPECTION WINDOW

DRIVE CHAIN ROLLER

'04:
Inspect the drive chain rollers for excessive wear or
DRIVE CHAIN ROLLERS
damage.

SERVICE LIMIT:
Upper: 35 mm (1.4 in)
l ower: 25 mm (1.0 in)
Install rhe dove Replace the rolier if necessary, and tigh t en the rolier
cham roiler with ,ts mounting bolts to the specified torque.
arrow mark side
TORQUE: 12 N·m (1.2 kgf·m , 9 Ibf·ft)
facing out.
Install the drive chain rollers as follows:
• Upper: Bearing shield coliar is orange.
• Lower: Bearing shield collar is black.
AFTER ' 04:
Inspect the drive chain rollers for excessive wear or
ARROW MARK DRIVE CHAIN ROLLERS
damage.

SERVICE LIMIT:
Upper: 39 mm (1.5 in)
Low er: 31 mm (1.2 in)
Replace the roller if necessary, and tighten the roller
mounting bolts to the specified to rque.
TORQUE: 12 N·m (1.2 kgf.m, 9Ibf.ft)

Install the drive chain rollers as follows:

• Upper: Arrow mark facing out.
• Lower: Dent ed side facing out.
DENT

DRIVE/DRIVEN SPROCKET
Never use a new Inspect the drive and driven sprocket teeth for wea r
drIVe cham on worn or damage, replace if necessary. Worn Sprocket Teeth
sprockets REPLACE

GOOD

Normal Sprocket Teeth

3-14
 MAINTENANCE

BRAKE FLUID
• Do not mix different types of fluid, as they are
not compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• Avoid spilling fluid on painted. plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
FLUID LEVEL INSPECTION
When the fluid level is low, check the brake pad for
wear (page 3-16), A low fluid level may be due to
wear of the brake pads. If the brake pads are worn.
the caliper piston is pushed Qut, and this accounts
for a low reservoir level. If the brake pads are not
worn and the fluid level is low, check the entire sys-
tem for leaks (page 3-17),
FRONT
Check the front brake fluid reservoir level through
the sight glass.
If the level is near the lower level mark, check the
brake pad wear (page 3-16).

REAR
Place the motorcycle on a level surface, and support
it in a upright position.
Check the rear brake fluid reservoir level.
If the level is near the lower level mark, check the
brake pad wear (page 3-161.

3-15
MAINTENANCE
FLUID FILLING
FRONT
Remove the screws, diaphragm cover and dia-
phragm. SCREWS UPPER MARK
Fill the reservoir with DOT 4 brake fluid to the upper
level mark.
Install the diaphragm and cover, lighten the screw
to the specified torque.
TORQUE: 1.5 N'm (0.15 kg'·m , 1.1Ibf.ft)

Check the entire system for leaks.

REAR
Remove the bolts, diaphragm cover and diaphragm.
Fill the reservoir with DOT 4 brake fluid to the upper
level mark.
Do nor bend the Install the diaphragm and cover, lighten the bolts to
diaphragm durmg the specified torque.
instal/arion.
TORQUE: 1.5 N ·m (0.15 kgf ·m, 1.1Ibf.ft)
Check the entire system for leaks.
Inspect the brake hose and fittings for deterioration,
cracks or signs of leakage. Tighten any loose fit-
tings.
Replace the hose and fittings as required.

BRAKE PAD WEAR

Check the brake pads for wear.
Replace the brake pads if either pad is worn to the
bottom of wear limit groove.
Refer to page 13-8 for brake pad replacement.

3-16
 MAINTENANCE
BRAKE SYSTEM
LEVER POSITION INSPECTION
The brake lever pOSition can be adjusted by loosen- , - - - - - - - - - - - - - - - - - - ,
In9 the lock nut and turning the adjuster.
\
Turning the adjuster clockwise moves the brake LOCK NUT
lever farther away from the grip; turning the
adjuster counterclockwise moves the brake lever

-
closer to the grip.
Applygfe8se /0 the Aher adjustment, hold the adjuster and tighten the
contac t faces of the lock nut to the specified torque.
adJuster boll and
TORQUE: 5.9 N·m (0.6 kgf-m , 4.3 Ibf·tt) LESS
{JIs/on
THAN
If the brake lever free play exceeds 20 mm (0.8 in), 20mm
there is air in the system that must be bled. (O.8 in)
Refer 10 page 13-6 for brake system bleeding . ADJUSTER

BRAKE PEDAL HEIGHT

Adjust the brake pedal to the desired height by loos-
ening the lock nut and turning the pedal height
adjusting bolt. J
Tighten the lock nut to the specified torque.
TORQUE: 5.9 N'm (O.6 kgf·m. 4.3 Ibf·ft)

79.6mm
(3.13 in)

CLUTCH SYSTEM
CLUTCH LEVER POSITION ADJUST-
MENT
I NOTICE I
• Make sure to adjust the clutch lever free play
after the clutch lever position adjustment or the
clutch cable is disconnected.
• Failure to check the clutch lever free play may
result in damaged clutch plates.
Clutch le .... er position can be adjusted by loosening , - - - -- -----------,
the lock nut and turning the adjuster.
LOCK NUT
TUrning the adjuster clockwise mo.... es the clutch
le .... er closer from the grip; turning the adjuster coun- ADJUSTER
terclockwise mo .... es the clutch lever farther away to
grip.
Tighten the lock nut securely.
Check the clut ch lever free play (page 3- 18).

3-17
MAINTENANCE
Turn the clutch cable end adjuster in direction A
until it seats lightlv and then turn it out 5 turns. CABLE END ADJUSTER

Loosen the lock nut and lurn the integral cable

adjuster to adjust the clutch lever free play 10 - 20
~================--:::;
ADJUSTER
mm (318 - 3/4 in) at the tip of lever.
LOCK NUT
Tighten the lock nut.

Adjust the clutch cable end adjuster for minor

CABLE END ADJUSTER
adjustment.

ADJUSTMENT
Measure the clutch free play at the lever end.

FREE PLAY: 10 - 20 mm (3 18 - 3/ 4 in)

10- 20 mm (318- 3/4 in )

3-18
 MAINTENANCE
Minor adjustments are made at the cable end
CABLE END ADJUSTER
adjuster on the lever.
Turning the adjuster to adjust the free play.
If the adjuster is threaded out near its limit and the
correct free play cannot be reached, turn the
adjuster all the way in and back QuI one turn and
make the adjustment with the integral cable
adjuster.

Major adjustments can be made at the integral ~=====-----==========:..:

adjuster. ADJUSTER
Loosen the lock nut and turn the adjuster, LOCK NUT
Tighten the lock nut after adjustment.
Test ride to be sure the clutch operates properly
without slipping or dragging .
If proper free play cannot be obtained using both
procedure or the clutch slips during the lest ride,
disassemble and inspect the clutch (page 9· 10).

CONTROL CABLES
Remove the throttle housing dust cover.
Remove the throttle cable end cover.
Disconnect the clutch cable upper and from the
clutch lev er.

Remove the throttle cable roller and collar.

Disconnect the throttle cable end from the throttle
grip.
II IS nor necessary Thoroughly lubricate the throttle cable pivot points
/0 /ubflcale the with a commerciallv available cable lubricant.
emile CiJble
If the throttle operation is nol smooth, replace the
cable.
Be sure the throttle relurns freely from fully open to
fully closed automatically, in all steering positions.
Installation is in the reverse order of removal.

3-19
MAINTENANCE
Disconnect the clutch cable upper end from the
clutch lever. CLUTCH CABLE
It IS not necessary Thoroughly lubricate the throttle cable pivot points
ro lubrica te
the with a commercially available cable lubricant.
cables
If the clutch lever operation is not smooth, replace
the cable.
Installation is in the reverse order of removal.
Apply grease to inside of the clutch cable end
adjuster.

EXPANSION CHAMBER/SILENCER
SILENCER GLASS WOOL REPLACE-
MENT
Remove the silencer (page 2~7).
BOLTS SCREW
Remove the silencer case bolts and screw.
Holdthemounrmg
tab (after removing
Pull out the inner pipe.
''\
collar rubber) of the
silencer case gen-
tlv In /I Vise pro-
tected wllh a shop
towel or soft jaws

INNER PIPE

Remove the glass wool packing.

Remove the carbon deposits from the inner pipe AFTER '04:
using a wire brush.
8e careful nor 10 Install the new glass wool packing material.
damage the glass Apply muffler sealant {high-temperature silicone) in
wool packmg the area shown.
Insert the inner pipe and packing into the silencer SILENCER BOLT
case and align the bolt hole.
Install and tighten the silencer case bolts to the
specified torque .
TORQUE: 4.9 N·m (0.5 kgf·m, 3.6Ibf·ft)

Wipe off any excess sealant.

La
V':

INNER PIPE

3-20
 MAINTENANCE

SUSPENSION
FRONT SUSPENSION INSPECTION
Loose. worn or Check the action of the fo rks by operating the front
damaged SlJspen- brake and compressing the front suspension several
Sion parts Impair times.
motorc f'cies stabl/- Check the entire fork assembly for signs of leaks,
lIy and control damage or loose fasteners.
Make sure that the fork protectors and dust seals
are clean and not packed with mud and dirt.
Remove any dirt that has accumulated on the bot-
tom of the fork seals.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.

Refer to page 11-12 for fork service.

Air pressure acts as a prog ressive spring and affects
the entire range of fo rk travel.
Air is an unstable gas; it increases in pressure as it
is worked (such as in a fork). so the fork action on
your CR will get stiffer as the race progresses.
Release built~up ai r pressure from the fork legs after
practice and between heats.
Be sure the fork is fully extended with the front tire
off the ground.
Loosen the pressure release screw fully, then
tighten them.
TORQUE: 1.2 N·m (0.12 kgf·m , 0.9Ibf.ft)

REAR SUSPENSION INSPECTION

Check the action of the shock absorber by com -
pressing it several times.
Refer to page 12-13 for shock absorber service.

Remove the sub-frame (page 2-5).

Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tigh t en all nuts and bolts.
Refer to page 12-13 fo r shock absorber service.

3-21
MAINTENANCE
Raise the rear wheel off the ground by placing a
workstand under the engine.
Hold the swing arm and move the rear wheel side-
ways with force to see if the wheel bearing are
worn.

SWINGARM/SHOCK LINKAGE
Raise the rear wheel off the ground by placing a
work stand under the engine.
Check for worn swing arm bearings by grabbing the
swing arm and attempting to move the swingarm
side to side.
Replace the bearings if excessively worn (page 12·
331.
Check that the shock linkage and needle bearings
are not damaged.
Disassemble, clean and inspect the 5wingarm and
shock linkage pivot bearings and related seals every
3 races or after about 7.5 hours of running (page 12·
28),
Lubricate and reassemble.

NUTS,BOlTS, FASTENERS
Check that all chassis nuts and bolts are tightened
to their correct torque values (page 1-11).
Check that all safety clips, hose clamps and cable
stays are in place and properly secured.

WHEELS/TIRES
Check the tires for cuts, embedded nails, or other
damage.
Check the front and rear wheels for trueness (refer
to page 11-7 and page 12-7).

r,re pressure Check the cold tire pressure.

should be checf.ed
TIRE PRESSURE:
when rhe fires are
rod FRONT: 100 kPa (1 .0 kgf/ cm2, 14 psi)
REAR: 100 kPa (1.0 kgf/cm2, 14 psi)

_.
AIR PRESSURE GAUGE
,

3-22
 I
MAINTENANCE
Inspect the wheel rims and spokes for damage.
Tighten any loose spokes to the specified torque. SPOKE

Y
TOOL:
Spoke wrench, 6.6 mm 070MA·KZ30100
(Equivalent com-
merciallyavail.
able in U.S.A .)

TORQUE: 3.9 N ·m (0.4 kgf·m , 2.9 Ibf.ft)

Tighten the rim locks to the specified torque.
TORQUE : 13 N-m (1 .3 kgf·m, 9 Ibf.ft)

STEERING HEAD BEARINGS

Raise the front wheel off the ground by placing a
work stand under the engine.

Check Ihllt the con- Check that the handlebar moves freely from side to ......
trol cables do not side.
Interfere with han·
dlebar (OIiJIK)(l
If the handlebar moves unevenly, binds, or has ver-
lical movement. inspect the steering head bearings
(page 11-34).
If excessive play has developed, check the steering
stem for cracks.

3-23
MEMO
 4. FU EL SYSTEM

COMPONENT LOCATION ............................. 4-2 CARBURETOR REMOVALIDISASSEMBLY 4-10

SERVICE INFORMATION .............................. 4-3 CARBURETOR ASSEMBLY I

INSTALLATION ·············································4-15
TROUBLESHOOTING ···································· 4-4
THROTTLE POSITION SENSOR ··················4-20
CARBURETOR ADJUSTMENT, MINOR ....... 4-5
REED VALVE ·················································4-21
CARBURETOR ADJUSTMENT, MAJOR ...... 4-5
AIR CLEANER HOUSING ·····························4-24
CARBURETOR TUNING INFORMATION ..... 4-7

4-1
FUEL SYSTEM
COMPONENT LOCATION
'04 model shown:

29 N·m (3.0 kgf·m. 22 Ibf·ft)

29 . (3.0 kgf·m, 22 Ibf.ft)

4-2
 FUEL SYSTEM

SERVICE INFORMATION
GENERAL
• 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.
• Refer to page 2-6 for fuel tank removal and installation.
• When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
• Before removing the carburetor, place an approved gasoline container under the float chamber, remove the drain plug
and drain the carburetor.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to
prevent any foreign material from dropping into the engine.
• If the vehicle is to be stored for more than one month, drain the float bowls. Fuel left in the float bowls may result in
clogged jets, resulting in hard starting or poor driveability.

SPECIFICATIONS

Main jet
ITEM
r-Carburetor identification number
-
I ~~r'04:±-
'04:
'04:
,.
-+_A~ft~,er '04:
11-_

+--
i
_ _ SPECIACATIONS- -
TMX04A
TMX05A
#420
#430
#40
~~_
==3
~

Slow jet

~eedCle-- ~~~'04~' ~
_~==~~~j6~D~GY~2~6i'~~====-
#55
_~"A",fter '04: . - 6DGY2a·68
Jet needle clip position
Air screw initial opening -l~"=0404,
lAtter '04,-
' _ __
_==== Jrd groove from top'--_ _ _
2 turns out
1-314 turns out
~at lev"e~I::::::=-
Throttle grip free play c=~=c.
Reed valve clearance service limit
--===:=;~
__---"3,,- 7.::~m~m~'~0~'3~oi;~n)G[:=--:====~
5 mm (l/a - 114 i-n-) -
0.2 mm (0.01 in ~
) _ _ __
~
~

TORQUE VALUES
Sub-frame mounting bolt (upper) 29 N·m (J.O kgf·m, 22 Ibf.ft)
(lower) 29 N'm (J.O kgf·m, 22 IbHt)
Reed valve mounting screw 1.0 N·m (0.1 kg f·m, 0.7Ibf.ft)
Thronle cable holder 2.9 N·m (O.J kgf·m, 2.2 Ibf·ft)
Float pin set screw 2.0 N·m (0.2 kgf·m, 1.4 Ibf·ft)
Carburetor air filter bolt 2.0 N·m (0.2 kgf·m, 1.4 Ibf·ft)
Main jet 2.0 N'm (0.2 kgf·m, 1.4 Ibf·ft)
Slow jet 1.0 N'm (0.1 kgf·m, 0.7 Ibf·ft)
Carburetor top screw 2.0 N'm (0.2 kgf.m, 1.4 Ibf·ft)
Thronle stop screw lock nut 2.0 N·m (0.2 kgf·m, 1.4 Ibf.ft)
Float chamber screw J.9 N'm (0.4 kgf·m, 2.9 Ibf·ft)
Carburetor drain plug J.9 N·m (0.4 kgf·m, 2.9 Ibf·ft)
Choke knob lock nut 3.9 N'm (0.4 kgf·m. 2.9 Ibf·ft)
Float valve seat set screw 1.0 N'm (0.1 kgf·m, 0.7 Ibf·ft)
Insulator band screw See page 1·13

4-3
FUEL SYSTEM
TOOL
Carburetor float level gauge
07401-0010000

P'
&r.
y

TROUBLESHOOTING
Engine cranks but w on't start
• Too much fuel getting to the engine
- Air cleaner clogged
- Flooded carburetor
• Intake air leak
• Fuel contaminated/deteriorated
• No fuel to carburetor
- Fuel filter clogged
- fuel hose clogged
- Fuel valve Sluck
- floallevel misadjusted
- Fuel tank breather hose clogged
• Slow circuit clogged
• No spark at plug (faulty spark plug or ignition malfunction)
Lean mixture
• Fuel jets clogged
• Fuel lank breather hose clogged
• Fuel filler clogged
• Fuel tine restricted
• Float valve faulty
• Fuel level too low
• Air vent hose clogged
• Advanced ignition timing
• Intake air leak
• Jetting incorrect for altitude/temperature condition
Rich mi)(ture
• Choke valve in "ON" position
• Float valve faulty
• Fuel level too high
• Air jets clogged
• Air cleaner element contaminated
• Flooded carburetor
• Worn crankshaft seal
• Jetting incorrect for altitude/temperature conditions.
Engine st alls, hard to st art, rough idling
• Fuel line restricted
• Ignition malfunction
• Low cylinder compression
• Fuel mi)(ture too lean/rich
• Fuel contaminated/deteriorated
• Intake air leak
• Float level misadjusted
• Fuel tank breather hose clogged
• Air screw misadjusted
• Slow circuit or starting enrichment circuit clogged

4-4
 FUEL SYSTEM

CARBURETOR ADJUSTMENT, MINOR

IDLE MIXTURE AND IDLE SPEED
:-__ .:-::=
The standard carburetor sellings are ideal for the ' C
following conditions: 32:1 premix ratio using Pro
Honda HP-2 2-stoke oil or its equivalent, sea level
altitude, and 20 °C (68 OF) air temperature. If your
conditions are different, you may need to adjust the
carburetor settings using the tuning information
chart (page 4-7).
, . Adjust the carburetor setting using the tuning
information chart (page 4-7).
STANDARD SETTING:
FLOAT lEVEL: 7.5 mm (0.30 in)
AIR SCREW INITIAL OPENING:
'04: 2 turns out
After '04: 1-3/4 turn s out
SLOW JET: '04: 040
After '04: 1155
MAIN JET: '04: ..20
After '04: 0430
JET NEEDLE: '04: 60GY26-69
After '04: 6DGY28-68
JET NEEDLE CUP POSITION: 3rd groove from
top
2. When the engine is warm enough to run without
the choke, push the choke knob down to its "OFF"
position.
3. Loosen the lock nut and turn the throttle stop
screw to obtain the smoothest idle.
• To decrease idle speed, turn the throttle stop
screw counterclockwise.
• To increase idle speed, turn the throttle stop
screw clockwise.
4. Adjust the air screw to obtain the best off-idle
performance.
• If the engine runs rich exiting a corner, turn the
air screw counterclockwise to lean the mixture.
• If the engine runs lean exiting a corner, turn the
air screw clockwise to ri chen the mixture.

CARBURETOR ADJUSTMENT, MAJOR

FOR TEMPERATURE AND ALTITUDE
1. Warm up the engine.
2. Make two or three laps of a course with the stan-
dard setting. Note engine acceleration and other
engine conditions in relation to throttle opening.
Verify the mixture by removing the spark plug
and reading the firing end.
3. Change the carburetor settings or select suitable
carburetor jets, taking into consideration the
engine conditions and tuning information chart
for temperature and altitude (page 4-7).

4-5
FUEL SYSTEM
4. Turn the fuel valve OFF, loosen the carburetor
insulator clamp screw and connecting boot
clamp screw.
5. Remove the drain plug and drain the gasoline
from the carburetor.
6. Change the jets as required and reinstall the
drain plug.

7. Remove the jet needle from the thronle valve

(page 4- 11) and change the jet needle clip posi-
-
SLOW JET MAIN JET

tion as required.
8. Reinstall the jet needle and carburetor lop (page
4· 19).
9. Tighten the carburetor insulator clamp screw
and connecting boot clamp screw.
10.Adjust the air screw opening as required.

4-6
 FUEL SYSTEM
CARBURETOR TUNING INFORMATION
CARBURETOR TUNING CHART
NOTE
• If you use the chart correctly, it should not be necessary to adjust more than one jet size richer or leaner to fin e lune
your CR. If a very large adjustment is required, there may be somethi ng w rong elsewhere. Check for worn crankshaft
seals, air leaks, blocked exhaust or fuel system, o r di rty air clea ner element.
• The tuning information chart will get you very close to the ideal setting. However, because of differences in pressure
and humidity, you may need to fine tune the carburetor for ra ce day condition.
'04 MODEL:

I-cCent.
I
Fahr.
.30 ' _ . 1]0
-21 '_ 0"
..
, -,
~ '" 20
~6" ~1 - ~5
19 _ 40"-
Temperature
4" ' 6"
39" SO"
15"- 21"
59- - 80
26"
19"
38"
100~
~

37"-- 49°
99 - 120
3,050 m AS: 2 2·1 /4 2· 1/2 2 2-1/4 2-1 /2 2-3/4
(10,000 ttl SJ: #40 #40 #40 #40 #37.5 #37.5 #37.5
I
2,300 m
NC:
IN:
3,d
6DGY26-69
3,d 2nd*nd
6DGY26~69 1 6DGY21~ 10 6DGY21~10
2nd
6DGY26-71
2nd
6DGY26-71
'st
6DGY27-7 1
(7,500 tt)
2,299 m
MJ :
AS:
#420
1-3/4
#410
2
#400
2-1/4
#390
2-1/2 #3~310
2 2-1/4
#3S0
2-112
(7,499 tt) SJ: #40 #40 #40 #40 #40 #37.5 #37.5
I NC: 3,d 3rd 3rd 2nd 2nd 2nd 2nd
1,500 m IN: 6DGY27-69 6DGY26-69 6DGY26-69 6DGY27-70 SDGY27-70 6DGY26-71 6DGY26-71
(5,000 tt) MJ: 1/430 #420 #410 #400 #390 #380 #370

'"' I '"' l
1,499 m AS: 1-112 1-3/4 2 2-1 /4 2- 1/2 2 2-114
~• (4,999 tt ) SJ: #40 #40 #40 #40 #40 #40 #37.5
il I NC: 3,d 3,d 3,d 3,d 2nd
E 750 m IN: 6DGY27-68 6DGY27-69 6DGY26-69 SDGY26-69 SDGY27-70 SDGY27-70 6DGY26-71
<
(2,500 tt) MJ: #440 #430 #420 #390 #380
749 m AS: 1-1 /4 1 1/2 1-314 2
(2,499 tt) SJ: #45 #40 #40 #40 #40 #40 #40
I NC: 4,h 3,d 3,d 3,d 3,d 2nd 2nd
300 m IN: SDGY26-68 6DGY27-S8 SDGY27-69 6DGY26-69 SDGY2S-69 SDGY27-70 SDGY27-70
(1,000 tt) MJ; #450 #440 1/430 #420 #410 #400 #390
299 m AS: 1-3/4 1-1/4 1- 1/2 2-1 12
(999 tt) SJ: #45 #45 #40 #40 #40 #40

~ SDGY27-67
I 4th 3,d 3,d
Om (0 tt)
See level
IN;
MJ:
41h
#460
SDGY27-68
#450
6DGY27-68
#440
SDGY27-69
#430
""
6DGY26-S9
#410
2nd
6DGY27-70
#400

Legend:
AS: Air Screw initial opening, SJ: Slow Jet, NC; jet Needle Clip position, IN: Jet Needle, MJ: Main Jet

4-7
FUEL SYSTEM
AFTER '04:

3,050 m A S : 2 2-1/4 21/2 2 r---:-::2_1/4 2-112 2-314

I (10,0 00
1
tt) SJ:
NC:
#55
3
#55
3
#55
2
#55
2
#50
2
#50
2
#50
1
2,300 m JNo 6DGY28·68 6DGY28·68 6DGY28·69 6DGY20.69 6DGY28·70 6DGY28·" 6DGY29·70 I
~'oi(7'i,5"OiiO"ft!..1~--iM"J~o_ _--<,#4;;3,,0,--+_ ,#420 #410 +---'.:#:;40:,;0;--+_,,#:-;3i"90,,---+_..;#;,,3;;80::---+- #370
2,299 m A S : '-3/4 2 2-1f4 2-1/2 2 2-114 2-1 ' 2
(7,499 ttl SJ: #55 #55 #55 #55 #55 #50 #50
I NC: 3 3 3 2 2 2 2
1,500 m IN: 6DGY29-68 6DGY28-68 BOGY28-68 SOGY28-69 BDGY29-69 6DGY28-70 6DGY28-71
(5,000 ttl MJ: #440 #430 #420 #410 #400 I #390 #380
1,499 m A S : 1-1 /2 1-314 2 2_1/a---~-2:C'"'";::2--l--"';i2"'---'-~2_ 1/4
~ (4,999 ttl SJ: #55 #55 #55 #55 #55 #55 #50
.a I NC: 3 3 3 3 2 2 2
~ 750 m IN: 60GY29-67 BOGY29-68 6DGY28-68 6DGY28-68 BDGY28-69 BOGY29-69 6DGY28-70
(2,500 ttl MJ: #450 #440 #430 #420 #4 10 #400 #390
749 m A S : '-1 /4 1- 1/2 1-3/4 2 2- 1/4 2- 1/2 2
(2,499 ttl SJ: #60 #55 #55 #55 #55 #55 #55
I NC: 4 3 3 3 3 2 2
300 m IN: 6DGY29-67 6DGY29-67 6DGY29-68 6DGY28-68 6DGY28-68 6DGY28-69 6DGY29-69
(1 ,000 tt) ~ J: #460 #450 #440 #430 #420 #410 #400
299 m A S : 1-3/4 - 1-1 /4 +- 1- 112 1-3/4 2- 1/4 2-112
(999 tt) SJ: #60 #60 #55 #55 ~ #55 #55
I NCo 4 4 3 3 3 3 2

~
Om(Ott) IN: 6DGY29-66 6DGY29-67 6DGY29-67 6DGY29-68 6DGY28-68 6DGY28-69
I See level MJ: #470 #460 #450 #440 #420 #410
Standard

l egend:
AS: Air Screw initial opening, SJ: Slow Jet, NC: jet Needle Clip position, IN: Jet Needle, MJ : Main Jet

JU ST OFF IDLE
- Engine stumblesfhesitates (rich) : t urn out t he air screw 1/4 turn.
- Engine surges (lean): turn in the air screw 1/4 turn.
NOTE ·
• The minimum to maximum range of air screw adjustment is 1 to 3 turns out from the lightly seated position .
- If you exceed 3 turns out, the next smaller slow jet is needed.
- If you are under 1 turn out, the next larger slow jet is needed.

ON THE TOP END

- Engine stumbles/hesitates (r ich): go to next smaller main jet.
- Engine surges (lean): go to next larger main jet.

I NOTICE I
To prevent engine damage, a/ways adjust the main jet (top end) before adjusting the jet needle (mid-range).

IN THE MIO·RANGE
- Engine stumbles/hesitates (rich): lower the jet needle by raising the needle clip one position.
- Engine surges (lean ): raise the jet needle by lowering the needle clip one position .

4-8
 FUEL SYSTEM
TUNING FOR SPECIAL CONDITIONS
Once you have adjusted the carburetor for temperature and altitude, it should not need major readjustment unless the race
conditions change drastically. Exclusive of the tuning information chart, there are some unique atmospheric conditions
that may require additional adjustments. They are as follows:
Main jet:
- Go richer on the main jet, by one number, when the track has a very long straightaway. steep clim bs, a high percentage
of sand, or the track is muddy.
- Go leaner on the main jet, by one number, when it is very humid or raining, or it is very hot [above 45 °C (113 OF)).

Jet needle:
- Under normal circumstances, the standard jet needle can be adjusted to suit most situations. However, a peculiar con-
dition may require replacement of the standard jet needle, But before replacing the standard needle, complete all the
carburetor adjustments (page 4-5), If mid-range performance is still not satisfactory, try one of the optional jet needles
(page 1-25),

4-9
FUEL SYSTEM
CARBURETOR REMOVAL!
OISASSEMBL Y
REMOVAL
Disconnect the TPS (throttle position sensor) 3P
(Natural) connector.
Unfasten the wire band.

Release the TPS wire from the wire clamp on the

upper engine hanger.

WIRE CLAMP

Disconnect the fuel hose.

Turn the handlebar to the left fully.
Remove the sub-f rame (page 2-5).
Loosen the carburetor insulator band.

Remove the screws and carburetor top, then pull

out the throttle valve.

4-10
 FUEL SYSTEM
DISASSEMBLY
Compress the spring and remove the collar from the
throttle valve .
Compress the spring and remove the throttle cable
from the cable holder.

Remove the throttle cable holder and jet needle , '.......J.::~::':..IIIIIIIIIIIII'l:T::'H~R~o~n~L~E~c~A~B:L~E~

from the throttle valve. COLLAR
Check the jet needle for stepped wear or damage. \ . I'
'e
Check the throttle valve for damage.
Repl"e the the'e p'"' if ,eoe,,,,y. 1!1
",
+ ~RING
•
Do '10/ remove the Release the throttle position sensor wire from the
mroflle poSition wire clamp on the carburetor body,
sensor unless Ills Remove the screws and throttle position sensor
replaced from the carburetor body.

Disconnect the air vent hoses and drain hose.

AIR VENT HOSES

DRAIN HOSE

4-11
FUEL SYSTEM
Remove the screws, float chamber and D-ring.
FLOAT CHAMBER

\ , SCREWS

Remove the baffle plate.

Remove the float pin set screw and float pin.
Remove the float and float valve.

A worn or contaml- Remove the valve seat set screw and valve seat.
naled valve does
Check the float for damage.
no r sea l properly
Check the float valve and valve seat for scoring,
and will eventually
scratches, clogs or damage.
flood the carbure-
Check the valve seat D-ring for wear or damage.
'" Check the tip of the float valve where it contacts the
valve seat, for stepped wear or contamination.
Replace or clean these parts if necessary.

Remove the main jet needle jet holder and slow jet.
MAIN JET NEEDLE JET HOLDER

4-12
 FUEL SYSTEM
Be careful nor ro Push the needle jet from the throttle bore using a
damage rhe needle suitable tool , and remove it.
Ie<

Before remOVIng Remove the air screw and throttle stop screw.
rhe air screw,
record rhe number
o f rums If) until ir
sears ligh rly. so Ir
can be rerurned ro
Irs oflgmal posmon

Check each jet for wear or damage.

NEEDLE JET HOLDER
•
Clean the jets with non-flammable or high flash •
point solvent and blow open with compressed air.
Check the air screw for stepped wear or damage.
Check the spring for damage.
Replace these parts if necessary.

I'
MAIN JET FLOAT VALVE SEAT

Unscrew the lock nul and remove the choke knob.

CHOKE KNOB

LOCK NUT

4-13
FUEL SYSTEM
Check the valve seat for damage or stepped wear.
Check the D-ring for damage. D-RING
Replace the choke knob assembly if necessary.

Remove the socket bolt. retaining plate and filter

mesh screen.

Cleanmg the air and Blow open all air and fuel passages in the carbure- , . . - - - - - -....,....
fuel psssage With 8 lor body with compressed air.
piece of WIfe WII!
daml1g6 rhe CiJrbir
re/Of" body

4·14
 FUEL SYSTEM
CARBURETOR ASSEMBLY/INSTALLATION
CHOKE KNOB CARBURETOR TOP

FLOAT PIN

THROTIlE
STOP SCREW
FLOAT VALVE

THROTTLE
fLOAT o VALVE SPRING
~
...J COLLAR

O-RING
g....--
o ," E--=-J::TNEEDLE HOLDER
"'-- ,~~ AIR SCREW ~ ~ NEEDLE CLIP
/ -. .J ~ ~ FLOAT

SLOW JET ~ ~ JET NEEDLE

~
FLOAT CHAMBER EEDLEJET
NEEDLE JET
HOLDER

I BAFFLE PLATE
MAIN JET
THROTTLE VALVE

ASSEMBLY
Install the choke knob and tighten the lock nut to the
specified torque. CHOKE KNOB

TORQUE: 3.9 N'm (0.4 kgf·m , 2.9 Ibf.ftl

Install the filter mesh screen and retaining plate,

tighten the socket bolt to the specified torque.

TORQUE: 3.9 N 'm (0.4 kgf· m , 2.9 Ibf.ft)

filTER SCI'EEN SOCKET BOLT

4-15
FUEL SYSTEM
Install the '" screw Install the air screw, air screw spring, thronle stop
and return 1110 Its screw and lock nUl.
orrgrnal positIOn 8S
noted during
removal

AIR SCREW
Install the needle jet while aligning its groove with
the carburetor body. GROOVE

Install the slow jet, needle jet holder and main jet.
MAIN JET NEEDLE JET HOLDER
TORQUE:
Slow jet: 1.0 N·m (0.1 kgf·m , 0.7 IbHtl
M ain jet: 2.0 N 'm (0.2 kgf·m , 1.4Ibf.ftl

Install the float valve seat and new O-ring .

Tighten the screw to the specified torque.
TORQUE: 1.0 N·m (0.1 kgf·m . 0.7 IbUt)

4-16
 FUEL SYSTEM
Install t he float valve, float and float pin.
Tighten t he screw to the specified torque.
TORQUE : 2.0 N'm (0.2 kgf·m , 1.4 Ibf.ft)

NOTE :
• Check the float level after checking the float valve
and float.
• Set the float level gauge so that it is perpendicu-
lar to the float chamber face and in line with the
main jet .
Install the baffle plate.

Set the carburetor so that the float valve just con-

tacts the float arm lip. Be sure that the float valve tip
is securely in contact with the valve seat
Measure the float level with t he float level gauge.
TOOL:
Carburetor flo at level gauge 0740'-0010000

Float level: 7.5 mm (0.30 in )

If t he level is out of specification, adjust the float
level by bending t he lip.

Install a new O-ring t o the float chamber.

Install the float chamber to the carburetor.

-!d! O-RING FLOAT CHAMBER

Install and tighten the float chamber screws to the

specified torque. FLOAT CH,'MI'ER SCREWS

TORQUE: 3.9 N·m (0.4 kgf·m , 2.9 Ibf·ft)

4-17
FUEL SYSTEM
Connect the air vent hoses and drain hose.
AIR VENT H9'5E5

DRAIN HOSE - - -

Install the throttle position sensor if it has been

removed.
See page 4-20 for detail installation procedure.

Install the jet needle clip to the jet needle.

Standard clip position: 3rd groove -~

CLIP

Install the jet needle into the throttle valve.

Install the cable holder into the throttle valve, then THROTTLE VALVE
lighten the cable holder to the specified torque.
TORQUE: 2.9 N'm (0.3 kgf·m , 2.2Ibf.ft)

JET NEEDLE
,
CABLE HOLDER

4-18
 FUEL SYSTEM
Align the throttle valve spring and coll ar to the
throttle cable.
Compress the throttle valve spring and insert the
throttle cable into the cable holder.
Install the collar by aligning the tab of the collar with
the cut-out in the cable holder.

INSTALLATION
Slide the throttle valve assembly into the carburetor
while pulling up the sensor shaft arm.

Install the carbu retor top cover and tighten the

screws to the specified torque.

TORQUE: 2.0 N·m (0.2 kgf·m , 1.4 Ibf.ft)

Align the lug on the carburetor with the groove of

the carburetor insulator.
Install the sub-frame (page 2-5).

4-19
FUEL SYSTEM
Tighten the insulator and connecting tube band
screws securely,

Route the TPS wire properly, clamp it with wire

clamp on the upper engine hanger.

WIRE CLAMP
Connect the TPS 3P (Natural) connector. ,-
3P (NATURAL) CONNECTOR
Clamp the TPS wire with a wire band.
After installation, adjust the following:
- Throttle grip free play (page 3-6)
- Air screw adjustment (page 4-5)
After installation, check the following:
- Secondary air leaks around the insulator and
connecting tube
- Fuel leaks around the fuel hose and carburetor
- Route the overflow hose, air vent hose and fuel
hose

THROTTLE POSITION SENSOR

REMOVAl/INSTALLATION
Remove the carburetor (page 4-10),
Remove the throttle position sensor (TPS) wire from
the clamp.
Remove the torx screws and TPS from the carbure-
tor.

4-20
 FUEL SYSTEM
Install the TPS by aligning the tabs of the TPS with
the flat side of the shaft as shown.
Apply a locking agent to the torx screw threads and
install the screw; then adjust the TPS position.

If the reSistance IS Measure the resistance between the Blue/green and

out of standard, Yellow/red wire terminals of the sensor side 3P con-
replace the TPS nector.
with a new one
STANDARD: 4 - 6 kQ (a t 20"CJ68"F)
Calculate the TPS resistance at the t hrottle valve Q
fully closed position using the equation below.
••
A x( O.11to O.13 ) =B

A: Resistance between the Blue/green and Yellow/

red wire terminals
B: TPS resistance between the Yellow/blue and Yel-
low/red at the throttle valve fully closed.
(Example)
If the resistance A is 5 kQ. then the resistance B at
the throttle valve fully closed position should be:
5 kQ x (0.11 to 0.13) =< 550 to 6500:
Adjust the TPS position so the resistance between
the Yellow/blue and Yellow/red terminals is the
resistance calculated, and tighten the torx screws.
Install the carburetor (page 4-15).

REED VALVE
REMOVAL
Remove the carbu retor (page 4-10).
Remove the bolts and insulator.

4-21
FUEL SYSTEM
Remove the reed valve inner piece, reed valve
assembly and gasket.

INSPECTION
Check the reed valve for fatigue or damage and
replace the reed valve if necessary. '04 MODEL SHOWN: REED VALVE

Check the reed valve stopper for cracks, damage

and clearance from the reed and replace the reed
valve stopper if necessary.

DISASSEMBLY I ASSEMBLY
NOTE
• Replace the reed valve after 3 races or about 7.5
hours.
'04:
Remove the screws, reed valve SlOppers, spacers,
SUB REED VALVE
sub-reed valves and reed valves.
Align the cuI-outs of the reed valve, sub-reed valve, STOPPER REED VALVE
spacer and reed valve stopper, then install them
onto the cage.
Clean the screw threads.
Do no r apply a Iad.:- Apply 8 small amount of locking agent to the tip of
my agem/o Ihe
reed valve
the screw threads.
Tighten the screws to the specified torque. 1afP - - - ''''''4'
TORQUE: 1.0 N·m (0.1 kgf·m , 0.7 IbUt)
SCREW ~
Align

After installation, check for reed valve clearance.

0.2 mm (0.01 in)
SERV ICE LIMIT: 0.2 mm (0.01 in )

4-22
 FUEl SYSTEM
After '04
Remove the screws, reed valve stoppers, sub-reed C-S
CTCO
=P=
P=E=R--:--c:-:-=,-,-,,---cc--RCECE
CD
' -'-V-AC'CVCE"
valves and reed valves.
Align the cut-outs of the reed valve, sub-reed valve
and reed valve stopper, then install them onto the
cage.
Clean the screw threads.
Do not /Jpp/ya Iock- ApplV a small amount of locking agent to the tip of
mg agenllO rhe the screw threads.
reed valve Tighten the screws to the specified torque.

TORQUE: 1.0 N-m (0.1 kgf·m , O.7Ibf.ft )

L
dj) Align
After installation, check for reed valve clearance.

SERVICE LIMIT: 0.2 mm (0.01 in) 0.2 mm (a.Ol in)

INSTALLATION
Install the reed valve inner piece into the reed valve
assembly with aligning their cut-outs.
Install a new gasket to the crankcase.
Install the reed valve assembly.

Install the insulator and bolts.

Tighten the bolts securely.
Install the carburetor (page 4-15 ),
After installation, check the following:
- Secondary air leaks around the insulator and
connecting hose
- Fuel leaks around the fuel hose and carburetor.

4-23
FUEL SYSTEM
AIR CLEANER HOUSING
REMOVAL
Remove the sub-frame (page 2·5).
MUD GUARD
Remove the screws and mud guard.

Remove the air cleaner mounting boltslwashers and

rear fender mounting bolts/collars.

BOLTSrNASHERS
Remove the air cleaner upper guide from the sub-
frame.
After '04 Unhook the insulator rubber from the sub-frame.
Remove the air cleaner housing from the sub-frame.
Remove the air cleaner element (page 3-6).
Check the carburetor connecting tube to see if it is
sealing properly at the air cleaner housing.
Check the air cleaner housing for damage.
Remove the carburetor connecting tube from the air
cleaner housing and seal thoroughly jf any sign of
inadequate sealing is detected.

4-24
 FUEL SYSTEM
INSTALLATION
Air cleaner housing installation is in the reverse
order of removal.
Refer to page 3-6 for the air cleaner element installa-
tion.
'04:

CONNECTING TUBE BAND

CONNECTING TUBE GASKET

\~ ELEMENT HOLDER

AIR CLEANER ELEMENT

CONNECTING TUBE

RETAINING BOLT

AIR CLEANER HOUSING

MUDGUARD

Afte r '04:

CONNECTING TUBE BAND

ELEMENT HOLDER

AlA CLEANER ELEMENT

CONNECTING TUBE
RETAINING BOLT

AIR CLEANER HOUSING

MUD GUARD

4-25
MEMO
 5. COOLING SYSTEM

COMPONENT LOCATION ............................. 5-2 COOLANT REPLACEMENT ····························5-8

SERVICE INFORMATION ······························ 5-4 RADIATOR ...................................................... 5-9

TROUBLESHOOTING .................................... 5-6 WATER PUMP ·············································· 5-11

SYSTEM TESTING········································· 5-7

5-1
COOLING SYSTEM
COMPONENT LOCATION
' 04:

12 N·m (1.2 kgf·m. 9Ibf.ft)

12 N-m (1.2 kgf-m, 9Ibf.ft)

9.8 N·m (1.0 kgf·m, 7Ibf.ft)

5-2
 COOLING SYSTEM
AFTER '04:

12 N·m (1.2 kgf·m, 9 Ibf·hl

/
9.8 N'm (1.0 kgf·m, 91bf.ft) 12 N·m (1.2 kgf·m, 9 Ibf.ft)

5-3
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
AWARNING
Removing the radiator cap while the engine is hot can allow the coolant to spray Qut, seriously scalding you.
Always let the engine and radiator cool down before removing the radialor cap.

I NOTICE I
Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages.
Using tap water mey cause engine damage.

• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• AU cooling system services can be done with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• Aher servicing the system, check for leaks with a cooling system lester.

SPECIFICATIONS
- -- --IT~ -- ~ -- SPECIFICATI ON S J
Coolant capacity -T~A~,~""~a~n~9;;'---l=~'O~4~';;:::jf=====O~.~B8~:liter (0.930 US qt, 0.774 Imp ~ --~
After 'O~ 0.93 liter (0.983 US qt, 0.818 Imp---q-t) ~
I At disassembly '04
After '04:
0 97 Iller (1 025 US qt, 0.854 Imp qt)
lOa liter (1.057 US qt, o.88OTmp---qrr--

~
~ Radiator cap relief pressure 108 lJ7kPa(1.1 1.4kg/cm',16-10pSI) - -
I Recommended antifreeze - - - Pro Honda HP Coolant or an equivalent high quality ethyl-
ene glYCOl antifreeze containing silica-free corrosion inhibl-
tors
L Standard coolant co ncentration -----=-t-+ , :1 mixtuT_e_w_;'_h_d;_, _,;_"e_d_ water
TORQUE VALUES
Water pump impeller 12 N-m (1.2 kgf·m. 9Ibf.ft)
Water pump cover bolt 12 N·m (1.2 kgf·m, 9lbHt)
Coolant drain bolt 9.8 N-m (1.0 kgf·m. 7 IbHt)

5-4
 COOLING SYSTEM
TOOLS
Driver Attachment, 24 x 26 mm Pilot, 12 mm
07749-0010000 07746·0010700 07746-0040200

Bearing remover, 7 mm Bearing driver, 7 mm Bearing remover, 12 mm

07931-KA30000 07946-KA30100 07936-1660101 or

Not available in U.S.A. Not available in U.S.A 07936- 166010A (U.SA only)

Remover head, 12 mm Remover shaft Remover weight

07936- 1660'10 07936- 1660120 07741·0010201

Not available in U.S.A. Not avaitable in U.S.A. or 07936-371020A (U.S.A. only)

or 07936-3710200

Water seal driver Remover handle

07945-KA30000 07936·3710100

or 07965415000A (U.S.A. only)

or GN-AH-065-41 5

5-5
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
• faulty radiator cap
• Insufficient coolant
• Passage blocked in radiator, hoses or water jacket
• Radiator air passages clogged with dirt
• Air in system
• Faulty water pump
Coolant leak
• Faulty water pump oil and water seat
• Deteriorated water pump oil and waler seat
• Damaged or deteriorated gasket
• Deteriorated water pump oil and water seal
• loose hose connection or clamp
• Damaged or deteriorated hose
• faulty radiator cap
• Damaged radiator

5-6
 COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Remove the radiator cap.

Test the coola nt gravity using a hydrometer (see

below for "Coolant gravity chart").
For maximum corrosion protection, a 1:1 solution of
ethylene glycol and distilled water is recommended
(page 5·8).
look for contamination and repl ace the coolant if
necessary.

COOLANT GRAVITY CHART

Coolant temperatureac I ~F) -~-.on-
o - ~ 10 15 20 25 30 35 I 40 45 50

~k-
(32) (41) (5 (59) 1681 (77) 1861 (95) I ( 104) (113) (122)
=
1 " : 1 5 , 009 1 009 1.0 08 1.008 1.007 1.006 l 005 1.003 lOOl 1 0.999 0.997
0 lO18 l017 I I .0 17 t016 lO15 1.014 l 013 lO', ' 1009 1007 1.005

il ;
"
E
•
~'--
30
35
5
0
5
-
l028
1.036
~.O45
l053
l063
l027 1.02.
1.035
1.044
1.052
1.062
1.0 34
I .043
1.0 51
1.0 60
1.025 1.024 l022 1. o
1.033 1.031 1.029 l o
1.042 1.040 1.038 I. o
1.047 1.046 1.045
l058 l056 1.054 l o
r-1.
o
~.025
4
1

5
1.012 j
1.019

1.032
3tlf:.040
g 40 1.072 1.070 I .0 68 l066 lO64 1.062 o
I-~l 066 1.063 , 1.060!
0 1.047 '
u 45
50
' l080
1.086
1.078
1.084 .:t
I .0
1.082
1.074 lO72
1.~~~
l080 1.077 1.074 l 071 1.068 I 1.065
l057
1.062
1.054
1.059
55 t095 t093 l091 l088 1.085 1.082 '.07~~.076 1.073 1.07~.067
r- 60 1.100 t098 l095 1.092 1.089 I 1.086 , 1.083 1.080 1.077 1.074 1071

5-7
COOLING SYSTEM
RADIATOR CAP/ SYSTEM PRESSURE
INSPECTION
Remove the radiator cap (page 5-7).

Before Installmg I/)eInSlall the radiator cap on the tester.

cap In the tester. Pressure test the radiator cap.
wet rile sealmg sur- Replace the radiator cap if it does not hold pressure,
faces
or if relief pressure is too high or too low.
It must hold the specified pressure for at leasI6 sec-
onds.
RADIATOR CAP RELIEF PRESSURE:
108 - 137 kPa (1.1 - 1.4 kgflc m 2 , 16 - 20 psi)

Pressure test the radiator, engine and hoses, and

check for leaks.

NOTICE
Excessive pressure can damage the cooling system
components. Do not exceed 137 kPa (1 .4 kgflcrrr, 20
psi).
Repair or replace components jf the system will not
hold the specified pressure for at least 6 seconds.

COOLANT REPLACEMENT
PREPARATION
• The effectiveness of coolant decreases with the ~-­
accumulation of rust or if there is a change in the
mixing proportion during usage, Therefore, for ANTIFREEZE
best performance change the coolant regularly
SOLUTION
as specified in the maintenance schedule.
• Mix only distilled water with the antifreeze.
RECOMMENDED ANTIFREEZE: (ETHYLENE
Pro Ho nda HP Coolant or and equivalent h ig h DISTILLED
GLYCOL BASE WATER
quality ethylene glycol antifreeze contai ning cor-
SOLUTION)
rosio n prot ection inhibito rs

RECOMMENDED MI XTURE :
1:1 (Disti lled w at er and antifreeze)
COOLANT
REPLACEMENT/AIR BLEEDING
When Mmg the Remove the radiator cap.
system or reserve
lank WlIh 8 coolant
(checkmg coolant
levell. pla ce Ihe
mOtorcycle In aver·
/1C81 POSlllO() on a
flal level surface

5-8
 COOLING SYSTEM
Remove the drain bolt on the water pump cover and
cylinder then drain the system coolant.
Reinstall the drain bolt with the new sealing wash -
ers.
Tighten the drain bolt to the specified torque.
TOROUE: 9.8 N'm (1.0 kgf·m , 7 Ibf·ft )

'04 model only. Remove the cylinder drain bolt and drain the cool-
ant from the cylinder.
Reinstall the drain bolt with the new sealing wash·
ers.
Tighten the drain bolt to the specified torque.
TOROUE: 9.8 N'm (1.0 kgf·m , 7 Ibf·ft )

Fill the system with the recommended coolant ::~~:!~:;~~!l~~[A~~!~~~~l

through the filler opening up to filler neck.

CAPACITY:
At change:
'04: 0.88 lit er (0.930 US OZ , 0.774 Imp oz)
After '04: 0.93 liter (0.983 US OZ , O.8181mp oz)
At disassembly:
'04: 0.97 liter (1.025 US OZ, 0.854 Imp ez)
After '04: 1.00 liter (1.057 US oz, 0.880 Imp oz)
lean the machine approximately 20° right and left
several times to bleed air trapped in the cooling sys-
tem,
If the coolant level drops, add more coolant and
repeat air bleeding procedure.

RADIATOR
REMOVAL
Drain the coolant (page 5-8).
Remove the right and left radiator grills.

5-9
COOLING SYSTEM
No re rhe direction Loosen the upper radiator hose clamps and discon-
of the hose ci8mps nect the upper radiator hoses.
Loosen the lower radiator hose clamp and discon-
nect the lower radiator hose.
Loosen the upper and lower joint hose clamps and
disconnect the upper and lower joint hose.
Remove the overflow hose from the right side radia -
tor.

Remove the upper and lower mounting bolts and

collars.
8e careful no t ro Remove the radiator.
damage Ihe radli'Jtor
core

INSTALLATION
'04:
RADIATOR GRILLS

RAOIATOR-TO-CYLI NDER
HEAD HOSE

LOWER RADIATOR HOSE

5-10
 COOLING SYSTEM
After '04:
RADIATOR GRILLS

RADIATOR-TO-CYLINDER
HEAD HOSE

LOWER RAIOIA"TOR HOSE

Be careful nor fO Installation is essentially the reverse order of

damage the radiator removal
core
Add recommended coolant mixture up to the filler
neck and bleed the air (page 5-8).
After installation, check the radiator and radiator
hoses for leaks.
Install the radiator shrouds (page 2-4).

WATER PUMP
MECHANICAL SEAL INSPECTION
Inspect the inspection hole for signs of coolant leak·
age.
If there is leakage. the mechanical seal is defective
and rebuild the water pump as an assembly.

5-11
COOLING SYSTEM
REMOVAL (,04)
Drain the coolant (page 5~81.

Remove the four flange bolts and water pump

cover.

Remove the outer gasket and plate.

Remove the inner gasket and dowel pins.

Remove the impeller and plain washer.
Remove the right crankcase cover (page 9-5).

Remove the water pump shaft from the right crank·

case cover.

IMPELLER

5-12
 COOLING SYSTEM
REMOVAL (AFTER '04)
Drain the coolant (page 5-8).
Disconnect the water hose from the water pump
cover.
Remove the five flange bolts and water pump cover.

Remove the gasket and dowel pins.

Remove the impeller and plain washer.
Remove the right crankcase cover (page 9-5),

Remove the water pump shaft from the right crank-

case cover.

PLAIN WASHER

INSPECTION
Check the water pump shaft and gear to be sure ~----------------~

they are not bent or damaged.

5-13
COOLING SYSTEM
Turn the inner race of the water pump shaft bearing
with your finger.
The bearing should turn smoothly and quietly.
Also check that t he bearing outer race fits tightly in
the right crankcase cover.
Replace the water pump shaft bearing jf necessary
(page 5-14).

Check the water seal for damage or deterioration.

Replace the water seal if necessary (page 5-15).

BEARING REPLACEMENT
RIGHT CRANKCASE COVER SIDE:
Remove the water pu m p shaft bea ring using the
special tools.
TOOLS;
Bearing remover, 12 mm 07936· 1 660101
Remover head. 12 mm 07936·1660100
Remover shaft 07936· 1660120
Remover weight 07741 ·0010201

U.S.A. TOOLS:
Bearing remover, 12 mm 07936-166010A
Remover handle 07936·3710100
Remover w eight 07936-371020A or
07936-3710200

Drive the new bearing into the right crankcase cover

using the special tools as shown.

TOOLS:
Driver 07749·0010000
Attachment, 24 x 26 mm 07746·0010700
Pilot, 12 mm 07746·0040200

5-14
 COOLING SYSTEM
RIGHT CRANKCASE SIDE:
Remove the water pump shaft bearing using the
special tool.

TOOL:
Bearing rem over, 7 mm 07931-KA30000
(Not available in
U.S.A .)

BEARING REMOVER
Drive the new bearing into the right crankcase using ~=B=E=A=R='N=G=D=R='V=E::R============;
the special tool as shown . ~

TOOl:
Bearing driver, 7 mm 07946·KA30100
(Not available in
U.S.A.)

WATER / OtL SEAL REPLACEMENT

Remove the water pump shaft bearing from the
right crankcase cover (page 5- 14).
Drive the wa ter seal and oil seat Qut from the right
crankcase cover.

Install t he water seal drive into the right crankcase

cover as shown. :11 SEAL WATER SEAL DRIVER
8e careful nor to Drive the new water seal into the right crankcase
damage the warer cover using the spe(:ial toots.
seal lops dUring
installatIOn.
TOOLS:
Water seal driver 07945-KA30000 or
Mechanical seal installer 07965-415000A
(U.S.A. only) or
GN-AH-065-415

L
5-15
COOLING SYSTEM
Install the new oil seal into t he right crankcase cover
as shown.
Install the water pump shaft bearing (page 5- 14).

F
$I OIL SEAL

INSTALLATION ('04)

WATER PUMP SHAFT

fI WATER SEAL

if
BEARING (')

s l lNNEA GASKET

fI OUTER GASKET

9.8 N-m (to kgf·m , 7 Ibf·ft)

Install the water pump shaft to the right crankcase

cover.
fnstallthe right crankcase cover (page 9-7),

IMPELLER

5-16
 COOLING SYSTEM
Install the plain washer and impeller onto the water
pump shaft.
Tighten the impeller to the specified torque.
TORQUE: 12 N·m (1 .2 kgf·m , 9Ibf·ft )
Install the dowel pins and new inner gasket.

Install the plate and new outer gasket.

Install the water pump cover and tighten the four

flange bolts to the specified torque.

TOROUE: 12 N 'm (1.2 kg'·m, 9Ibf.ft)

Add the recommended coolant mixture up to the
filler neck and bleed the air (page 5-8).

5-17
COOLING SYSTEM
INSTALLATION (AFTER '04)

DOWEL PINS

BEARING
fI WATER SEAL
WATER PUMP COVER

PLAIN WASHER

IMPELLER
12 N·m (1.2 kgf·m, 9Ibf·ft)
12 N·m
9.8 N·m (1.0 kgf.m, 7 Ibf.ft) (1.2 kgf·m, 9Ibf·ft)

Install the water pump shaft to the right crankcase

cover.
Install the right crankcase cover (page 9-7).

PLAIN WASHER

Inslall the plain washer and impeller onto the water

pump shaft.
Tighten the impeller to the specified torque.
TOROUE: 12 N -m (1.2 kgf-m , 9 IbUt)

Install the dowel pins and new gasket.

5-18
 COOLING SYSTEM
Install t he water pump cover and tigh ten the five
flange bolts to the specified torque.

TORQUE: 12 N·m (1.2 kgf·m , 9 Ibf.ft)

Connect the water hose to the water pump cover.
Add the recommended coolant mixture up to the
filler neck and bleed the air (page 5-8).

5-19
MEMO
 6. ENGINE REMOVAL/INSTALLATION

COMPONENT LOCATION ······· .. ·· .. · .. ············· 6·2 ENGINE REMOVAL ········································6·4

SERVICE INFORMATION ······························ 6·3 ENGINE INSTALLATION· ····· ·························· 6·6

6-1
ENGINE REMOVAL/ INSTALLATION
COMPONENT LOCATION
'04 model shown:

88 N·m (9.0 kgf·m, 65 Ibf·h)

54 N·m (5.5 kgf·m,

~?=:>':2~~~~~
2.0 N·m (0.2 kgf.m,
401bf·hl ,

j I,
,c5Y"
, , 1.4Ibf.ft)

'04~ ~ 4.9 N'm (0.5 kgf·m,

) " 3.6Ibf·tt)

25 N'm

~JJ ~
(2.6 kgf·m, 19 IbOt)
AFTER '04:
36N·m
(3.7 kgf·m, 27 Ibot)
/
tp=A~~

6-2
 ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
• During engine removal and installation, support the motorcycle using a workstand.
• The following components can be serviced with the engine installed in the frame.
- alternator (page 14-lS)
- clutchlkickstarter/gearshift linkage (page 9-3)
- cylinder head/cylinder/pi ston (page 7-4)
- RC valve system (page 8-4)
• The following components require engine removal for service.
- crankshafVtransmission (page 10·3)

SPECIFICATION
ITEM SPECIFiCAfioNS, - - _
Engine dry weight 18.5 kg (40.8 Ibs)

~
Recommended transmission oil ro Honda HP Trans Oil, Pro Honda GN4 or HP4 (without
molybdenum additives) 4-stroke oil or an equivalent
API service classification SG or Higher except oils labeled
as energy conserving on the circular APt service labet
JASO T 903 standard: MA
Viscosity: SAE 10W-40
Transmission oil at draining hJY===~
t O.·~7 liter (0.60 US qt, 0.50 Imp qt) ----<

capacity I at disassembly ~5 liter (D.S9 US qt, 0.57 Imp qt) -1

Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethyl-
ene glycol antifreeze containing corrosion protection inhib-
itors
I Coolant -capacity at dra~;n'";n~g;----'i
'04"', ~;=::::~O~.88 liter (0.930 US qt, 0.774 Imp qt ) - -- -
Aher '04: 0.93 liter (0.983 US qt, 0.818 Imp qt)
'o;r:- 0.97 liter (1.025 US qt, 0.854 Imp qt)-~_ _ _
L _ __ _ _
at disassembly
t After '04"'-~1.'"'00 liter (1.057 US qt. 0.880 Imp qt)

TORQUE VALUES
Engine hanger ptate nut 34 N·m (3.5 kgf·m, 25 Ibf·h)
Engine mounting nut 54 N·m (5.5 kgf·m, 40 Ibf·h)
Swingarm pivot nut 88 N'm (9.0 kgf·m, 65 Ibf·h)
Alternator cover bolt 2.0 N·m (0.2 kgf·m, 1.4 Ibf·h)
Brake pedal pivot bolt '04: 25 N·m (2.6 kgf·m, 19 Ibl·h)
Aher '04: 36 N·m (3.7 kgf·m, 27 Ibl-h)

6-3
ENGINE REMOVAL/ INSTALLATION
ENGINE REMOVAL
Remove the springs, bolts and expansion chamber.
SPRINGS

~
BOLTS EXPANSION CHAMBER
Remove the bolts and exhaust pipe joint.
Drain the transmission oil (page 3-1 1j,
Drain the coolant (page 5-8).
Remove the fuel tank (page 2·6).

'04 Disco nnect the upper radiator hoses from the cylin - ,..,-:,-
der head.
Disconnect the spark plug cap from the spark plug.

Aftor '04 Disconnect the upper radiator joint hose from the
cylinder head.
Discon nect the spark plug cap from the spark plug.

6-4
 ENGINE REMOVAL/INSTALLATION
Remove the left radiator mounting bolts.

'()4 Disconnect the alternator 3P (Black) connector.

..;;Pi< CONNECTOR

Aller '()4 Disconnect the alternator 3P (Black) and ignition

pulse generator 2P (Black) connectors.

Disconnect the lower radiator hose from the right

crankcase cover.

LOWER RADIATOR HOSE

6-5
ENGINE REMOVALIINSTALLATION
Remove the alternator wire bands.
T""CONTROl CABLES ('04 MO~
Remove the following:
- AC valve control cables ('04 model only)
c"" eH CABLE ~
- alternator cover
- clutch cable
- drive chain

Remove the bolts, nuts, wire clamp and engine

hanger plates.

WIRE C""MP
Remove the brake pedal pivot bolt.
Remove the engine mounting boll and nuts. PIVOT BOLT/NUT
Remove the swingarm pivot bolt and nut.
NOle the direction Remove the engine from the frame.
of the engme
Reinstall the swingarm pivot bolt and nut so the
moumm" boilS. chassis can be moved and stored safely.
hanger plale bol/s
and s w'ngarm Pivot
00"

BRAKE PEDAL HANGER BOlTSfNUTS

ENGINE INSTALLATION
NOTE'
• Install the swingarm pivot bolt first. then install
the engine mounting bolts.
• Aoute the wire and cables properly (page 1-18),
• 00 nOI lighten the swingarm pivot nut and
engine mounting nuts yet.

6-6
 ENGINE REMOVAL/INSTALLATION
Inslall the engine to the frame.
Inslall the swingarm pivot boll and nut. PIVOT BOLT/NUT
Install the engine mounting bolts and nuts.

BRAKE PEDAL HANGER BOLTS/NUTS

Install the engine hanger plates, wire clamp, hanger

bolts and nuts.
r~~~~~~---;;iiiiiiiiiiii.iii~~;;:::"':':::;
Tighten the engine mounting nuts, engine hanger
plate nuts and 5wingarm pivot nut to the specified
torque.
TORQUE:
Engine mounting nut: 54 N'm (5.5 kgf·m, 40 IbUtl
Engine hanger p late
nut: 34 N 'm (3.5 kgf·m , 24 IbUt)
Swingarm pivot nut: 88 N'm (9.0 kgf·m , 65 IbUt)

Install the washer and brake pedal pivot bolt,

tighten the pivot bolt to the specified torque.
TORQUE: 25 N·m 12.6 kgf.m. 19 IbHtl
Install the drive chain onto the drive sprocket.
Co nnect the clutch cable to the clutch arm.
CABLES ('04 MOD~

·04 model only Connect the RC valve control cables to the RC valve CU"LHCABLE~
pulley.
Secure the alternator wire with the wire clamp.
Install the wire bands.
Install the following:
- alternator cover
- RC valve cover ('04 model only: )
- carburetor
- sub-frame

Connect the lower radiator hose to the right crank-

case cover, tighten the clamp screw.

LOWER RADIATOR HOSE

6-7
ENGINE REMOVALIINSTALLATION
'{)4 Connect the alternator 3P (Black) connector.

Afler"(}4 Connect the alternator 3P (Black) and ignition pulse

generator 2P (Black) connectors.

Install and tighten the left radialor mounting boils.

"()4 Connect the upper radialor hoses to the cylinder

head and tighten the clamp screws.
Connect the spark plug cap to the spark plug.

6-8
 ENGINE REMOVAL/INSTALLATION
After '()4 Connect the upper radiator joint hose from the cyl+
inder head.
Connect the spark plug cap from the spark plug.

'04 Install the exhaust pipe joint and tighten the bolts
securely.

Afrer"().4 Install the exhaust pipe joint with the flat facing
down.
1~~~Fi" PI:~~~~~.iw"""='-
Install and tighten the exhaust manifold bolts
securely _

Apply grease to the new D-ring and install it 10 the

exhaust pipe joint.
r-_l~~~~~~~~~~~~~~~
fI ~ a -RING EXHAUST
Apply grease to the exhaust pipe joint outer surface. / PORT

EXHAUST PIPE JO"'N,,T_ _--'

6-9
ENGINE REMOVAL/ INSTALLATION
Always Install a Install the expansion chamber (page 2-8),
SPRINGS
new !J<ISkel lind 0- Install the fuel tank (page 2·6).

~
nng al rhe 8xpan-
Fill the transmission with re commended oil to the
sum chamber Insfal-
correct level (page 3-11),
latlon
Pour radiator coolant mixture into the radiator up to
the correct level (page 5-8),
Aher installing the engine. perform the following
inspections and adjustments:
- throttle grip free play adjustment
- feaf brake pedal height
- drive chain slack
- clu tch lever free play
Check the exhaust system for leaks. BOLTS EXPANSION CHAMBER

6-10
 7. CYLINDER HEAD/CYLINDER/PISTON

COMPONENT LOCATION ... .......... .... .. .... ...... 7-2 CYLINDER HEAD ...................... ...................... 7-6

SERVICE INFORMATION ···· ·· ········· ··············· 7-4 CYLINDER/ PISTON ····························· ····· .... ·· 7-8

TROUBLESHOOTING .................................... 7-5

7-1
CYLINDER HEAD/CYLINDER/PISTON
COMPONENT LOCATION
'04:

18 N·m (1.8 kgf·m, 13Ibf.tt)

27 N-m (2.8 kgf·m, 20 Ibf.ft)

27 N·m (2.8 kgf·m,
201bUt)

4.9 N-m (0.5 kgf·m,

3.6Ibf.ftl

4.9 N·m (0.5 kgf·m, Ibf.ft)

7-2
 CYLINDER HEAD/CYLINDER/PISTON
AFTER ' 04:

27 N·m (2.B kgf·m, 20 Ibf.ft)

12 N·m
(1.2 kgf·m, 9Ibf.ft)

27 N·m (2.8 kgf·m, 20 Ibf.ft)

j
/
2.9 N·m (0.3 kgf·m, 2.2 Ibf·ft)

12 N'm
(1.2 kgf·m, 9 Ibf·ft) o
"""J.--- 34N·m
(3.5 kgf·m, 25 Ibf·ft)

9.8 N·m (1.0 kgf·m, 7 Ibf·h)

7-3
CYLINDER HEAD/ CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, cylinder and piston. These procedures can be done with the engine in
the frame.
• Before disassembling. clean the engine thoroughly to keep dirt from entering the engine.
• Do not use screwdriver to remove the cylinder head.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
• Before assembling, apply clean pro Honda HP2 2-stroke Oil to all sliding surfaces.
• Under racing conditions, the piston and piston rings should be replaced after 7.5 hours of running. Replace the piston
pin and connecting rod small end bearing after 22.5 hours of running.
• See page 4·21 for reed valve servicing.
• See page 8-4 for RC valve system decarbonizing, disassembly and assembly.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT I
Cylinder head warpage 0.05 (0.002)
Cylinder I.D. 53.976 53.983 (2.1250 - 2.1253} - - - - 54.013 (2.1265)
53.968 - 53.976 (2.1247 - 2.1250) 54.006 (2.1 262)
Out of round 0.05 (0.002)
Taper 0.05 (0.002)
Warpage -~ , iOC;.O~5 (0.002)
Piston, piston Piston mark direction "IN" mark facing toward the intake side -
ring Piston 0.0. A 53.933 53.940 (2.1233 - 2. 1236) 53.883 (2. 1214)
B 53.925 - 53.933 (2. 1230 - 2.1233) 53.875 (2.1211)
Piston 0.0. mea· '04: 10 mm (0.39 in) from the bottom of skirt
surement point After '04: 11 mm (0.43 in) from the bottom of~'~k~;rt'-I-",
Piston pin bore 1.0. 15.002 15.015 (0.5906 - 0.5911) 15.022 (0.5914)

f Piston pin 0.0.

Piston·to·piston pin clearance
14.994 - 15.000 (0.5903 - 0.5906)
0.002 - 0.021 (0.0001 - 0.0008)
.+- 14.980 (0.5900)
0.03 (0.001)
Piston ring·to-ring groove clear- 0.045 0.080 (0.0018 - 0.0031) 0.09 (0.004)
ance ('04 model only)
Piston ring end gap 0.40 - 0.55 (0.016 - 0.022) 0.65 (0.026)
Cylinder-to-piston clearance 0.035 - 0.050 (0.0014 - 0.0020) 0.07 (0.003)
Connecting rod small end 1.0. 19.002 - 19.014 (0.7481 - 0.7486) ---=:::::~19~.O~22 (0.7489)

TORQUE VALUES
Cylinder head nut 27 N·m (2 .8 kgf·m, 20 Ibf·ft)
Cylinder mounting nut 27 N·m (2.8 kgf·m, 20 Ibf·ft)
Cylinder stud bolt 12 N·m (1.2 kgf.m. 9Ibf·ft) Applya locking agent to the threads
Cylinder sealing bolt 9.8 N'm (1.0 kgf·m, 7 Ibf·ft)
Engine hanger plate nut 34 N·m (3.5 kgf·m. 25 Ibf·ft)
Left RC valve cover bolt '04: 4.9 N'm (0.5 kgf·m. 3.6Ibf·ft)
After '04: 12 N'm (1.2 kgf·m, 9Ibf·ft)
Right RC valve cover bolt '04; 4.9 N'm (0.5 kgf·m, 3.6Ibf·ft)
After '04; 12 N·m (1.2 kgf·m, 9Ibf·ft)
RC valve cover screw 2.9 N·m (0.3 kgf·m, 2.2 Ibf·ft )

7-4
 CYLINDER HEAD/CYLINDER/PISTON
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Blown cylinder head gasket
• Loose spark plug
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
• Faulty reed lIalve
• Worn crankshaft seals
Compression too high. overheating or knocking
• Excessive ca rbon build-up on top of piston or in combustion chamber
Abnormal noise'piston
• Worn or cracked piston
• Worn cylinder and piston
• Worn piston pin or piston pi n bore
• Worn connecting rod small end bearing
Abnormal noise· piston ring
• Worn, stuck or broken piston ring
• Worn or damaged cylinder
Contaminated coolant
• Leaking cylinder head gasket

7-5
CYLINDER HEAD/CYLINDER/PISTON
CYLINDER HEAD
REMOVAL
Drain the radiator cool ant (page 5-8).
Remove the seal (page 2-3) ,
Remove the fuel tank (page 2·6).
Note the directIOn Loosen the radiator hose clamps and remove the
of the hose clamp radiator hose(s) from the cylinder head.
Remove the spark plug cap and spark plug .

Release the throttle position sensor wire from the

wire clamp.
Remove the engine upper hanger plate bolts, wire
clamp and hanger plates.

To avoid warping Remove the five cylinder head nuts.

the cylmder head,
Remove the bolt and ground wire.
use 8 Crisscross
patrern 10 loosen Remove the cylinder head.
BBCh nut about 1/4
tum m two or three
sleps. then remove
the nuts

Remove the cylinder head gasket and dowel pins.

7-6
 CYLINDER HEAD/CYLINDER/PISTON
INSPECTION
Be careful nor to Clean the head gasket surface off any gasket mate-
damage the cylm· rial. COMBUSTION CH,'M IBER
der head
Remove the carbon deposits from the combustion
chamber.

CYLINDER HEAD

Check the cylinder head for warpage in diagonal

directions using a straight edge and feeler gauge.

SERVICE LIMIT: 0.05 mm (0.002 in )

INSTALLATION
Install the dowel pins.
Install the new cyli nder head gasket with the "UP"
mark facing up and tab to the rear.

Place the cylinder head on the cylinder.

Install the five cylinder head nuts in a crisscross pat-
tern i n two or three steps.
Then tighten the nuts to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 Ibf.ftl
Connect the g round wire and lighten the bolt
securely.

7-7
CYLINDER HEAD/CYLINDER/PISTON
Route the ClutCh Install the engine upper hanger brackets. bolts, nuts
cable berween the and washer.
hiJnger plates Tighten the engine hanger bracket nuts to the speci-
fied torque.
TORQUE: 34 N ·m (3.5 kgf·m , 25 Ibf.ft)

Install the spark plug and spark plug cap.

Note the dlrecMn Connect the radiator hose(s) to the cylinder head
of rile hose clamp and tighten the clamp screw.
Add recommended coolant mixture into the radiator
up to the correct level (page 5·8).
Install the fuel lank (page 2-7).
Install the seat (page 2-3).

CYLINDER/PISTON
CYLINDER REMOVAL (,04)
Remove the cylinder head (page 7-6).
Remove the expansion chamber (page 2-8).
Disconnect the AC valve control cables from the pul.
ley.

Loosen the clamp screw and disconnect the water

hose from the water joint.

7-8
 CYLINDER HEAD/CYLINDER/PISTON
Remove the right AC valve cover screw and bolts.
Remove the right AC valve cover, gasket and rubber
seal.

Remove the bolts, exhaust pipe joint and gasket.

Loosen the cylinder mounting nuts in a crisscross

pattern in two or three steps.
Remove the cylinder.

Remove the gasket and dowel pins.

7-9
CYLINDER HEAD / CYLINDER/ PISTDN
CYLINDER REMDVAl (AFTER '04)
Remove the cylinder head (page 7-6).
Remove the following:
- Right RC valve cover bolts and screw
- Right RC valve cover
- Gasket
- Rubber seal

Be careful nor to Remove the a -clip, setting collar and tie rod from
drop /he a·dlp and the RC valve shaft.
collar mto the fight
crankcase cover

Remove the bolts, wi re clamp and left RC valve :=~;~:;;:;:;

cover.

Loosen the radiator hose band screw and discon- lr;:iO~5E'iiiiNo;;c;R€w

neet the radiator hose .
Remove the radiator lower mounting boilS and
swing the radiator forward.

7-10
 CYLINDER HEAD/CYLINDER/PISTON
Remove the expansion chamber{page 2-8).
Remove the bolts, exhaust pipe joint and gasket.

Loosen the cylinder mounting nuts in a crisscross

pattern in two or three steps.
Remove the cylinder.

Remove the gasket and dowel pi ns.

PISTON REMOVAL
00 nor Ie/ the clips Remove the piston pin clips.
fall into the crank-
~,.
Always support the piston when pressing out the
pin.
Remove the piston.

7-11
CYLINDER HEAD/ CYLINDER/PISTON
Under racing conditions, the piston and piston rings
should be replaced according to the maintenance
schedule (page 3-4).
Do nOl damage the Spread the piston rings and remove them by lifting
{)Iston rmgs by up at a point just opposite the gap.
spreadIng /he ends
100 far

CYLINDER INSPECTION
Remove the AC valve from the cyli nder (page 8-9).
CABLE GUIDE
'04 model only. Remove the bolt and RC valve cable guide.

'04 mode/only. Remove the bolts, water joint and D-ring,

Remove the carbon deposits from the exhaust porI

area.

EXHAUST

7-12
 CYLINDER HEAD/CYLINDER/PISTON
Inspect the top of the cylinder for warpage.
Use a straight edge and feeler gauge to check the
head gasket surface on the cylinder for warpage.
SERVICE LIMIT: 0.05 mm (0.002 in)
If warpage is beyond the service limit, correct as
necessary.

Measure the bore diameter at four positions, top,

middle (A), middle (B) and bottom.

With the exception of the bottom, measure both "X" , - - - - - - - - - -- - -- - - - - ,

and "Y" axis at each position.
Measure only the "X" axis of the bottom position.
~X~ axis at each position:
Top: 5 mm (0.2 inl
Middle (AI: 25 mm (1.0 inl
Middle (Bl: 70 mm (2.8 inl
~Y" uis at each position:
Top: 5 mm (0.2 in)
Middle (AI: 25 mm (1.0 in)
Middle (Bl: 70 mm (2.8 in)
Bottom: 95 mm (3.7 in)
Use the large figure measurement to determine the
cylinder wear.
SERVICE LIMIT: A: 54.013 mm (2.1265 in)
B: 54.006mm (2.1262inl

PISTON INSPECTION
'04 Measure the piston 0 .0. 10 mm (0.39 in) from the
bottom of the skirt and at a right angle to the piston
pin hole.
After'04 Measure the piston 0.0. 11 mm (0.43 in) from the
bottom of the skirt and at a right angle to the piston
pin hole.
SERVICE LIMIT: A: 53.883 mm (2.1214 in)
B: 53.875 mm (2.1211 in)

If the 0.0. is under the service limit or if nearly 7.5

hours of running time have elapsed, replace the pis-
ton with a new one.
Calculate the cylinder-to-piston clearance.
SERVICE LIMIT: 0.07 mm (0.003 in)

7-13
CYLINDER HEAD / CYLINDER/PISTON
Remove any carbon deposits from the piston ring
grooves.
"04 model only Measure the piston ring-ta-ring groove clearance.
SERVICE LIMIT: 0.09 mm (O.004 in)

Measure the piston pin bore 1.0.

SERVICE LIMIT: 15.035 mm (0.5919 in )

Check the piston pin for wear and excessive discol-

oration.
Measure the piston pin 0.0.
SERVICE LIMIT: 14.98 mm (O.590 in)
If the 0.0. is under the service limit, discolored, or
nearly 22.5 hours of funning time have elapsed,
replace the piston pin and bearing.
Calculate the piston pin-to-piston clearance.
SERVICE LIMIT: 0.03 mm (0.001 in)
Usmg the pIston to Insert the piston ring into the cylinder to distance
PISTON RING
push the rmg from the cylinder bottom shown.
squarely mto the
Measure the piston ring end gap with a feeler
cylmder
gauge.
SERVICE LIMIT: 0.65 mm (0.026 inl

CYLINDER/PISTON SELECTION
The cylinders and pistons are select fined.
0.0. CODE LEITER
Record the piston 0.0. code letter (A or B)

E0
IN

7-14
 CYLINDER HEAD/CYLINDER/PISTON
Record the cylinder LO. code letter (A or Bl.
'04 MODEL SHOWN:
Use new cylinders and pistons with the same I.D.
and 0.0. codes when replacing the cylinder andlor
piston.
~
0)
lQ./' '\
l~ c=J
)' ,---, .J(

1.0. CODE LETTER

CONNECTING ROD INSPECTION

Install the needle bearing and piston pin in the con-
necting rod small end and check it for excessive
play.

If it feels loose, measure the connecting rod small

end I.D.

SERV ICE LIMIT: 19.022 m m (0.7489 in)

If the I.D. is not over the service limit, replace the
piston pin and bearing.
If the I.D. is over the service limit, replace the crank-
shaft (page 10-11).

PISTON INSTALLATION
Clean the piston ring grooves.
lubricate the piston ring and piston ring groove
with clean Pro Honda HP2 2-stroke oil.
Install the piston ring on the piston with the mark
facing up.
Locate the ring end gap on the pin in the piston ring
groove.

7-15
CYLINDER HEAD / CYLINDER/PISTON
Be care ful not to Clean off any gasket material from the cylinder mat-
remove any mare- ing surface.
nat from the gasket
Lubricate the small end bearing and piston pin with
surlace
etean Pro Honda HP2 2-stroke oil.

Instalilhe connecting rod small end bearing, piston

and piston ring.
Install the piston with the "IN " mark facing the intake
side.
If the "IN" mark is obliterated, install the piston with
the hole facing the intake side.
Do nor reuse the Install the new piston pin clips in the g roove on the
Piston pm Clips and pOSition.
do not let the piston Do not align the piston pin clip end gap with the pis-
pm clips fall mto the ton cut-out.
crankcase

CYLINDER INSTALLATION (,04)

Install a new O-ring into the water joint groove.
Instalilhe water joint to the cylinder and tighten the
bolts securely.

C-RING

Install the RC valve cable guide and tighten the bolt

securely. CABLE GUIDE

7-16
 CYLINDER HEAD/ CYLINDER / PISTON
Place the dowel pins and new base gasket on the
crankcase.

Install the AC valve system into the cylinder (page 8-

12).
Align the ring end gap with the piston ring stopper
pin.

Do nOI rolale tile Lubricate the piston with Pro Honda HP2 2-stroke oi l 1~~'7YLINi)E R
cylinder, since this and slip the cylinder over the piston while com -
may cause the PiS- pressi ng the piston ring.
ton rmg to snag a Install the cyl inder onto the crankca se.
cylmder pon and
break

Before tightening the cylinder nuts, be sure the cyl.

inder is seated completely against the crankcas e.
Install and tighten the four cylinder mounti ng nuts
in a crisscross pattern in two or three steps.
TORQUE: 27 N·m (2.8 kgf·m , 20 Ibf.ft)

7-17
CYLINDER HEAD/CYLINDER/PISTON
Install rubber seal onto the right crankcase cover.
Install the new gasket onto the right RC valve cover.

Install the right RC valve cover and temporarily

install the mounting bolts and screw.
Tighten the cover mounting bolts first, then the
mounting screw.
TORQUE:
Cover bolts: 4.9 N'm (0.5 kgf.m, 3.6 IbUt)
Cover screw: 2.9 N'm (0.3 kgf·m , 2.2 IbUt)

Connect the water hose to the cylinder water joint

and tighten the clamp screw securely. }
r-
ATER JOINT

Install the new gasket to the exhaust port.

7-18
 CYLINDER HEAD / CYLINDER/ PISTON
Apply grease to the new O-ring and install il to the
exhaust pipe joint groove. EXHAUST PIPE JOINT
Install the exhaust pipe joint as shown and tighten
the bolts. (

Connect and adjust the RC valve control cables

(page 8-12).
Install the expansion chamber (page 2-8).
Install the cylinder head (page 7-7),
Pour recommended coolant mixture into the radia-
tor to the correct level (page 5-8).
Check for the following:
- compression leaks
abnormal engine noise
secondary air leak
- coolant leaks

CYLINDER INSTALLATION (AFTER '04)

Place the dowel pins and new base gasket on the
crankcase.

Install the RC valve system into the cylinder (page 8-

12).
Align the ring end gap with the piston ring stopper
pin.

7-19
CYLINDER HEAD / CYLINDER/ PISTON
Do not rotate the Lubricate the piston surface and cylinder inner sur-
cylinder, since thisface with Pro Honda HP2 2-stroke oil.
may cause the PiS- Slip the cylinder over the piston while compressing
ron ring to snag a the piston ring.
cylmder port and Install the cylinder onto the crankcase.
brea/(.

Before tightening the cylinder nuts, be sure the cyl-

inder is seated completely against the crankcase ,
Install and tighten the four cylinder mounting nuts
in a crisscross pattern in two or three steps.
TORQUE: 27 N·m (2.8 kgf-m , 20 Ibf.ft )

Apply molybdenum paste/oil solution to the flap

valve arm pi n.
Install the t ie rod onto the flap valve arm pin.
Install the collar and B-clip.

Install a new gasket onto the right RC valve cover.

Install the rubber seal onto the brim of the right
crankcase cover.

7-20
 CYLINDER HEAD/CYLINDER/PISTON
Install the right RC valve cover, then tighten the
bolts and screw to the specified torque.

TORQUE:
Cover bolts: 12 N·m (1 .2 kgf·m, 9 Ibf.ft)
Cover st:rew: 2.9 N·m (0.3 kgf·m , 2.2 Ibf.ftl

Connet:t the radiator hose and tighten the hose

band screw securely.
Install the radiator lower mounting bolts and tighten
them securely.

Install a new gasket onto the left RC valve cover.

Install the left RC valve cover.

Install the left RC cover bolts and wire clamp.

Tighten the left RC valve cover bolts to the specified
torque.
TORQUE: 12 N'm (1.2 kgf·m , 9Ibf.ft'

7-21
CYLINDER HEAD / CYLINDER / PISTON
Install the new gasket to the exhaust port,

Install the exhaust pipe joint with its flat facing

down.
Install and tighten the exhaust pipe joint bolts
securely.
Apply grease to the new C-ring and install it to the
exhaust pipe joint.
Install the expansion chamber (page 2-8).
Install the cylinder head (page 7-7).
Pour recommended coolant mixture into the radia-
tor to the correct level (page 5·8).
Check for the following:
- compression leaks
- abnormal engine noise
- secondary air leak
- coolant leaks

7-22
 8. RC VALVE

COMPONENT LOCATION ............................. 8-2 EXHAUST VALVE ······································· ···· 8-7

SERVICE INFORMATION ······························ 8-4 SERVO MOTOR (·04) ·············· ··· ···················8-15

TROUBLESHOOTING .................................... 8-5 GOVERNOR / VALVE LINKAGE

(AFTER ·04) ·.. · .... · .. ····· .. ·· .. ·· .. ························· 8-17
EXHAUST DEPOSIT DRAINING ('04) .. ········· 8-7
RC VALVE CABLE (·04) ··················· ·············8-21

8-1
RCVALVE
COMPONENT LOCATION
'04:

4.9 N·m (5.0 kgf·m, 3.6 Ibf.ft)

2.9 N·m
(0.3 kgf·m, 2.2 Ibf.tt)

4.9N·m

I~ (O.S kgf·m, 3.6 Ibf.ft)

8.8N·m
(0.9 kgf·m, 6.5Ibf.ft)

~ 0~
"'~ ~,
~ '@~

\
8.8 N·m (0.9 kgf·m, 6.5 Ibf·h)

8-2
 RC VALVE
AFTER '04:

27 N·m kgf·m, 201bHt)

12 N'm . kgf·m,9Ibf·ftl

20Ibf.ft)
8.8N·m
(0.9 kgf·m, 6.5 Ibf·ft)

9.BN·m
(1.0 kgf·m, 7Ibf·ft)

'7Ibf'~
2.9 N'm (0.3 ,2.2 Ibf.ft)

12 N·m
(1.2 kgf·m, 9 Ibf·ft)

I§?
37 N'm
(3.B kgf·m, 27 Ibf.ft)

6.5Ibf·ft)

8-3
RC VALVE
SERVICE INFORMATION
GENERAL
• This section covers the maintenance of the AC valve.
• Decarbonize the AC valves and valve shah every 2.5 hours of operation (each race),
• If the RC valves or AC valve shaft is worn or damaged, replace the AC valve shah and RC valves as an assembly.

TORQUE VALUES
AC valve shaft nut 8.8 N'm (0.9 kgf.m, 6.5 Ibf.ft)
AC valve shaft pulley nut 8.8 N·m (0.9 kgf·m, 6.5 Ibf.ft) '04 only:
Left RC valve cover bolt '04: 4.9 N'm (5.0 kgf·m, 3.6 IbHt)
After '04: 12 N·m (1.2 kgf·m, 9 Ibf.ft)
Right RC valve cover bolt '04: 4.9 N'm (5.0 kgf·m, 3.6 Ibf.ft)
After '04: 12 N·m (1.2 kgf·m, 9Ibf·ft )
Right RC valve cover screw 2.9 N'm (0.3 kgf.m, 2.2 Ibf.tt)
RC valve shaft s\opper plate bolt 9.8 N·m (1.0 kgf·m, 7 IbHt) '04 only:
RC valve shaft collar set plate bolt 9.8 N'm (1.0 kgf·m, 7 Ibf.ft) After '04 only:
Pinion gear/tie rod retaining screw 8.B N·m (0.9 kgf·m, 6.5Ibf.ft) After '04 only:
Blow-by oil drain bolt 9.8 N·m (1.0 kgf·m, 7 IbUt) '04 only:

TOOLS (AFTER ' 04)

Bearing remover, 7 mm Bearing driver, 7 mm
07931-KA30000 07946-KA30100

8-4
 RCVAlVE
TROUBLESHOOTING
Poor pe rformance at low s peed
• Exhaust valve does not close fully
- Incorrect RC valve cable adjust ment ('04 only)
- Faulty serve motor ('04 only)
- Faulty governor (After '04 only)
- Bent RC valve shaft
• Excessive carbon build·up on the RC valves
• Damaged RC valves and valve shaft
• Faulty throttle position sensor
Poor perform ance at high speed
• Exhaust valve does not open fully
- Incorrect RC valve cable adjustment (,04 only)
- Faulty serve motor ('04 only)
- Faulty governor (After '04 only)
- Improper installation
• Excessive carbon build-up on the RC valves
• Damaged RC valves and valve shaft
Engine starts, but does not operate the RC valve ('04 only)
1. RC Valve Control Cable Operating Condition
Remove the AC valve cover (page 8-7).
Check the RC valve cable operating condition
(page 8-21).
Is the control cable good condition?
YES - GO TO STEP 2,
NO - . Incorrect RC valve cable adjustment
• Stuck RC valve cable

2. RC Valve Pulley Operation

Disconnect the RC valve control cables from the
RC valve pulley. "I I
Turn the pu lley with you r finger, and check for
smooth turn. \\\1\\\ \ \\
\.
Does the pulley turn smoothly? \, \'\ ,
YES - GO TO STEP 3.
NO _ . Excessive carbon build-up on the RC
valve
• Stuck RC valve
• Bent RC valve shaft

8-5
RC VALVE
3. Servo Motor Operating Condition
Disconnect the servo motor 6P connector (page , - - - -- - - - - - - - - -- - - - -
8.15). 6P (NATURAL) CONNECTOR
Connect the 12 V battery to the servo motor 6P
connect or and inspect the se rvo motor opera-
tion.
Connection: White/ black (+) - White/ green (.)

Does the servo motor turn counterclockwise?

YES - GO TO STEP 4.
NO - Faulty servo motor

4. Potentiometer In spection
Inspect the potentiometer in the servo motor , -- - - - - - - - - - - - - - - -- ,
(page 8-16). 6P (NATURAL) CONNECTOR
c'
Is there normal condition ?
YES - GO TO STEP 5.
NO - Faulty servo motor

5. Wire Harness Continuity Inspection

Disconnect the ECM 8P (Black) connector.
Check fo r continuity between the ECM and servo 6P(NATURALlCONNECTOR
motor 6P connector. '; /
Connection : White / black (+' - White / green (.)
Is there continuityi'
YES - Faulty ECM
NO _ . Open circuit between the ECM and
servo motor
• Loose or poor contact s of connec-
tors,
I

8-6
 RC VALVE
EXHAUST DEPOSIT DRAINING ('04)
Under racing condi- Remove the drain bolt and drain the exhaust depos-
tIOns, dram the its from the right crankcase cover.
exhaust deposits
Install and tighten the drain bolt to the specified
after eVery 22.5
torque.
hours of runnmg
TORQUE: 9.8 N·m (1.0 kgf·m, 7 Ibf.ft)

EXHAUST VALVE
OPERATING INSPECTION ('04)
NOTE :
The RC valve operates from fully closed to fully
open and returns to initial position in the initial
stage after engine starts.
Wa rm up the engine to operating temperature.
Stop the engine.
Remove the bolts, wire clamp, RC valve cover and
gasket.

Connect the tachometer.

Start the engine and check that the RC valve pulley
is in the initial position . \
,\
Increase the engine speed to approximately l' ,500 \
rpm and check that the RC valve pulley turns to the I
fully-open position . J"\)'
If the exhaust valve does not operate properly,
check the following.

8-7
RC VALVE
Remove the dust covers.
Loosen the lock nuts and disconnect the AC valve
cables from the RC valve pulley.

Turn the AC valve pulley with your finger.

The RC valve pulley should turn smoothly.
If the RC valve pulley does not turn smoothly, check
the following:
• Carbon deposits on the AC valve
• Stuck RC valves
• Bent RC valve shaft
If the RC valve pulley turns smoothly, check the fol -
lowing:
• Incorrect AC valve cable adjustment
• Stuck RC valve cables
• Faulty servo motor

Connect the AC valve cables to the RC valve pulley

(page 8-81.
Install the new gasket.

Install the RC valve cover, wire damp and bolts.

Tighten the bolts to the specified torque.
TORQUE: 4.9 N·m (5.0 kgf -m , 3.6 Ibf·ft J
Install the alternator wire to the wife clamp.

8-8
 RC VALVE
OPERATING INSPECTION (AFTER '04)
Remove the bolts and right RC valve cover (page 7- ~......_~~t ~
10).
Remove the B-clip and setting collar, then remove
the tie rod from the valve shaft arm.

Check that the exhaust valve turns smoothly by

hand.
If the exhaust valve turns unsmoothly, remove the
exhaust valve and decarbonize the RC valves and
valve shaft.

Install the tie rod, setting collar and B-clip to the

valve shaft arm.
Install a new gasket and right RC valve cover.
Tighten the bolts to the specified torque.
TORQUE : 12 N·m (1.2 kgf.m, 9 Ibf.ftJ

REMOVAL/DISASSEMBLY ('04)
Clean the engine thoroughly to keep dirt from enter-
ing the engine.
Remove the cylinder (page 7-8).
Remove the RC valve shaft nut and washer from the
right side of the cylinder.

8-9
RC VALVE
Remove the RC valve shaft stopper socket bolt and
stopper plate.
Loosen the AC valve pulley nut.

SOCKET
Remove the RC valve shaft assembly, collar, right , - - -- - - - - -- - - - -- - -
RC valve and left RC valve from the cylinder. COLLAR
-
~@~

FLAP VALVES

Remove the nut, washer, RC valve pulley and spe-

cial washer from the RC valve shaft.

NUT

FLAP

RC VALVE PULLEY

REMOVAL/DISASSEMBL Y
(AFTER '04)
Clean the engine thoroughly to keep dirt from enter- - - - . "'.,.",.",.",,,.,,=T'"
ing the engine.
Remove the cylinder (page 7-10),
When the AC valve shaft is to be disassembled,
loosen the right RC valve shaft nut, but do not
remove it.

8-10
 RC VALVE
Remove the socket bolt and stopper plate.
Remove the left flap valve shaft nut and washer.

Remove the collar, flap valve shaft assembly and '-;:c-,:-:::-::::-- - - - - - - - - - - - - - -

flap valves from the cylinder.

~ COLLAR

O,"G~ ~
~. ReVALVES

FLAP VALVE SHAFT

Remove the nut and disassemble the flap valve
shaft.

VALVE NUT
DECARBONIZING/INSPECTION
Decarbonize the Remove the carbon deposits from the flap valves.
'04 MODEL SHOWN: FLAP VALVES
flap valves each Inspect the flap valves fo r wear or damage.
race

Replace the flap Replace the f lap valves if necessary.

valves and flap
valve shaft as a ser

8-11
RC VALVE
Decarbomze the Remove the carbon deposits from the flap valve
'04 MODEL SHOWN:
flap valve shaft shaft.
each race Inspect the flap valve shaft for wear or damage.
Replace the flap Replace the flap valve shaft if necessary.
valves and flap
valve shaft as a sel

FLAP VALVE SHAFT

Inspect the oil seal for deterioration or damage.

Ij~M~OOEL SHOWN, OIL SEAL
Be careful nOI /0 Replace the oil seal if necessary.
dama ge the cylm -
der when replacing
the 0" seal.

ASSEMBLY/INSTALLATION ('04)
Install the special washer to the flap valve shaft,
aligning the cut-Qut. FLAP VALVE SHAFT
Install the RC valve pulley to the flap valve shaft,
aligning the cut-out.
Install the washer and nut to the flap valve shaft and PULLEY
loosely tighten t he nut.

SPECIAL WASHER

WASHER NUT

Apply molybdenum oil solution to the shaft hole

inner surface of the flap valves and flap valve shaft COLLAR

~@~
sliding surface.
Install the flap valves and flap valve shaft assembly FLAP VALVE
into the cylinder. SHAFT
ASSEMBLY

FLAP VALVES

8-12
 RCVALVE
Install the stopper plate and tighten t he flap valve
shaft stopper plate socket bolt.

TORQUE: 9.8 N'm (1 .0 kgf.m , 7 Ibf.ftl

Tighten the RC valve pulley nut to the specified
torque.
TORQUE: 8.8 N'm (0.9 kgf·m , 6.5 Ibf·ft )

Tighten the fl ap v alve shah nut to the specified

torque.
SOCKET
-
TORQUE: 8.8 N·m (0.9 kgf·m , 6.5 Ibf.ft)

Install the cylinder (page 7·16).

ASSEMBLY IINSTALLATION
(AFTER '04)
Assemble the flap valve shaft, valve shaft arm , valve
FLAP VALVE SHAFT
shaft arm spring. valve stopper, special washer and
nut.
VALVE SHAFT ARM

VALVE STOPPER

~,J?
VALVE ARM SPRING •
TT
WASHER

Make sure that the valve shaft arm and cu t -out of

CUT-OUT
the flap valve shaft are positioned as shown.

VALVE SHAFT ARM

8-13
RC VALVE
Apply molybdenum oil solution to the shaft hole
inner surface of the flap valves and valve shaft slid-
CYLINDER
ing surface.
-l!?=.. ~ ... ~
in.fln
:=:iV COLLAR

RC VALVES

RC VALVE SHAFT

Install the flap valves into the slot on the cylinder as

shown.
Install the flap valve shaft assembly aligning the cut-
out on the valve shaft with the flap valves.
Install the collar aligning the cut-out on the collar
with the flap valves.
Make sure that the cut-outs of the valve shaft and
collar are aligned.

Install the stopper plale and socket bolt, and tighten

the socket bolt securely.

TOROUE : 9.8 N·m (1.0 kg'·m , 71bf·ft)

Install the washer and left valve shaft nut.
Tighten the valve shaft nul to the specified torque.
TORQUE: 8.8 N·m (0.9 kgf·m, 6.5 Ibf·tt)

Tighten the right valve shaft nut to the specified

torque.

TORQUE: 8.8 N·m (0.9 kgf.m, 6.5 Ibf.ft)

Install the cylinder (page 7-16).

8-14
 RC VALVE
SERVO MOTOR ('04)
INSPECTION
Remove the fuel tank (page 2-6).
Disconnect the RC valve cables from the RC valve
pulley (page 8-8).
Remove the screw and servo motor cover.

Disconnect the RC valve cables from the servo

motor.

Remove the wire band.

Disconnect the servo motor 6P connector.

MOTOR INSPECTION
Connect the 12 V battery to the servo motor side 6P
connector. 6P (NATURAL) CONNECTOR
Check that the servo motor pulley turns counter· I
clockwise.
Connection: White/black (+) - White / green (.)
Then, switch the 12 V battery connection.
Check that the servo motor pul ley turns clockwise.
Connection : White/green {+' - White/ black H
Replace the servo motor if the servo motor opera-
tion is abnormal.
<ll e

8-15
RC VALVE
POTENTIOMETER INSPECTION
Measure the resistance at the servo motor side SP r - - - - - -- - - - - - - - - - - --
connector.

Connection: Yellow/red - Blue/ green

Aesistance: 3.5- 6.5 kD (20 CC / 68 OF)

Be careful not fO
short the battery
Connect the 12 V battery 10 the servo motor side SP
connector.
~===::;:::;===.==~=.=.==:;;;:;====~
terminals Measure the resistance at the servo motor side SP
connector using the analogue tester.
Battery connection:
White/ black (+) - Wh ite/green (.)
Tester connection:
light green - Blue/green
Resista nce: Repeat 0 to 3.5 - 6.5 kD (20 "e/S8 F)
Replace the servo motor if the servo motor opera-
tion is abnormal.

6P (NATURAL) CONNECTOR

REMOVAL/INSTALLATION
Remove the fuel tank (page 2-6),
Disconnect the AC valve control cables from the AC
valve pulley (page 8-8),
Remove the screw and servo motor cover.

Disconnect the RC valve cables from the servo

motor.

8-16
 RC VALVE
Remove the wire band and disconnect the servo
motor 6P connector.

Remove the nuts, bolts and servo motor.

Installation is in the reverse order of removal.
Route the RC valve cables properly (page 1-18).

GOVERNORIVALVE LINKAGE
(AFTER '04)
REMOVAL
Remove the right crankcase cover (page 9-6).
Remove the pinion gearltie rod retaining screw and
washer from the right crankcase cover.

Remove the governor assembly by pulling it off the

shah.

8-17
RC VALVE
Remove the grommet.
Remove the pinion gear/tie rod from the right crank- PINION GEARfTlE ROD

~~
case cover.

(
t ~~

,-J (,'::
I r [)

r" J'_ ~\
).\ '\J~) ~ GROMMET

INSPECTION
Do nor dlSBssemble Inspect the governor gear teeth for excessive wear
the governor or damage. GOIIER'"OR GEAR

'I. , .
"r. "
'~ ' f
! , ,

(1-.. .

Inspect the pinion gear for excessive wear or dam-

age. TIE ROD
Inspect the lie rod for bend or damage.

PINION GEAR
Inspect the oil seal for deterioration, wear or dam-
age.

8-18
 RC VALVE
GOVERNOR SHAFT BEARING
REPLACEMENT
RIGHT CRANKCASE SIDE:
Remove the bearing using the special tool.

TOOL:
Bearing remover, 7 mm 07931 -KA30000
(not available in
U.S.A .)

Drive in the new bearing into the right crankcase.

TOOL:
Bearing driver, 7 mm 07946·KA30100
(not available in
U.S.A.)

RIGHT CRANKCASE COVER SIDE:

Remove the bearing by thermally expanding the
right crankcase cover. INDUSTRIAL DRYER
Slowly and uniformly heat the crankcase cover with
a heat gun (industrial dryer).

ACAUTION
I
To avoid burns, wear insulated gloves when
handling the heated parts.

I NOTICE I
Using a torch to heat the crankcase cover may
cause warping.

Drive in the new bearing into the right crankcase.

TOOL:
Bearing driver, 7 mm 07946· KA30100
(not available in
U.S.A .)

8-19
RC VALVE
INSTALLATION
Apply recommended transmission oil \0 the pinion
gear.
Install the pinion gearltie rod to the right crankcase 2.0 mm (0.08 in)
cover as shown.
Extend the tie rod fully.

Apply molybdenum oil solution to the tie rod joint L~:::::::::::::;;:;;;-;;:;;;;;:::=:;;:=:;;;;

and governor bearing rol ling area.
Install the governor by positioning the pinion lever
toward the top of the right crankcase cover. When
the governor is installed, it will spin the pinion lever
downward to its proper position.

Make sure the tie rod joint is positioned between

TIE ROO JOINT
the grommet end of right crankcase caver and gov-
ernor end as shown.
Push the pinion gear in the right crankcase cover
until fully seated.

Install the washer and retaining screw.

Tighten the retaining screw 10 Ihe specified lorque.
TORQUE: 8.8 N·m (0.9 kgf·m, 6.5 Ibf.ft)
Inslall Ihe grommet with its tab facing outside as
shown.
Install the rig hi crankcase cover (page 9-8).

GROMMET

8-20
 RC VALVE
RC VALVE CABLE ('04)
RC VALVE CABLE CONNECTION!
ADJUSTMENT
Cable adjustment is done automatically via the
servo motor and spring.
SERVO MOTOR SIDE
Connect the rear RC valve cable to the servo motor
pulley.
Connect the front RC valve cable (spring /seat) to the
servo motor pulley.
Install the AC valve cables to the grooves in the
servo motor body.
Route the RC valve cables properly (page 1-18).

CYLINDER sloe (REAR CABLE)

Turn the outer lock nut until it seats against the
REAR RC VALVE CABLE OUTER LOCK NUT
adjuster,
Connect the rear RC valve control cable to the RC
valve pulley.
Turn the AC valve pulley counterclockwise fully.
ADJU5TER
0 1
~~*i
~omm
Turn the adjuster clockwise until the inner lock nul
seats t o the cylinder.
Tighten the out er lock nul securely.

~omm
RC VALVE PULLEY INNER LOCK NUT
CYLINDER sIDe (FRONT)
Turn the RC valve pulley clockwise fully until RC
valve pulley stops against the pin .
Loosen the inner and outer lock nuts.
Connect the front RC valve control cable (springl
seat) to the RC valve pulley.
Install the seat to the cable guide while compressing
OUTER
the spring. LOCK
Pull up the f ront RC valve control cable while swing- NUT
ing it front and rear.

INNER LOCK NUT CABLE GUIDE

8-21
RCVALVE
Turn the adjuster until the inner lock nut seats to the
OUTER LOCK NUT ADJUSTER
cylinder while pulling the adjuster.
Tighten the outer lock nut securely.

INNER LOCK NUT

Install the servo motor cover and tighten the screw

securely. Ir~;~;~~~~~:~~I----"
Install the fuel tank (page 2-7).
ReqUires removing Check the RC valve operation (page 8-7) ,
the cover. rhar7s Install the RC valve cover (page 8-8).
way cover installa-
tIOn should come
lafe~

Install the new gasket.

Install the RC valve cover, wire clamp and bolts.

Tighten the bolts to the specified torque.
TORQUE: 4.9 N ·m (5.0 kgf·m , 3.6 Ibf·ft)

Install the alternator wire to the wire clamp.

8-22
 9. CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE

COMPONENT LOCATION .............. ............... 9-2 CLUTCH .... ........ · ........ · ............ ·.. ·.. ·· ...... ·· .... · .. 9-10

SERVICE INFORMATION .............................. 9-3 KICKSTARTER .. .. .......................................... 9-17

TROUBLESHOOTING .............. ·.... ·.. · ...... ·.... ·· 9-4 GEARSHIFT LINKAGE .. · .... · ............ · ............ ·9-21

RIGHT CRANKCASE COVER ........................ · 9-5

9-1
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
COMPONENT LOCATION
12 N·m (1.2 kgf·m, 9Ibf·ft)

22 N'm (2.2 , 6 Ibf.ft)

12 N·m (1.2 kgf·m, 9Ibf.ft)

69 N'm {7.0 kgf·m,

51 Ibf.ftl

<

9.8 N·m (to kg'·m, 7Ibf.ft)

37 N·m (3.8 kgf·m, 27 Ib'·h)

9.8 N'm (1.0 kgf·m, 7 rbf·h)

9-2
 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch, kickstarter and gearshift linkage. All service can be done with the engine
installed in the frame .
• Transmission oil viscosity and level have an effect on clutch disengagement. Oil additive also aHect clutch performance
and are not recommended. When the clutch does not disengage or the motorcycle creeps with clutch disengaged,
inspect the transmission oille... el before servicing the clutch system.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT'
- Clutch lever free play 10 20 (318 - 314[11=~:::==-_ --=+=:~;
Clutch spring free length 36.1 (1A2) 35.4 (l39)c---;
Clutch outer guide 1.0. 20.000 20.021 (0.7874 0.7882) _ _~~2~O.~05 (0-:-789)
Clutch disc Ihidcness 2.92 - 3.08 (0. '14 - 0.121) 2.85 (0.006)
Clutch plate warpage 0.15 (0.008)
Kickstarter pinion gear 1.0. 16.55 (0.652)
Kidc.starter spindle 0.0. 16.466 16.45 (0.648)
Kickslarter idle gear 1.0. 17.016 17.034 _ ~=t~1~I~05~IO.~67~1~1 ~
__
Countershaft 0 .0. at kickstarter idle gear 16.983 16.97 (0.668)

TORQUE VALUES
Right crankcase cover bolt 9.8 N·m (1.0 kgf·m, 7 Ibf.ft)
Clutch cover bolt 9.8 N'm (lO kgf·m, 7 Ibf·ft)
Gearshih drum center pin 22 N·m (2.2 kgf·m. 18 Ibf·h) Apply a locking agent to the threads
Gearshih drum stopper arm bolt 12 N'm (1.2 kgf·m, 9 Ibf·h)
Clutch spring bolt 9.8 N·m (1.0 kgf·m, 7 Ibf·ft)
Clutch center lock nut 80 N·m (8.2 kgf·m, 59 !bf·ft)
Gearshih pedal bolt 12 N·m (1.2 kgf·m. 9Ibf·h)
Kickstarter pedal bolt 37 N·m (3.8 kgf·m. 27 Ibf·h)

TOOL
Clutch center holder
07724-0050002

or 07724-0050001
or equivalent commercially avail-
able in U.S.A.

9-3
ClUTCH/KICKSTARTER/GEARSHIFT LINKAGE
TROUBLESHOOTING
Hard t o shift
• Incorrect clutch adjustment
• loose stopper plate bolt
• Damaged stopper plate and pin
• Damaged gearshift spindle
Transmission jumps out of gear
• Worn shift drum stopper arm
• Worn or broken gearshift spindle return spring
• loose stopper plate bolt
Gearshift pedal will not return
• Weak or broken gearshift spindle return spri ng
• Bent gearshift spindle
Clutch slips w hen accelerating
• Incorrect clutch adjustment
• Worn clutch discs
• Weak clutch springs
• Transmission oil mixed wi t h molybdenum or graphite additive
M otorcycle creeps with th e engine idling
• Incorrect clutch adjustment
• Clutch plate warped
• Faulty clutch lifter
• Incorrect transmission oil

9-4
 ClUTCH/KICKSTARTER/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER
REMOVAL 1'04)
Drain the coolant (page 5-8).
Drain the transmission oil (page 3-11).
Remove the expansion chamber (page 2-8 ),
Remove the brake pedal pivot bolt and move the
pedal aside (page 13-24) ,
Remove the kickstarter pedal bolt and kickstarter
pedal.
Remove the right RC valve cover (page 8-7).
Remove the water pump cover (page 5-9).

Loosen the clamp screw and disconnect the radiator

hose from the right crankcase cover.
Remove the bolts, hose guide and right crankcase
cover.

Remove the gasket and dowel pins.

Check the starter spindle oil seal for deteriorated or

damage. Oil SEAL

9-5
CLUTCH / KICKSTARTER/ GEARSHIFT LINKAGE
REMOVAL (AFTER '04)
Drain the coolant (page 5·8).
Drain the transmission oil (page 3-11).
Remove the expansion chamber (page 2-8).
Remove the brake pedal pivot bolt and move the
pedal aside (page 13-24).
Remove the kickstarter pedal bolt and kickstarter
pedal.

Remove the screw, bolts and right RC valve cover.

Remove the grommet.

Remove the B-clip and setting collar, then remove

the tie rod from the valve shaft arm.

Remove the water pump cover (page 5-9).

Remove the bolts, hose guide and right crankcase
cover.

9-6
 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Remove the gasket, dowel pins and D-ring.

Check the starter spindle oil seal for deteriorated or

damage.

INSTALLATION ('04)
Place a new gasket on the right crankcase cover and
cut the end of the gasket flush with the end as
shown.

Install the dowel pins and new gasket.

9-7
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Install the right crankcase cover while engaging the
water pump gear with the primary drive gear.
Install the hose guide and tighten the bolt s to the
specified torque.
TORQUE: 9.8 N·m (1 .0 kgf·m , 7 IbUt)
Connect the radiator hose to the righ t crankcase
cover and tighten the clamp screw securely.
Install the water pump cover (page 5-12).

Install the kickstarter pedal, tighten the pedal bolt to

the specified torque.

TORQUE: 37 N·m (3.8 kgf·m, 27 Ibf·ft)

Install the brake pedal (page 13-24),
Install the expansion chamber (page 2-8).
Fill the transmission with the recommended oil to
the correct level (page 3-11).
Pour the radiator coolant mixtu re into the radiator
to the correct level (page 5-8) .
Check and adjust the rear brake pedal height (page
3-17).
Start the engine and check for oil leaks. PEDAL""""'Il EXPANSION_CHAMBER

INSTALLATION (AFTER '04)

Place a new gasket on the right crankcase cover and ' - -
,d!
-c--R-'G
-,--H-Tc C
"C:"
R-A-N- K-C
cA- -c
S-E-C-O-V-E-R-G-A-S-K-E-T-
cut the end of the gasket flush with the end as .......
shown.

Install the dowel pins, new gasket and G-ring.

9-8
 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Install the right crankcase cover while engaging the
water pump gear with the primary drive gear.
Install the hose guide and right crankcase cover
bolts.
Tighten the bolts to the specified torque.
TORQUE: 9.8 N'm (1 .0 kgf·m , 7 Ibf.ft)
Install the water pump cover (page 5·12).

Connect the tie rod to the valve shaft arm, then r-:-:.,.,-,-::----,
install the setting collar and B·clip.
Install the grommet onto the right crankcase cover.
Install the new gasket onto the right RC valve cover.

Install the right RC valve cover and tighten the bolts

and screw to the specified torque.
~~~~~:~~i.i~~~~~~~
TORQUE:
Bolt: 12 N·m (1.2 kgf.m, 9 Ibf.ft)
Screw: 2.9 N'm (0.3 kgf·m , 2.2 Ibf·ft )

Install the kickstarter pedal. tighten the pedal bolt to

the specified torque.

TORQUE: 37 N'm (3.8 kgf·m, 27 Ibf.tt)

Install the brake pedal (page 13·24).
Install the expansion chamber (page 2·8).
Fill the transmission with the recommended oil to
the correct level (page 3·' 1).
Pour the radiator coolant mixture into the radiator
to the correct level (page 5·8).
Check and adjust the rear brake pedal height (page
3·17).
Start the engine and check for oil leaks.

9-9
CLUTCH / KICKSTARTER/ GEARSHIFT LINKAGE
CLUTCH
REMOVAL
Remove the brake pedal pivot bolt and move the
pedal aside (page 13-24).
Remove the bolts and clutch cover.

Remove the six clutch spring bolts in a crisscross

pattern in two or three sleps.
Remove the clutch springs.
Remove the clutch pressure pia Ie.

Turn the clutch lifter with your finger, check that the
dutch lifter needle bearing turns smoothly.

Remove the clutch lifter and lifter rod.

Remove the eight clutch friction discs and seven
clutch plates.

9-10
 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Bend the tabs of the lock washer away from the lock
nut.

Hold the clutch center with the clutch center holder.

Remove the lock nut, lock washer and thrust
washer.
TOOL:
Clutch center holder 07724·0050002 or
07724-0050001
or equivalent com-
merciallyavail-
able in U.S.A.
Remove the Icol and clutch center.

Remove the thrust washer and clutch outer.

Remove the needle bearing and clutch outer guide.

9-11
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Remove the alternator cover (page 14-15).
Disconnect the clutch cable from the clu tch lifter
lever by loosening the clutch cable adjuster,
Remove the flywheel and stator (page 14- IS).
Remove the clutch lifter lever from the left crank-
case.

INSPECTION
CLUTCH SPRING
Replace the clutch Measu re the clutch spring f ree length.
springs 8S 8 set
SERVICE LIMIT: 35.4 mm (1 .39 in )

CLUTCH DISC
Check the clutch discs for sign of scoring or discol-
oration.
M easu re the thickness of each disc.
SERVICE LIMIT: 2.85 mm (0.112 in)

CLUTCH PLATE
Check each clutch plate for excessive warpage or
discoloration.
Replace the clurcfl Check the plate warpage on a surface plate using a
discs and plates 8S feeler ga uge.
a S(l/
SERVICE LIMIT: 0.20 mm (0.008 in)

9-12
 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
CLUTCH CENTER
Check the clutch center for nicks, indentations or
abnormal wear made by the clutch plate. CLUTCH CENTER

CLUTCH LIFTER
Check the clutch lifter for wear or damage.
CLUTCH LIFTER
CLUTCH LIFTER ROD

~
Check the clutch lifter rod for damage o r warpage.
LIFTER ROD

/
CLUTCH OUTER
Check the clutch outer for nicks, indentations or
abnormal wear made by the clutch discs. CLUTCH OUTER
Check the serrated teeth of the primary driven gear
for wear or damage.

CLUTCH OUTER GUIDE

Check the clutch outer guide for abnormal wear or
damage.
Measure the I.D. of the clutch outer guide.
SERVICE LIMIT: 20.05 mm (0789 in)

NEEDLE BEARING
Check the needle bearing for wear or damage.
Check the mainshaft for wear or damage at the slid-
ing suriace of the clutch outer guide.

NEEDLE BEARING OUTER GUIDE

9-13
CLUTCH/ KICKSTARTER/GEARSHIFT LINKAGE
CLU TCH LIFTER LEVER
Check the clutch lifter lever for damage.

LEVER
Check the oil seal and needle bearing for wear or
damage.

INSTALLATION
THRUST WASHER CLUTCH OUTER
OUTER GUIDE
CLUTCH CENTER
THRUST WASHER

69 N·m (7.0 kgf·m, 51 Ibf.ft)

NEEDLE BEARING

CLUTCH PLATE

CLUTCH

LOCK WASHER

CLUTCH SPRING
CLUTCH ROD

CLUTCH LIFTER

9.8 N ·m ( 1.0 kgf-m, 7Ibf·ft) PRESSURE PLATE

9-14
 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Apply Pro Honda Moly 60 or equivalent molybde-
num paste to the clutch lifter lever sliding surface.
Install the clutch lifter lever to the crankcase.
Install the stator and flywheel (page 14-15).
Connect the clutch cable to the clutch lifter lever.
After installation, check the following:
- ignition timi ng (page 14-18)
- clutch operation (page 3-17)

Apply transmission oil to the clutch outer guide and

needle bearing.
Install the clutch outer guide and needle bearing
onto the mainshaft.

Install the clutch outer and thrust washer.

Install the clutch center onto the mainshaft.

Install the thrust washer.
Align the groove in the new lock washer with a rib
on the clutch center and slip it into place on the
mainshaft.

9-15
- - - -- -- - -

CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
InSlalllhe clutch center lock nut and tighten the nut
to the specified torque while holding the clutch cen-
ter with the clutch center holder.

TOOL:
Clutch center holder 07724-0050002 or
07724·0050001
or equivalent com·
merciallyavail-
able in U.S.A.)

TORQUE: 69 N·m (7.0 kgf·m, 51 Ibf.ft)

Bend the tabs of the lock washer up against the

clutch center nut.

Coal the clutch plates and discs with clean transmis-

TheouterciurdJ
plale IS aluminum
sion oil.
Install the eight friction discs and seven clutch
plates (five aluminum plate and two steel plates)
alternately, starting with a disc.
l

(STEEL)

Apply grease to the clutch lifter rod tips.

Insert the clutch lifter rod into the mainshaft.
Install the clutch lifter.

9-16
 ClUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Install the clutch pressure plate.
Install the six springs and spring bolts.
Tighten the spring bolts in a crisscross pattern in
two or three steps.
TORQUE: 9.8 N·m (1.0 kgf·m , 7 Ibf.ft)

Check that the clutch cover a-ring is in good condi·

tion .
Apply oil to the D -ring and install the clutch cover.

Install and tighten the dutch cover bolts securely.

TORQUE: 9.8 N·m (1.0 kgf-m, 7Ibf.ft)

Install the brake pedal (page 13-24),
Adjust the clutch lever free play (page 3-17).

KICKSTARTER
REMOVAL
Remove the right crankcase cover (page 9-5). • KICI(SlrAFm.~
Remove the clutch (page 9-10).
Remove the idle gear and washer.
Unhook the kickstarter return spring from the crank-
case, and pull the kickstarter spindle assembly oul.

9-17
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
OISASSEMBL Y
Disassemble the kickstarter spindle by removing the

?rIo
RATCHET SPRING
following:
- thrust washer and collar '" SNAP RING
- return spring PINION GEAR

~
- ratchet spring and starter ratchet
- snap ring, thrust washer and pinion gear
STARTER RETURN SPRING
V~ JiWASHER
RATCHET

WASHERS
KICKSTARTER
/ ~
PII
j
SPINDLE ? <
COLLAR

INSPECTION
Check the return spring and ratchet spring for weak·
ness or damage,
Check the starter ratchet for wear or damage.
Measure the kickstarter pinion gear 1.0.
SERVICE LIMIT: 22.05 mm 10.868 i n)
Measure the kickstarter spindle 0,0.
SERVICE LIMIT: 21 .95 mm (0.864 in)

Check the starter idle gear and bushing for wear or

damage.
Measure the starter idle gear 1.0.
S ERVICE LIMIT: 20.07 mm (0.790 in)
Measure the starter idle gear bushing 1.0. and 0 .0 .
SERVICE LIMITS: 1.0 .: 17.04 mm (0.671 in)
0 .0 .: 19.96 mm (0.786 in )

Measure the counters haft 0.0. at the idle gear bush-

ing sliding surface.

SERVICE LIMIT: 16.95 mm (0.667 in)

9-18
 ClUTCH/KICKSTARTER/GEARSHIFT LINKAGE
ASSEMBLY
STARTER RATCHET
RATCHET SPRING

~
SNAP I

PINION

KICKS1-AR"'ER SPINDLE

WASHER

WASHER
IDLE GEAR

THRUST WASHER

THRUST WASHER

Apply molybdenum disulfide oil to the kickstarter

spindle.
r:;r'CcllAFil1:i
Install the pinion gear onto the kickstarter spindle.
Insert the return spring into the spring hook on the
starter spindle.
Install the collar aligning the groove of the collar
w ith the spring, then install the thrust washer.

GEAR

Install the thrust washer onto the pinion gear.

SNAP RING
Instal/ the snap rmg Install the snap ring in the groove of the spi ndle.
so the sharp edge
faCing out

THRUST WASH':R

9-19
CLUTCH/ KICKSTARTER / GEARSHIFT LINKAGE
Align the punch marks and install the st arter ratchet.
STARTER RATCHET

Install the ratchet spring.

RATCHET SPRING

, ,
I

, ~.j
'.
••

INSTALLATION
Install the washer and idle gear to the countershaft.

Be sure to preren- Inst all the kickstarter spindle and hook the return
SIOfI the rerum spring end to the crankcase.
sprmg before
Ins/allmg It Into the
Install the following:
crankcase - clutch (page 9-14)
- right crankcase cover (page 9·7)

9-20
 CLUTCH / KICKSTARTER / GEARSHIFT LINKAGE
GEARSHIFT LINKAGE
REMOVAL
Remove the following:
- right crankcase cover (page 9-5)
- clutch (page 9-10)
Remove the bolt and gearshift peda l.

Pull the gearshift spi ndle out of the crankcase.

Re move the shifter collar.

Remove the guide plale mounting bolts.
Do not ler the Remove the guide plate and drum shifter as an
ratchet pawls fall assembly.
when removing the
guide plate and
drum shlfre~

Remove the shift drum center pin and shift drum

center.

9-21
CLUTCH / KICKSTARTER/GEARSHIFT LINKAGE
Remove the bolt, stopper arm, return spring and
washer.
Remove the drum pin from the shift drum.

INSPECTION
GEARSHIFT SPINDLE
Check the gearshift spindle for wear or damage.
Check the return spring for fatigue or damage. GE,'R"HII'T SPINDLE

RETURN ·SPRING

RATCHET PAWL
Clean the ratchet pawls, plungers, springs and drum
shifter with clean transmission ojl,
Check each part for wear or damage.
Apply clean transmission oil to e8ch parts.
Assemble the drum shifter, springs, plungers and
ratchet pawls in the guide plate as shown. RATCHET
PAWL

SPRING DRUM SHIFTER

INSTALLATION
Inslall the drum pin to t he hole in the shift drum.
Install the return spring, washer and stopper arm
and tighten the stopper arm bolt to the speci fied
torque.
TORQUE: 12 N·m (1 .2 kgf·m , 9Ibf.ft)
Check the stopper arm for proper operation.

9-22
 ClUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Move the stopper arm Qut of the way using a screw-
driver.
Align the shift drum center hole with the drum pin
and slip it into place.

Clean and apply a locking agent to the gearshift

drum center pin threads.
Install and tighten the shift drum center pin to the
specified torque.
TORQUE: 22 N 'm (2.2 kgf·m , 16 IbUt)

Position the drum center in a gear other than neu-

traL
Holding the ratchet pawls in place in the guide plate
and drum shifter, install the assembly onto the shift
drum center pin .
Install and tighten the guide plale bolts securely.
Install the shifter collar onto the drum shifter.

Do not forger ro Assemble and install the washer to the gearshift

lOs/ali the washer spindle.
onto the gearshift
spmdle

9-23
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Install the gearshift pedal, tighten the bolt to the
specified torque.

TORQUE: 12 N·m !1 .2 kgf·m, 9Ibf·ft)

Move the gearshift pedal and check the shift mecha-
nism for smooth operation.
Install the kickstarter, if removed (page 9-201,
Inst all the clutch (page 9-14).
Install the right crankcase cover (page 9-7).

9-24
 10. CRANKCASE/CRANKSHAFT/TRANSMISSION

COMPONENT LOCATION ··························· 10-2 CRANKSHAFT REMOVAL·························· 10-11

SERVICE INFORMATION ········· ··················· 10-3 CRANKCASE BEARING REPLACEMENT ·· 10-13

TROUBLESHOOTING .................................. 10-6 CRANKSHAFT INSTALLATION ........ ...... ... 10-16_

CRANKCASE SEPARATION ························ 10-7 TRANSMISSION ASSEMBLY I

INSTALLATION ··········································· 10-17
TRANSMISSION REMOVALI
DISASSEMBLY ............................................ 10-9 CRANKCASE ASSEMBLY ·························· 10-19

10-1
CRANKCASE/CRANKSHAFT/TRANSMISSION
COMPONENT LOCATION
AFTER '04:

64N ·m

.~
(6.5 kgf·m. 47 Ibf.ft)

1'~()
9.8 N'm (1.0 kgf·m, 7Ibf.ft)

AFTER '04:

31 N·m (3.2 . 231bUt)

10-2
 CRANKCASE/CRANKSHAFT/TRANSMISSION
SERVICE INFORMATION
GENERAL
• The following parts must be removed before separating the crankcase.
- alternator (page 14- lS)
- clutch (page 9-1 O)/kickstarter (page 9·17)/gearshih linkage (page 9-21)
- cylinder head (page 7-6l/cylinder/piston (page 7-8)
- engine (page 6·4)

SPECIFICATIONS
Unit: mm (in)
ITE-M- - STANDARD ~RVIC E lI MIT~
Crankshah Runout
rl Connecting rod big end side clear- 0.4 - 0.8 (0.02 - 0.03)
-+-~.~5 (0.002)
0.9 (0.04)
4
ance
Connecting rod big end radial clear- 0,010 - 0.022(0.0004 - 0.0009) t 0""])32 (0.0013) I

Transmission
-r anee
Gear I.D.

C2
~~I- C3
M4, M5
Cl
__ + 23.020 - 23.041 (0.9063
20.020=20.041 (0.7882
-==±-27.020 27.041 (1.0638 1.064~
0.9071)
0.7890)
23.06 (O.90B)
20.06 (0.790)
27.06 (1.065)

r eusing 0 D M4, M5
C1
C2
25.020 - 25.04 1 (0.9850 -
22.979 23.000 (0.9047.
I 19.979 - 20 000 (0.7866 - 0.7874)
26.979 - 27.000 (1 0622 - 1.0630)
--t-
25.06 (o.987
22.95 (0.904)
19.95 (0.785)
R
26.95 (1.06~".-_

I Bu,;09I.D.
C3
MS
-=H4.979 25000 (0.9834 - 0.9845)
20.000- 20.021 10 7874-0.77821
24.95 (0.982)
20.0410.7am-
~
17.03 (0.67~

Gear-to-
Jj
Cl
C2
C3
M4, C1, C2, C3
17.000 - 17.018 (0.6693 - 0.6700)
24 000 24.021 (0.9449 0.9457)
--tL
22000 22.021 (08661 0.8670)
0 020 - 0 062 (~.0008 00024)
24.04 (0.946)
iiif) ---j1
22.04 (0.8SS
0.11 (0.0041-- j
bushing M5 0.040 - 0.082 (0.0016 - 0.0032) ± 0.12 (0.005)

l
clearance
~.~~shah M5 i 9.959 - 19.980 (0.7858 - 0.7866) 19.94 (0'7 8S)

I
~
Shih fork,
CouoIe,· C, bu,h;09
shah O.D'~2 bushing
C3 bushing
Starter idle g~ar
Fork claw thickness
'6.983 '6.99410.6686 - 0.669')
23.959 - 23.980 (0.9433 - 0.9441)
21.959 - 21.980 (0.8645 0.8651)
16.983 - 16.994 (0.6686 - 0.6691)
4.93 5.00 (0.194 0.197)
+ .'c,:6C;.97 (0.668)
23.94 (0.943)
21.94 (0.864)
16.97 (0.668)
4.8 (0. 19) ~
13
L
shih fork shah r Shlh fork I.D.
Fork shah 0.0.
11.035 - 11.056 (0.4344 0.43~S~3)~~
10.983 - 10.994 (0.4324 - 0.4328)
11.065 (0.4356)
10.973 (0.4320)

TORQUE VALUES
Primary drive gear bolt 64 N·m (6.5 kgf·m, 47 Ibf·h)
Countershah bearing set plate screw 9.8 N·m (1.0 kgf·m, 7Ibf·h) Apply a locking agent 10 the threads
Gearshih drum bearing set plate bolt 9.8 N·m (1.0 kgf·m, 7 Ibf·h) Apply a locking agent to the threads
Drive sprocket bolt 31 N'm (3.2 kgf·m, 23 Ibf·h )

10-3
CRANKCASE / CRANKSHAFT/TRANSMISSION
TOOLS
Universal holder Crankcase puller Assembly tool shaft
07725-0030000 07937-4300001 07965- 1660200

I
or 07937-4300000 with
Bolt, 6 mm: 07PMC-KZ40100 I
or use two 6 x 100 mm boils

I
~
Assembly collar Thread adaptor Assembly collar
07965-1660302 07965-KA30000 07965-VM00100

\
I

9
Not available in U.S ,A.
or 07965-' 660300
or 07965-1660301
or 07965· 166030A (U.S.A. only)

Threaded shaft Universal bearing puller Gear holder

07965·VM00200 07631·0010000 07724·0010200

or 07931·ME4010B and or equivalent commercially avail- or 07724-001A200 (U.S.A. only)

07931·HB3020A (U.s.A. only) able in U.S.A.

10-4
 CRANKCASE/CRANKSHAFT/TRANSMISSION
Bearing remover, 17 mm Remover handle Remover weight
07936-3710300 07936-3710100 07741-0010201

or 07936-3710200 or 07936-3710200
or 07936-37 1020A (U.S.A. only)

Driver Attachment, 37 x 40 mm Attachment, 42 x 47 mm

07749-0010000 07746·0010200 07746-0010300

Attachment, 52 x 55 mm Pilot, 17 mm Pilot, 20 mm

07746-0010400 07746-0040400 07746·0040500

C:)
Pilot, 22 mm Pilot, 25 mm
07746-0041000 07746·0040600

10-5
CRANKCASE/CRANKSHAFT/TRANSMISSION
TROUBLESHOOTING
Excessive noise
• Worn crankpin bearing
• Worn transmission bearing Is)
• Worn crankshaft bearing (5)
Transmission jumps out of gear
• Worn gear dogs and slots
• Bent fork shaft
• Broken shift drum stopper
• Worn or bent shift forks
• Broken shift linkage return spring
Hard to shift
• Improper clutch operation
• Incorrect transmission oil weight
• Incorrect clutch adjustment
• Bent shift fork
• Bent shift fork shaft
• Bent shift fork claw
• Damaged shift drum cam grooves
• Bent shift spindle
Engine vibration
• Excessive crankshaft (unout

10-6
 CRANKCASE/CRANKSHAFT/TRANSMISSION
CRANKCASE SEPARATION
Refer 10 page 10-3 Remove the two bolts and drive sprocket guard.
fOl the parIs whIch
must be removed
before separatmg
the crankcase

'04 Loosen the drive sprocket bolt while holding the

sprocket with the universal holder.
ii~~~~~~~~~~r'llll
TOOL:
Universal holder 07724·0030000
Remove the cone spring washer and drive sprocket.

After '04 Loosen the d rive sprocket bolt while holding the
sprocket with the universal holder.
~~~~~~~~i~~~~:~~
I
TOOL: ~
Universal holder 07724-0030000
Remove the collar, cone spring washer and drive
sprocket.

Temporarilv install the clutch outer guide, needle

GEAR HOLDER
bearing and clutch outer onto the mainshaft .
Insert the gear holder between the primary drive
and driven gear.
TOOL:
Gear holder 07724·0010200 or

the washer and drive gear.

07724·001A200
(U.S.A. only)
Remove the primary drive gear bolt, then remove

Check the primary d rive gear for wear or damage.

c
Oq
I~ i/h
"r;
~
BOLT_ __
L -_ _ _ _ WASHER

10-7
CRANKCASE/CRANKSHAFT/TRANSMISSION
Remove the clutch outer, needle bearing and outer
guide.
Remove the collar from the crankshaft.

CRANKSHAFT COLLAR
Remove the countershaft collar and O-ring.

Loosen the crankcase bolts in a crisscross pattern in

two or three steps. BOLTS
Remove the ten crankcase bolts.

Do not pry the Attach the crankcase puller to the left crankcase.
CRANKCASE PULLER
cmni::case halves Separate the right and left crankcase from each
apart With a screw- other while tapping them at several locations with a
drivel soft hammer.
TOOLS:
Crankcase puller 07937·4300001 or
07937-4300000 with
Bolt, 6 mm 07PMC-KZ40100 or
Commercially available two
6 x 100 mm bolts

10-8
 CRANKCASE/CRANKSHAFT/TRANSMISSION
'04 Remove the gaskets, dowel pins and breather hose.

After '04 Remove the gaskets, dowel pins, O-ring and

breather hose.

TRANSMISSION REMOVAL!
DISASSEMBLY
Separate the crankcase halves (page 10-7).
Remove the shift fork shafts and shift forks.
Remove the shift drum.

Remove the mainshaft and countershaft assemblies

as a set .
• Keep track of the disassembled parts (gear, bush-
ings, washers, and snap rings) by sliding them
onto a tool or a piece of wire .
• Do not remove the snap rings over the shafts,
expand the snap ring ends and slide it off the
shaft, along with the gear behind it.
Disassemble the mainshaft and countershaft.

10-9
CRANKCASE/CRANKSHAFT/TRANSMISSION
INSPECTION
GEAR/ GEAR BUSHING
Check the gear dogs, dog holders and teeth for
damage or excessive wear.
Measure the 1.0. of each gear.
SERVICE LIMITS:
M4, M5: 23.06 mm (0.908 in)
Cl : 20.06 mm (0.790 in)

6
C2: 27.06 mm (1 .065 in)
CZ, C3: 25.06 mm (0.987 in)
Check the bushings for damage or excessive wear.
Measure theD.D. and 1.0. of each bushing.
SERVICE LIMITS:
1.0.
M5: 20.04 mm (0.789 in)
Cl : 17.03 mm (0.670 in)
C2: 24.04 mm (0.946 in)
C3: 22.04 mm (0.868 in)
0 .0 .
M4, M5: 22.95 mm (0.904 in)
Cl: 19.95 mm (0.785 in)
CZ: 26.95 mm (1.061 in)
C3: 24.95 mm (0.982 in)
MAINSHAFT/COUNTERSHAFT
Check the spline grooves and sliding surfaces for
damage or abnormal wear.
M5
Measure the 0.0. of the mains haft and countershaft
at the gear and bushing sliding area.
SERVICE LIMITS:
Mainshaft:
M5 19.94 mm (0.785 in)
Countershaft
C1 bushing : 16.97 mm (0.668 in)
C2 bushing: 23.94 mm (0.943 in)
C3 bushing : 21.94 mm (0.864 in)
Starter idle gear: 16.97 mm (0.668 in)
C2 C3 C1fIOLE GEAR

SHIFT FORK
Check the shift fork for abnormal wear or deforma-
tion.
Measure the shift fork 1.0.
SERVICE LIMITS: 11 .065 mm (0.4356 in)

Measure the shift fork claw thickness.

SERVICE LIMIT: 4.8 mm (0.19 in)

10-10
 CRANKCASE/CRANKSHAFT/TRANSMISSION
SHIFT FORK SHAFT
Check the shift fork shah for abnormal wear or
deformation.
Measure the shift fork shaft 0.0.
SERVICE UMITS: 10.973 m m (0.4320 in )

SHIFT DRUM
Inspect the shih drum for scoring. scratches or evi-
dence of insufficient lubrication.
Check the shift drum grooves for abnormal wear or
damage.

TRANSMISSION BEARING
Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the crankcase.
Replace the bearings jf the race does not turn
smoothly and quietly, or if they fits loosely in the
crankcase (page 10-14).

CRANKSHAFT REMOVAL
Separate the crankcase halves (page 10-7).
Remove the transmission (page 10-9),
When removmg. Remove the crankshaft from the right crank case
Iftsra11mgand using a hydraulic press as shown.
msp6CMg {he
crankshafr, be care-
ful nor 10 damage
Of nICk the hollow

crank we/gilt
CRANKCASE/CRANKSHAFT/TRANSMISSION
If the crankshaft bearing is removed with the crank-
UNIVERSAL BEARING PULLER
shaft, remove the bearing using the bearing puller
and discard the bearing .

TOOL:
Universal bearing puller 0763'-0010000 or
equ ivalent com-
merciallyavail-
able in U.S.A.

INSPECTION
Place the crankshaft on a stand or V-blocks.
Set the dial indicator on the main journal.
Rotate the crankshaft two revolutions and read the
funout.
SERVICE LIMIT: 0.05 mm (0.002 in)
o

36 mm (1.4 in) 19 mm (0.7 in)

I I
Measure the connect ing rod big end axial/radial
play.
SERVICE LIMIT: 0.032 mm (0.0013 in )

Measure the connecting rod big end side clearance.

SERVICE LIMIT: 0.9 mm (0.04 in )

10-12
 CRANKCASE/CRANKSHAFT/TRANSMISSION
CRANKCASE BEARING REPLACEMENT
CRANKCASE BEARING/OIL SEAL LOCATION

RIGHT CRANKCASE SIDE:

CRANKSHAFT OIL SEAL

MAINSHAFT COUNTEASHAFT SHIFT DRUM

CRANKSHAFT BEARINGS BEARINGS BEARINGS BEARINGS

\
CRANKS HAFT OIL SEAL
CLUTCH LEVER
~UNTERS~H:A~~~======~13::Gt::dV
OIL SEAL
NEEDLE BEARING
CLUTCH LEVER
OIL SEAL SHIFT SPINDLE
OIL SEAL
LEFT CRANKCASE SIDE:

CRANKSHAFT BEARING
Remove the crankshaft oil seals and bearings from
both crankcase halves.

Dflve the newbesr- Drive new crankshaft bearings into both crankcases
mgs In squarely using the speciallools as shown.

TOOLS:
Driver 07149·0010000
Attachme nt. 52 )( 55 mm 07746-0010400
Pilot. 22 mm 07746-0041000

10-13
CRANKCASE/CRANKSHAFT/TRANSMISSION
TRANSMISSION BEARINGS
lEFT CRANKCASE
Remove the ccuntershah oil seal.

Remove the screws and countershaft bearing set

plates.
Remove the countershaft bearing and shift drum
bearing.

Remove the mainshaft bearing using the special

tools as shown.

TOOLS:
Bearing remover, 17 mm 07936·3710300
- Remover handle 07936·3710100
- Remover weight 07741-0010201 or
07936·3710200 or
07936-371020A
(U.S.A .only)

Drive In the new Drive new bearings into the left crank case using the
beaFings squarely special tools.
TOOLS:
Shift drum bearing:
Driver 07749·0010000
Attachment, 37 x 40 mm 07746-0010200
Mainshaft bearing:
Driver 07749·0010000
Attachment, 37 x 40 mm 07746·0010200
Pilot, 17 mm 07746-0040400
Countershaft bearing:
Driller 07749-0010000
Attachment, 42 x 47 mm 07746·0010300
Pilot, 22 mm 07746-0041000

10-14
 CRANKCASE/CRANKSHAFT/TRANSMISSION
Clean and apply a locking agent to the countershaft
bearing set plate screws and tighten the screws with
the set plate.
TORQUE: 9.8 N·m 11 .0 kgf·m , 7 Ibf.ft)

Apply grease to the new countershaft oil seal lips.

Install the countershaft oil seal untit the seal flush
with the crankcase as shown.

RIGHT CRANKCASE
Remove the mainshaft and countershaft bearings.
Remove the shift drum bearing set plate bolts and
sel plates.
Remove the shift drum bearing .

Drive new bearings into the right crankcase using

the special tools as shown.

TOOLS:
Shift drum bearing :
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 25 mm 07746-0040600
Mainshaft bearing:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Countershaft bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, l' mm 07746-0040400

10-15
CRANKCASE/CRANKSHAFT/TRANSMISSION
Clean and apply a locking agent to the shift drum
bearing set plate bolts and tighten the bolts with the
set plate.
TORQUE: 9.8 N ·m (1.0 kgf·m , 7 Ibf.ft)

CRANKSHAFT INSTALLATION
Clean both crankcase mating surfaces before
assembling and check for wear or damage .
• If there is minor roughness or irregularities on
the crankcase mating surfaces, dress them with
an oil stone .
• After cleaning. lubricate the crankshaft bearings
with recommended clean 2-stoke oil.

Install the threaded adaptor onto the crankshaft.

TOOL: \:}>: >':J

Thread ada pter 07965·KA3 0000 « \ (

, {"
.~ . ~ l',
,~~
THREAD ADAPTER :;.--- ~
InSlall the crankshaft into the right crankcase using
the special tools.
~=================
TOOLS:
A ssembly too l shaft 07965· 1660200
Assembly collar 07965· 1660302 or
07965· 1660301 o r
07965-1660300 o r
07965-166030A
(U.S.A.onIV)

ASSEMBLY TOOL

10-16
 CRANKCASE/CRANKSHAFT/TRANSMISSION
TRANSMISSION ASSEMBLY /
INSTALLATION
ASSEMBLY
NOTE :
• Check the gear freedom of movement or rotation
on the shaft.
• Install the washers and snap rings with the
chamfered edge facing the thrust load side.
• Do not reuse worn snap rings which could easily
spin in the grooves.
• Check that the snap rings are seated in the
grooves. Align their end gaps with the grooves of
the spindle.
MAINSHAFT:

MAINSHAFTlMI GEAR (13T)

SNAP RING

SNAP RING

M5 BUSHING

SPLI NE WASHER

M4 BUSHING

10-17
CRANKCASE / CRANKSHAFT/TRANSMISSION
COUNTERSHAFT:

C1 GEAR (30T)
C1 BUSHING
THRUST WASHER

SNAP RING
SPLINE WASHER
C3 BUSHING

C3 GEAR (26T) ~

THRUST WASHER ~~

~ COUNTEASHAFT

C4 GEAR (221)

C2 BUSHING
THRUST WASHER C2 GEAR (28T)

Apply transmission oil to the following parts:

MAIN5HAFT
- mainshaft
- countershah
- each gear
- mainshaft bearing
- countershaft bearing
- shift drum bearing

INSTALLATION
Engage the mainshaft and countershaft gears and
TRANSMISSION ~SSEr~BI_~
place the transmission assembly into the right
crankcase.

10-18
 CRANKCASE/CRANKSHAFT/TRANSMISSION
InslaH the shift forks into the shifter gear grooves.
IDENTIFICATION MARKS
• Each shift fork has an identification mark, "R"
(three marks) is for the right shift fork, "l " is the
left shift fork and · C· is for the cenler shift fork.
• Face the shift fork marks as toward the left crank-
case.

ApplV molybdenum oil solution to the following

parts:
- shift drum guide grooves
- shift fork claws and guide pins
- shift fork sliding surfaces
- shift fork shaft
Install the shift forks to the grooves of the shifter
gear.
install the shift drum by aligning the guide pins on
the shift forks with the guide grooves of the shift
drum.
Slide the shift fork shafts through the shift forks,
and inlO the crankcase.

CRANKCASE ASSEMBLY
NOTE
• Before assembly, lubricate the transmission
bearings with clean transmission oil.
'04 Clean off any gasket material from the crankcase
mating surface.
Install the dowel pins and new gaskets,
qI
Install the crankcase breather hose onto the left GASKETS
crankcase.

DOWEL PINS

After '04 Clean off any gasket material from the crankcase
mating surface.
Install the dowel pins, new gaskets and new D -ring.
Install the crankcase breather hose onto the left
....
~ O-RING GASKETS

11!
crankcase.

10-19
CRANKCASE/CRANKSHAFT/TRANSMISSION
Place the left crankcase onto the right crankcase
using the special tools as shown.
ASSEMBLY TOOL

TOOLS:
Assembly tool shaft 07965· 1660200
Assembly collar 07965· 1660302 or
07965, '660301 or
07965-1660300 or
07965· 166030A
(U.S.A.onlv)

Pack grease inlO the cavity between the oil seal lips.
lEFT CRANKSHAFT RIGHT CRANKSHAFT
Press the oil seals into the crankcase using the OIL SEAL OIL SEAL
crankcase assembly tool until seals are flush with

~
the case as shown.
TOOLS:
left crankshaft oil seal:
Assembly tool shaft 07965· 1660200
Assembly collar 07965· 1660302 or
07965· 1660301 or
07965-1660300 or
07965·166030A
(U.S.A. only)
Right crankshaft oil seal:
Threaded adaptor 07931· KA30000
Assembly collar 07965·VM00100
Assembly shaft 07965-VM00200
U.S.A.only:
Threaded adaptor, 07VMF·HM8010A
10 x 12.5 - 16 x 1.5
Assembly collar 07965-VM00100
Assembly shaft 07931·ME4010B
Special nut 07931-HB3020A
Tighten the crankcase bolts in a crisscross pattern in
two or three progressive steps. BOLTS
Carefully trim the protruding gasket material from
the cylinder bas gasket surface.
NOTE
• Do not let gasket material fall into the crankcase .
• Do not damage the cylinder base gasket surface.
Check that the crankshaft turns smoothly.

10-20
 CRANKCASE/CRANKSHAFT/TRANSMISSION
Coat the countershaft O-ring and the inside of the
counters haft collar with grease.
Install the O-ring and coliar onto the countershaft.

"04 Install the drive sprocket onto the countershaft with

its flat side facing Dul. FLAT SIDE
Install the cone washer with the "OUT SIDE" mark
facing out.
Hold the drive sprocket with the universal holder
and install and tighten the sprocket boll to the spec-
ified torque.
TOOL:
Universa l holder 07724-0030000

TORQUE: 31 N-m (3.2 kgf·m, 23 Ibf-ft )

WASHER

After '04' Install the drive sprocket onto the countershatt with
its flat side facing out. FLAT SIDE
Install the cone washer and collar with the "OUT
SIDE" marks facing out.
BOLT
Hold the drive sprocket with the universal holder
and install and lighten the sprocket bolt to the spec-
ified torque.
TOOL:
Universal holder 07724-0030000

TOROUE: 31 N·m (3.2 kgf.m, 23 Ibf·ft)

COLLAR

Install the drive sprocket guard and tighten the

bolts.

10-21
CRANKCASE/CRANKSHAFT/TRANSMISSION
Install the collar ont o the crankshah.

CRANKSHAFT COLLAR

Inslall the primary drive gear, bolt and washer.

Temporarily install the clutch outer guide, need le

bearing and clutch outer guide.
Attach the gear holder between the primary drive
and driven gear.
TOOL:
Gear holder 07724·0010200 or
07724·001A200
(U.S.A. only)
Tighten the primary d rive gear bolt to the specified
torque.
TORQUE: 64 N·m (6.5 kgf·m , 47 IbHtl
GEAR HOLDER

Refer to service
mformatlOn (page
Install the remai ning parts in the reverse order of
removal.
L~"r.;r.;;;;iil=--:-;;;;;'~;;;;~irl
10-3) for Installa·
Start the engine and check for leaks from the
(Ion of pans
inspection hole.
removed to per·
form CTankcase!
transmiSSIOn S8T-
.<e

10-22
 11. FRONT WHEEL/SUSPENSION/STEERING

COMPONENT LOCATION ····· .. ···················· "-2 FORK ...................................................... ····· " -'2

SERVICE INFORMATION ............................ "-3 HANDLEBAR ··············································· "-27

TROUBLESHOOTING .................................. "-6 STEERING STEM ········································ " -34

FRONT WHEEL ............................................ "-7

11-1
FRONT WHEEL/ SUSPENSION / STEERING
COMPONENT LOCATION
1.2 N-m (0,12 kgf·m, O.9IbHt)

22 N·m (2.2 kgf·m, 16 Ibf.ft)

108 N·m ('1.0 kgf·m, 80 Ibf.ft) 29 N·m (3.0 kgf·m,

22 Ibf.ft)

23 N·m (2.3 kgf·m, 17 Ibf.ft)

44 N·m (4.5 kgf·m,

331bUt) 928 12.9
e::>
N·m
21 IbOt)
kgf·m,

i/
/ /
/ /
Ii
6.9 N·m (0.7 kgf·m,
5.1 Ibf·ftl
~~
~::::=i=tMb===~- 3Q N·m (3.1 kgf·m,
Ibf·tt)

88 N'm (9.0 kgf·m, 65 IbOt)

54 N·m (5.5 kgf·m, 40 Ibf.ft)

13 N·m (1.3 kgf·m, 9Ibf·ft)

11-2
 FRONT WHEEL/SUSPENSION / STEERING
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the front wheel, fork and steering stem.
• When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist.
• A contaminated brake disc or pad reduces Slopping power. Oiscard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• Optional lighter and heavier than standard springs are available. Refer to General Information (page '·25) for details.
• For optimum for performance, the fork should be completely disassembled and cleaned after the first 3 hours of riding.
Thereafter it should be disassembled and cleaner on a regular basis to ensure maximum performance and service life
from the internal parts.
• Refer to page 13-3 for brake system information.

SPECIFICATIONS
Unit: mm (in)
ITEM ~. STANDARD SERVICE LIMIT
I Cold tire pr:~'~'~,"~'~',--__ _ _ _ _ _ _~
----'100 2
kPa (1.0 kgf/cm , 14 psi)
C Axie runout 0.20 (0.008) 1
T R~~d~"if'========-~~ j
I
Wheel rim runout
_-;""=-:e:",,,
r Ax=,,"-'
Wheel hub-to-tim distance
Fork
,,~~!"'~"===---~+tlI 27.25
Spring free length
r-Tube runout
(1.073)
476.0 (18, . 7,~4~1___
-
t - 2.0 (0.08fil_ _ _
__~'c2.c"0(0.08)
473 (18.6j
-;;:=;o;-_4____0~.2~(0,011
Recomm~'~O~d~'~d~f~O~'k'f"'"~;~d'----JJPro Honda HP Fork Oil 5W o r equiva-
lent __ -+_
~
FIUid level 71 (2,S) I

_
Fluid capacity 462 ± 4cm 1
~~',!"~t§i'==::t~~(15.6 ± 0. 14 US OZ, 16.3 ± 0.14 Imp oz)
Compression damping adjuster sta_~dard position 15 cl ides out from full in
--~
I
- 1 .:-:==:=::=---1
1

t
_ Rebound damping adjuster standard position 6 clicks out from full in _ _ _~._ _ _

TORQUE VALUES
Front brake hose guide bolt 4.9 N·m (0.5 kgf'm, 3.6 Ibf·h)
Front axle nut 88 N·m (9.0 kgf·m, 65 tbf·h)
Front axle holder bolt 20 N·m (2.0 kgf'm, 14 Ibf.ft)
Front spoke nipple 3.9 N'm (0.4 kgf·m, 2.9 Ibf·ft)
Front rim lock 13 N·m (1.3 kgf'm, 9 IbUt)
Front brake disc nut 16 N·m (1.6 kgf'm, 121bHt)
Handlebar upper holder bolt 22 N·m (2.2 kgf'm, 16Ibf.ft)
Handlebar lower holder nut 44 N·m (4.5 kgf'm, 33 lbf.ft) U-nut
Steering stem nut IDS N'm (11.0 kgf.m, SO tbf.fO
Steering stem adjusting nut 6.9 N·m (0.7 kgf'm, 5.1 Ibf,h)
Fork tube top pinch bolt 23 N·m (2.3 kgf'm, 17 Ibf·ftl
Fork tube bottom pinch bolt 20 N·m (2.0 kgf'm, 14 IbUt)
Fork cap 29 N·m (3,0 kgf·m, 22 Ibf·ft)
Fork cap lock nut 2S N·m (2.9 kgf'm, 21 Ibf·ft )
Fork center bolt 54 N·m (5.5 kgf'm, 40 Ibf·ft) Apply a lodeing agent to the threads
Fork protector mounting bolt 6.9 N'm (0,7 kgf'm, 5.1 Ibf·h) Apply a locking agent to the threads
Front brake disc cover bolt 13 N·m (1.3 kgf'm, 9Ibf,ft)
Fork air pressure release screw 1.2 N'm (0.12 kgf'm, 0,9Ibf.ft)
Clutch lever pivot bolt 2.0 N'm (0,2 kgf'm , 1.4 Ibf·ft)
Clutch lever pivot nut 9.S N·m (1.0 kgf·m, 7 Ibf·ft)
Clutch lever bracket holder bolt 8.8 N'm (0,9 kgf·m, 6.5 Ibf,h)
Front master cylinder holder bolt 9.8 N·m (1.0 kgf'm, 7Ibf,h)
Throttle housing cover screw 2.0 N·m (0.2 kgf'm, 1.4 Ibf·ft)
Throttle housing mounting bolt 8.8 N·m (0,9 kgf·m, 6.5 Ibf·h)
Engine slop bunon screw 2.0 N·m (0.2 kgf·m, 1.4 Ibf·ft)
Front brake caliper mounting bolt 30 N·m (3.1 kgf'm, 22 Ibf·ft) Apply a locking agent to the threads.

11-3
FRONT WHEEL/ SUSPENSION/STEERING
TOOLS
! sPOke wrench, 5.8 x 6.1 mm - rBearing remover shaft Bearing remover head, 20 mm
I Oh01-0020300 I ()7746-0050100 07746-0050600

or equivalent commercially avail-

able in U.S.A.

Driver Attachment, 37 x 40 mm Pilot, 20 mm

07749-0010000 07746·0010200 07746-0040500

Fork rod holder handle Fork seal driver, 46 mm Ball ra ce remover

070MB·KSR0100 07YMD·MAC0100 07946·3710500

(not available in U.S.A.) or 07TMD·MAC010A (U.SAonly)

Driver Attachment, 28 x 30 mm Bearing race installer

07949·3710001 07946-1870100 07VMF--KZ30100

GJ
~qu;,_ed _ _ _

11-4
 FRONT WHEEL/SUSPENSION/STEERING
InstaUer shah Steeri ng stem socket Adjustable pin spanner wrench
07VMF-KZ30200 07916-3710101 07702-0020001 (U.S.A. only)

Holder handle
07TMB-Q01010A
,

11-5
FRONT WHEEL/SUSPENSION/STEERING
TROUBLESHOOTING
Hard st eering
• Steering stem adjusting nut too tight
• Faulty or damaged steering head bearing
• Insufficient tire pressure
Steers to one side or does not track straight
• Bent fork
• Bent front axle
• Wheel installed incorrectly
• Unequal oil quantity in each for tube
• Faulty steering head bearings
• Bent frame
• Worn wheel bearings
• Worn swingarm pivot components
• Unevenly adjusted right and left fork legs
Front wheel wobbling
• Bent rim
• Worn front wheel bearings
• Bent spokes
• Faulty tire
• Axle not tightened properly
• Unbalanced tire and wheel
Front wheel hard to turn
• Faulty wheel bearings
• Bent front axle
• Brake drag
Soft suspension
• Insufficient fluid in fork
• Fork oil viscosity too high
• Weak fork spring
• Tire pressure too low
Stiff suspension
• Excess fork fluid
• Fork fluid viscosity too thick
• Bent or damage for tubes
• Clogged fork fluid passage
Suspension noisy
• Insufficient fluid in fork
• Loose fork fasteners

11-6
 FRONT WHEEL/SUSPENSION / STEERING
FRONT WHEEL
REMOVAL
Remove the bolts and front brake disc cover.
DISC COVER \j
~

Support the motorcycle using a safety stand or hoist

under the engine.
Remove the axle nut.
Loosen the left axle holder bolts.

loosen the right axle holder bolts and pull out the
axle.
Remove the front wheel assembly.

INSPECTION
AXLE
Sel the axle in V-blocks.
Turn the axle and measure the runout using a dial AXLE

\
indicator.
Actual runcut is 112 of the total indicator reading.
SERVICE UMIT: 0.20 mm (0.008 in )

11-7
FRONT WHEEL/SUSPENSION/STEERING
WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly,
Also check that th e bearing outer race fits lightly in
the hub.
Replace the bear· Remove and discard the bearings if they do not turn
lOgs In pairs smoothly, quietly, or if they fit loosely in the hub.

WHEEL BEARING

WHEEL RIM
Check the rim runout by placing the wheelan a r------------------~

turning stand.
Then rotate the wheel by hand, and read the runout
using a dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS:
Radial: 2.0 rnm (0.08 in)
Axia l: 2.0 rnm (0.08 in)
Check the spokes and tighten any spoke nipple.

OISASSEMBL Y
Remove the right side collar and dust seal.

Remove the left side collar and dust seal.

Remove the brake disc bolts and nuts.
Remove the brake disc.

11-8
 FRONT WHEEL/SUSPENSION/ STEERING
Install the bearing remover head into the bearing. riiEMCIVER
From the opposite side, install the bearing remover
shah and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS :
Bearing re move r head, 20 mm 07746-0050600
Bearing remover shaft 07746·0050100

Replace the bearing Never install the oil bearings; once the bearings
In pairS have been removed, they must be replaced wit new
ones.

ASSEMBLY

16 N·m (1.6 kgf·m, 12Ibf.ft)

RIGHT WHEEL BEARING

RIGHT SIDE COLLAR!

DUST SEAL CAP

~ DUST SEAL

BRAKE DISC

. .-.
DUST SEAL

DISTANCE COLLAR

LEFT SIDE COLLAR

LEFT WHEEL BEARING

Place the rim on the work bench.

Place the hub with the disc side down and begin lac-
ing with new spokes. 27.25 mm
Adjust the hub position so that the distance from (1.073 in)
the hub left end surface to the side of rim is as
shown.
STANDARD: 27.25 mm 11.073 in)

11-9
FRONT WHEEL/SUSPENSION/STEERING
Torque the spokes in 2 or 3 progressive sleps.
SPOKE
TOOL:
Spoke wrench, 5.8 )I 6.1 mm 07701-0020300 or
equivalent com·
mercially avail-
able in U.S.A.

TORQUE: 3.9 N'm (0.4 kgf-m . 2.9 Ibf.ft)

q p n
~ SPOKE WRENCH
Install the rim lock, rim band, lube and lire.
SETIING RUBBER VALVE
Torque the rim lock to the specified torque.
TORQUE: 13 N-m (1.3 kgf-m , 9 Ibf.ft)

VALVE NUT

TUBE

Pack the new bearing cavi t ies with grease.

Replace the wheel Drive in a new left wheel bearing squarely into the
bearmgs In palfS hub using the special tools as shown.
Do (Jor rellse old
bearmgs
TOOLS:
Driver 07749-0010000
Attach ment, 32 x 35 mm 07746·0010100
Pilot, 15 mm 07746-0040300
Install the distance collar into place, then drive the
right wheel bearing using the same special 10015.

Pack the right dust seal lip with grease and install it
into the right wheel hub.

11-10
 FRONT WHEEL/SUSPENSION / STEERING
Install the brake disc onto the left wheel hub with its
"DRIVE" mark facing out.
Clean and apply a locking agent to the brake disc
bolt threads.
Install the brake disc bolts and nuts. then tighten the
nut to the specified torque.
TORQUE: 16 N ·m (1.6 kgf.m , 12 Ibf·ft)
Pack the left dust seal lip with grease and install it
into the left wheel hub.

Check the right and left wheel collars for wear or ~:~~~~~~:
damage.
Install the right and left wheel collars to the wheel
as shown.

INSTALLATION
Clean the clamping surface of the axle shaft and
axle holders.
Install the front wheel between the fork legs.
Fit the caliper over the disc, taking care not to dam-
age the brake pads.
Apply a thin layer of grease to the axle and insert
the axle from the right side.

Install and tighten the axle nut to the specified

torque.

TORQUE: 88 N 'm (9.0 kgf·m , 65 Ibf.ft)

Tighten the left axle holder bolts to the specified
torque.
TORQUE: 20 N 'm (2.0 kgf.m , 14 Ibf·ft)

11-11
FRONT WHEEL/SUSPENSION/STEERING
With the front brake applied, pump the front sus-
pension up and down several times to seal the axle
and check the front brake operation,

Be sure the fork legs are parallel, then tighten the

right axle holder bolts to the specified torque.

TORGUE: 20 N -m (2.0 kgf·m, 14 IbUt)

Install the front brake disc cOlier.

Install and tighten the front brake disc cover bolts to
the specified torque.
TORQUE: 13 N·m (1.3 kgf·m . 9 Ibl·ftl

FORK
REMOVAL
Remove the f ront wheel (page 11-7).
Do nor operate rhe Remove the brake caliper (page 13-17).
/)rake lever she'
Remove the bolts and brake hose guide.
removmg the c811-
Remove the brake caliper mounting bolts and brake
per and fronl
caliper.
wheel. To do SO wrll
CBuse diffICulty In Remove the bolts and fork protector.
f,ttmg rhe brake
disc belwBfHl the
brake pad

11-12
 FRONT WHEEL/ SUSPENSION / STEERING
Loosen the fork top bridge pinch bolts.

When the fork is ready to be disassembled. remove

the handlebar and loosen the fork cap. but do not
remove it.
NOTE ·
• Do not use a crescent or adjustable wrench to
loosen the fork cap; they could be damaged .
• When disassembling the fork leg. record the
number of clicks to hardest position, then turn
the rebound adjuster and compression adjuster
counterclockwise to the softest position to pre·
vent damage to the needle.

Loosen the fork bottom pinch bolts and pull the fork
leg down and out.

DISASSEMBLY
Be careful nollO Clean the fork assembly, especially the sliding sur-
serif/eh the slider face of the fork slider and bottom of the slider FORK CAP

/
and no/ to damage around the center bolt before disassembling the
the dust seal fork.
Hold the outer tube, remove the fork cap from the
outer tube.

OUTER TUBE

11-13
 FRONT WHEEL/ SUSPENSION / STEERING
Slider the outer tube down to the dust seal on the
axle holder. DUST SEAL

AXLE HOLDER

Hold the lock nut and remove the fork cap from the
damper rod. CAP

NUT

Remove the spring seat and fork spring.

SPRING SEAT

I NOTICE
When the fork cap is removed from the damper rod,
the slider can move up and down freely on the outer
tube. Always hold both the outer tube and slider
with your hands after removing the fork cap. or the
guide and slider bushings might be damaged.

11-14
 FRONT WHEEL/SUSPENSION / STEERING
Remove the distance collar, lock nut, spring guide
and D-ring . LOCK NUT DISTANCE COLLAR

~r
SPRING GUIDE

/'
D-RING

Remove the partition plate.

Pou r out the fork fluid from the fork leg bV pumping PARTITION PLATE I
the fork eight or ten t imes.

To avoid damaging the dust seat, lower the outer , -- - - - - - - - - -- - - -----,

tube gently onto the axle holder. FORK DAMPER HOLDER
Anach the fork damper holder to the fork damper as
shown.
TOOL:
Fork damper holder 070MB·KSR0100
(not available in
U.S.A.)

U.S.A . TOOLS:
Holder handle 07TMB·001010A
Fork rod holder attachment, 22 mm
07AMB·KSRA100

Do not oveN/gillen
the 8xle holder
Set the lower end (axle holder) of the slider in a vise
w ith a piece of weod or soft jaws to avoid damage.
:=================~
FORK DAMPER HOLDER
Hold the fork damper holder and loosen the center
bolt.
Remove the center bolt and sealing washer.
CENTER BOLT

11-15
FRONT WHEEL/ SUSPENSION / STEERING
Remove the fork damper from the slider.
FORK DAMPER
Cover the damper end orifice with thumb while
pumping out fork oil to prevent oil from exiti ng
through the end passage .

Be careful not /0 Remove the dust seal and SlOp ring.

scratch the slider
Check that the slider moves smoothly in the outer
tube.
If it does not, check the slider for bent or damage,
and the bushings for wear or damage.
If the slider and bushings are normal, check the
outer tube .

STOP RING

DUST SEAL

In quick successive motions, pull the slider QuI of

the outer tube.

Do not damage the Carefully remove the slider bushing by prying the
slot with a screwdriver until the bushing can be Oil SEAL
Slider bushing.
especlill/y the slid- pulled off by hand. DUST
mgsurface Topt&-
Remo ve the following:
vent loss of
tenslOfl. do nor - guide bushing
open rhe bush'ng - back·up ring
more rhan neces- - oil seal
sary - stop ring
- dust seal

BACK· UP RING

11-16
 FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
FORK CAP
Check that the D-ring on the fork cap is in good con -
diton. FORK CAP

D-RING

FORK CENTER BOLT

Check the for center bolt for damage.
Replace the O-rings and sealing washer with a new CENTER BOLT

\
one.
Measure the fork spring free length .

eI SEALING WASHER

SUDER/ OUTER TUBE

Check the slider for score marks, scratches and
excessive or abnormal wear. OUTER TUBE
Check the outer tube for damage or deformation.

FORK SLIDER

Inspect the wear ring for wear or damage.

WEAR RING
Install the wear ringReplace the wear ring. if it is w ithin 1.5 mm (0.06 in)
securely in the pro- of the protector guide.
tector groove
I NOTICE
The outer tube can move up and down freely on the
slider. Always hold the slider and fork rube with
your hands, or the guide and slider bushings might
be damaged.

11-17
FRONT WHEEL/SUSPENSION/STEERING
Sel the slider in V-blocks and measure the fork
slider runout by rotating it with a dial indicator.
Actual runout is 112 the to tal indicator reading .
SERVICE LIMIT: O.20mm (0.008 in )

Do nor reuse the Replace if the service limit is exceeded, or there are
slider If It IS bent. scratches or nicks that will allow fork oil to leak past
the seals.

Fo rk spri ng
Measure the fork spring free length by placing on a
flat surface.

SERVICE LIMIT: 473 mm (18.6 in )

SPRING GUIDE
Check the spring guide for wear or damage.
SPRING GUIDE

/
BUSHING/BACK·UP RING
Check the bushings for excessive wear or scratches. 1
If copper appears on the entire surface, replace the
bushings. BUSHING
Replace the back-up ring if there is distortion at the
points shown . BACK-UP RING
Remove any metal powder from the slider and :,' -"
guide bushings with a nylon brush and fork ffuid.
- r@ @
'- 0 V
CHECK POINTS

COPPER SURFACES

11-18
 FRONT WHEEL/SUSPENSION/STEERING
FORK DAMPER
Check the damper rod of the damper for bend, wear
or damage. FORK DAMPER STOP RINGS

/
Check the bladder and stop rings for damage.

BLADDER
DISTANCE COLLAR
Check the distance collar for bend, wear or damage.

ASSEMBLY

DISTANCE COLLAR
OUTER TUBE FORK CAP
29 N'm {3.0
f / kgf·m, 22lbf·ft)

~_ _ _ O-RING
FORK SLIDER
~ SPRING SEAT

K
~LOCKNUT 28 N·m {2.9 kgf·m,
WEAR 21 IbHt)
RING

~
o
SUDER
BUSHING

e
_ SPRING GUIDE
\ ~ GUIDE
BUSHING II
~
!I~
BACK-UP:
RING ~ Oil SEAL

LJ
S~~USTSEAL
FORK SPRING

FORK DAMPER
CENTER BOLT
54 N·m (5.5 kgf·m, 40 Ibf·ft)

11-19
FRONT WHEEL/ SUSPENSION/STEERING
Before assembly. wash all parts with a high flash or
non-flammable solvent and wipe them dry. TAPE

Wrap the end of the slider with tape.

Coat the new oil seal lips with fork fluid .
Ins/all the 011 seal - dust seal
WI//) .rs marked - stop ring
Side facmg the dust - oil seat
seal

OIL

Remove the tape from the end of slider.

BACK·· UP RING
Remove the burrs Install the following onto the slider.
from the bushing SLIDER BUSHING
- back-up ring
rakmg care no /0
- guide busing
peel of Its coatrng
- slider bushing

RING

OIL SEAL

Coat the slider and guide bushings with the recom-

mended fork fluid and instatl the slider into the
outer tube.

Drive the guide bushing together with the back-up

ring and oil seat into the outer tube, using the spe- DUST SEAL

I
cial tool.

TOOL: STOP RING

Fork sea l driver, 46 mm OTMO-MAC0100 or
07TMD· MAC010A
OIL SEAL
(U.S.A.only)
BACK·UP
RING

GUIDE BUSHING

11-20
 FRONT WHEEL/ SUSPENSION / STEERING
Install the stop ring to the groove of the slider.
Install the dust seal.

To avoid damaging the dust seal, lower the outer

tube gently onto the axle holder, DUST

NOTICE
The outer tube can move up and down freely on the
slider. Always grip both the outer tube and slider
with your hands, or the guide, bushings and dust
seal might be damaged.

AXLE HOLDER
Ifyou removed the bladder from the fork damper,
measure the full length of bladder.
r~=~==~:':::::'~::==~~=--~=...l
BLADDER
If the full length is under the service limit, replace
with a new one. \ ,
c
SERVICE LIMIT: 387 mm (15.2 in )
II r

II
'lI
Apply fork fluid to the bladder lips.
Install the bladder aligning the lips on the bladder !1IJ! RINGS
STOP
.......
with the grooves on the fork damper.
Check the bladder is not twisted.
Install the new six stop rings securely.
o
o
o

BLADDER

11-21
FRONT WHEEL/SUSPENSION / STEERING
Install the fork damper into the outer lube.
OUTER TUBE

Coat the O-ring of the center bolt with the recom -

mended fork fluid.

CENTER BOLT
00 not overttghten Hold the axle holder in a vise with a piece of wood , -- - -- - - - -- -- - - - - - - ,
ths81fiBholder or soh jaws. DAMPER HOLDER
Apply a locking agent to the center bolt threads.
Install the center bolt with a new sealing washer.
Attach the fork damper holder to the fork damper as
shown .
TOOL:
Fork damper holder 070MB·KSR0100
(not available in
U.S.A .)

U.S.A . TOOLS:
Holder handle 07TMB·001010A
Forll: rod holder attachment, 22 rnm
07AMB·KSRA100
Tighten the bolt using the special tool as shown.
FORK DAMPER HOLDER
TORQUE: 54 N 'm {5.S kgf·m , 40 Ibf.ftJ

11-22
 FRONT WHEEl/SUSPENSION / STEERING
Ins/all the lock nut Install the distance collar into the fork damper.
wnh the threaded Install the spring guide, new O-ring and lock nut to LOCK NUT ~('STANCE COLLAR
side facmg up the fork damper and turn the lock nut by hand until
it bonoms on the damper rod.

111
SPRING GUIDE

/
I!J
----
O-RING

Pour recommended fork fluid into the damper rod

... - - - -- - -- --,
, - - - - -----C--
until the oil flows out the damper rod end.
Pour half the amount of the recommend fork fluid
into the fork leg.
RECOMMENDED FORK FLUID:
Pro Ho nda HP Fork Fluid 5W or equivalent
STANDARD FLUID LEVEL:
71 mm (2.8 in)
STANDARD FLUID CAPACITY:
~2 ± 4 cm 3 (15.6 ± O. 14 US oz. 16.3 ± 0.14 Imp o z )

Bleed the air as follows:

1. Extend the fork. Cover the top of the outer tube
with your hand and compress the fork slowly.
2. With the damper rod pushed fully in, pour the
recommended fork fluid into the rod until a lillie
flows out of the end rod.
3. Pump the outer tube and rod slowly eight or ten
times.
4. Add additional fluid up to the specified capacity
and repeat step 3.

Be sure the fluid level is the same in both fork legs.

Support the fork leg vertically and the fork is com- ROD
pressed fully whenever measuring the fluid level.

Maximum 37 mm (1.5 in) Slightly stiffer as

fluid level 499 cm 3 (16.9 US the fork nears full
capacity oz, 17.6 Imp oz) compression. OIL LEVEL
Minimum 113 mm (4.4 in) Slightly softer as
fluid level 420 cm ] (14.2 US the fork nears full
capacity oz, 14.8 Imp oz) compression.

, TUBE

11-23
FRONT WHEEL/ SUSPENSION / STEERING
Remove the lock nut and spring guide.
PARTITION
Install the partition plate.
Reinstall the spring guide and lock nut.

For details regarding the fluid level adjustment,

MECHANIC'S WIRE
refer to the Owner's Manual.
Attach a 600 mm (2 feet) length of mechanic's wire
to the lock nut on the damper rod. ~
Wipe off any excess fluid from fork spring, then
install it over the wire and into the slider with
tapered side facing up.
LOCK NUT ----t

FORK SPRING

Pull the mechanic's wi re up and hold the damper

rod at the damper rod. LOCK
Remove the mechanic's wire from the damper rod.
Turn the lock nut by hand until it bottoms on the
damper rod.

InSlalithe spring seat onto the fork spring.

SPFIING SEAT

11-24
 FRONT WHEEL/SUSPENSION/STEERING
Check that the fork cap O-ring is in good condition,
replace if necessary.
Screw the fork cap on the damper rod.
CAP
Hold the lock nut and lighten the fork cap to the
specified torque.
TORQUE: 28 N ·m (2.9 kgf·m, 21 Ibl·tt)

LOCK NUT

Temporarily install the fork cap in the outer tube.

FORK CAP

/
OUTER TUBE

INSTALLATION
• Overtightening the pinch bolts can deform the
outer tubes. A deformed outer tube must be
replaced.
Install the fork leg.
Tighten the bottom pinch bolts to the specified
torque.
TORQUE: 20 N·m (2.0 kgf·m, 14Ibf·ft )

Tighten the fork cap to the specified torque.

TORQUE: 29 N·m (3.0 kgf·m, 22 Ibl·tt)

11-25
FRONT WHEel/SUSPENSION/STEERING
5 TANDARD POSITION
Loosen the bottom pinch bolts.
For ease of releasing the air pressure after the forks
are installed, position the fork outer tubes so that
the pressure release screws are in from of the
rebound adjusters.
Align the top surface of the top bridge with the
index line of the outer tube.

Tighten the bottom pinch bolts to the specified

torque.

TORQUE: 20 N·m (2.0 kgf·m , 14 Ibf.ft)

Tighten the top bridge pinch bolts to the specified

torque.
TORQUE : 23 N'm (2.3 kgf·m , 17 Ibf·h )

Turn the wear ring with the end gap facing rear-
ward.

11-26
 FRONT WHEEL/SUSPENSION/STEERING
Tighten the brake hose gu ide bolts to the specified
torque. .

TORQUE: 4.9 N·m (0.5 kgf·m, 3.6 Ibf.ft)

Clean and apply a locking agent to the fork protect or
mounting bolt threads.
Install the fork protector and tighten the mounting
bolts to the specified torque.
TORQUE: 6.9 N·m (0.7 kg'·m , 5.1 Ibf.ft)
Clean and apply a locking agent to the front brake
caliper mounting bolt threads.
Install and tighten the brake caliper mounting bolts
to the specified torque. CALIPER
TORQUE: 30 N·m (3 .1 kgf·m . 22lbf.ft)
Return rebound and compression adjuster to
original position as noted during removal.
Install the front wheel {page" -" J.

HANDLEBAR
REMOVAL
Unhook the holding tab of the number plate.
NU M BER TAB HANDLEBAR PAD
Remove the handlebar pad.

Disconnect the engine stop button connectors.

CONNECTORS

11-27
FRONT WHEEL/SUSPENSION/STEERING
Remove the wire bands securing the engine stop
bunon wire. WIRE BANDS

Remove the screw and engine SlOP button.

ENGINE STOP BUTTON

Remove the clutch lever holder bolts, holder and

clutch lever bracket.

Do not disconnect Remove the front brake master cylinder, with its
tho hydraulrc hne holder, keeping it upright to prevent air from enter-
ing the hydraulic system.

11-28
 FRONT WHEEL/SUSPENSION / STEERING
If you will not disassemble the throttle housing,
remove Ihe throttle housing as an assembly as fol - THROTTLE HOUSING
lows.
loosen the throttle housing bolts, turn the handle-
bar to the left fully, then remove the throttle hous-
ing.

If you will disassemble the throttle housing, remove

the throttle housing dust cover. DUST COVER HOUSING COVER

Remove the throttle housing cover by removing the

screws. Slide the rubber protector off the throttle
cable and loosen Ihe lock nut and adjuster.
/

Remove the throttle cable rolier and cotlar.

COLLAR ROLLER
Disconnect the throttle cable and from the throttle
drum, remove the cable from the housing by
removing the lock nut and adjuster.

Loosen the throttle housing mounting bolts and

remove the throttle drum from the handlebar. THROTTLE HOUSIING

BOLTS

11-29
FRONT WHEEL/ SUSPENSION / STEERING
Remove the handlebar holder bolts, upper holders
and handlebar. BOLTS

Replace the handlebar grips as follows:

Apply Honda Bond A or Pro Honda Hand Grip
Cement (U.S.A. only) to the inside surface of the
grips and to the clean surface of the left handlebar
and throttle pipe.
Wait three or five minutes and install the grips.
Allow 'he adhesIVe Rotate the grips for even application of the adhe·
to d'"'01"an hour sive.
'before uSing ~. ~': ~ ~ .;-: ~

Align the index mark on the throttle grip flange with

the edge of the throttle drum.
Align the "S mark on the leh handlebar grip flange
with the paint mark on the handlebar.

INDEX MARK "6" MARK

INSTALLATION
Install the bushings, lower holders, washers and
handlebar holder nuts as shown (standard position). FORWARD

LOWER HOLDERS

11-30
 FRONT WHEEL/SUSPENSION/STEERING
By turning the lower holder 180 degrees, you can
install the handlebar 6 mm forward of the standard I sonTURN,
position. By installing the optional lower holder, STANDARD
HOLDER STANDARD
you can set the handlebar 3 mm (9.12 in) forward of POSITION POSITION
the standard position.
Standard: 3 mm (0.12 in) offset to rearwa rd
Standard 180 degrees turn: 3 mm (0.12 in) offset
to forward
... /
- Optional: No offset

OPTIONAL
LOWER
HOLDER
POSITION

;~~~~~o
Loosely install the handlebar and upper holders.
the lowee hoi dee out> to the specified
•
: •
I
~LO~W~E~R~H~O~L~D~E~R~S=~;·~I~;• •••• Iii.i
BUSHI N ! '

TORQUE: 44 N'm (4.5 kgf·m , 33 Ibf.ft)

Align the paint mark on the handlebar with the lop

BOLTS
of the lower holder.
Place the upper holder on the handlebar with the
punch marks facing forward.
Install and tighten the front handlebar holder bolts
first, then tighten the rear bolts.
TORQUE: 22 N·m (2.2 kgf·m , 16Ibf.ft)

If you did not disassemble the throttle housing,

place the dust cover over the throttle housing .
VIEW FROM STEERING STEM TOWARD
HANDLEBAR GRIP
I I
Align the -t::,." mark on the dust cover with the paint
mark on the handlebar.
Tighten the throttle housing upper bolt first, then
the lower bolt.

HANDLEBAR

11-31
FRONT WHEEL/SUSPENSION/STEERING
If you disassembled the throttle housing, install the
THROTTLE CABLE
throttle housing as follows:

~
Apply thin coat of oil to the sliding surface of the
throttle pipe and throttle housing .
Connect the throttle cable end to the throttle drum.

Install the throttle housing by aligning the punch

mark on the handlebar.
Tighten the upper bolt first, then the lower bolt.

Install the throttle cable roller and collar.

COLLAR ROLLER

Install the throttle housing cover and tighten the

screws to the specified torque. DUST COVEA HOUSING caVEA

TORQUE: 2.0 N ·m (0.2 kgf.m , 1,4 Ibf.ft)

/

11-32
 FRONT WHEEL/SUSPENSION/STEERING
Place the dust cover over the throttle housi ng.
Align the "1\" mark on the dust cover with the punch THROTTLE HnUSING
mark on the handlebar.
Tighten the throttle housing upper bolt first, then
the lower bolt.
TORQUE: 8.8 N·m (0.9 kgf·m, 6.5 IbU t )
Adjust the throttle grip free play (page 3-6).

BOLTS

Position and brake master cylinder on the handle-

bar.
Install the master cylinder holder with the "UP"
mark facing up and al ign the end of the holder with ...........
the punch mark on the handlebar.
"j
Tighten the master cylinder upper holder bolt first,
then the lower boll.
TORQUE: 9.8 N·m (1.0 kgf·m, 7 IbUt)

Install the clutch lever bracket and holder with the

punch mark on the holder facing up. CLUTCH LEVER BRACKET
Align the end of the holder with the punch mark on
the handlebar.
Tighten the upper bolt fi rst, then the lower bolt.
TORQUE : 8.8 N·m (0.9 kgf·m , 6.5 Ibf.ft)
Connect the clutch cable.
Adjust the clutch lever free play (page 3-17 ).

Route the engine stop button wire.

Install the engine stop button on the handlebar and ENGINE STOP BUTTON
align the end of engine stop button holder with the SCREW
punch mark on the handlebar.
Install and tighten the engine stop button screw
with the ground wi re.
TORQUE: 2.0 N·m (0.2 kgf·m, 1.4 IbUt)

11-33
FRONT WHEEL/ SUSPENSION / STEERING
Attach the engine stop button wire to the handlebar
using the wire bands. WIRE BA,ms

Connect the engine stop button connectors.

CONNECTORS

II
If ,

Install the handlebar pad.

NUMBER PLATE TAB HANDLEBAR PAD
Route the number plate tab around the handlebar
cross bar as shown.

STEERING STEM
REMOVAL
Remove the following:
- number plale (page 2-4)
- handlebar (page' 1-27)
- front wheel (page 11-7)
Remove the fender bolts, collars and washers.
Remove the front fender and brake hose guide.

11-34
 FRONT WHEEL/SUSPENSION / STEERING
Remove the steering stem nut and washer.
TOP BRIDGE
Remove the fork legs (page' 1- 12),
Remove the fork top bridge.

Remove sleering stem adjusting nut.

STEERING STEM SOCKET
TOOLS:
Steering stem socket 07916·3710101 or
Adjustable pin spanner wrench 07702-0020001

'-
ADJUSTING NUT

Remove the steering stem .

DUST UPPER BEARING
Remove the dust seal upper tapered roller bearing.
Check the head bearings, ouler races for wear or
damage.

BEARING RACE REPLACEMENT

Always rep/ace the Remove the upper and lower bearing outer races
bearings and races using the speciallools.
8S a set
TOOLS:
Ba ll race remover 07946·3710500
Driver 07949·3710001
Attachment, 28 x 30 mm 07946-1870100

11-35
FRONT WHEEL/SUSPENSION/STEERING
Install a new lower outer race, bearing race installer
and install shaft as shown. INSTALLER SHAFT
Hold the shah with a w rench, turn the installer to
instalilhe lower outer race.
TOOLS:
Bearing race installer 07VMF·KZ30100
(2 required)
Inst aller shaft 07VMF·KZ30200

fI
LOWER OUTER RACE

install a new upper o uter race, bearing race installer ~==:--=============:;

and installer shaft as shown.
Hold the shaft wi t h a wrench, turn t he installer to
install the upper ouler race.
INSTALLER SHAFT
fI
UPPER OUTER RACE
TOOLS:
Bearing race installer 07VMf-KZ30100
(2 required)
Installer shaft 07VMF· KZ30200

BEARING RACE INSTALLER

11-36
 FRONT WHEEL/SUSPENSION/STEERING
Temporarily install the stem nut to avoid damaging
the steering stem threads. DUST LOWER BEARING
Remove the lower tapered roller bearing and dust
seal from the steering stem

Install the new dust seal.

Pack the new lower tapered roller bearing with
grease.
Make sure press install the lower bearing using a hydraulic press and
only the steering special tool as shown.
slem with the
attamment
TOOL:
Attachment, 30 rnm 1.0 . 07746· 0030300

INSTALLATION

UPPER BEARING
LOWER BEARING

~
~
STEM NUT
108 N·m
111.0 kgf·m,
ea Ibf·ft)
LOWER DUST SEAL

WASHER

STEERING STEM LOWER OUTER RACE

~ All of bearing area

11-37
FRONT WHEEL/SUSPENSION/STEERING
Apply grease to all of the bearing area.
DUST SEAL UPPER BEARING
Pack the upper tapered roller bearing with grease.
Install the upper bearing into the steering stem.
Slide the steering stem into the steering head from
the bottom.
Install the dust seat.

Install the steering sl em adjusting nUl.

71ISrEEIRINIG STEM SOCKET
Tighten the steering head adjusting nut with the
steering stem sockel.
TOOl:
Steering stem socket 07916-3710101 or
Adjustable pin spanner wrench 07702-0020001
(U.S.A. only)

TORQUE: 6.9 N·m (0.7 kgf·m . 5.1 IbUt)

A",JU~!'N(j NUT

Turn the steering stem lock-ta-Iock five times to seat

the bearings, then tighten the adjusting nut again.

Inslall the following:

- number plate (page 2~41
- handlebar (page 11-27)
- front wheel (page 11-7)
Retighten the stem adjusting nut to the specified
torque.
TOOl:
Stem socket wrench 0791S-KA50100

TORQUE: 4 N·m (0.4 kgf·m , 2.9 Ibf·h)

11-38
 FRONT WHEEL/SUSPENSION / STEERING
Install the following:
STEM NUTIWASHER
- top bridge
- fork legs (page 11-25)
,
,,
- washer onto the top bridge ,
install and tigh t en the stem nut to the specified
torque.
TORQUE: 108 N'm (11,0 kgf·m , 80 Ibf.ftl

Recheck the steering stem adjustment.

Turning the bridge side-ta -side and check for

smoothness and no binding .
rBo:LT'SiCi;:~~~~~~:;'~:I~,:::
Install the brake hose g uide and tighten the beft to
the specified torque.
TORQUE: 4.9 N·m (0.5 kgf·m , 3.6 Ibf.ft)

Install the f ront fender, washers, coliars and tighten

the bolts.
Install the following:
- number plate (page 2-4)
- front wheel (page 11-11)
- handlebar (page 11-30)

11-39
MEMO
 12. REAR WHEEL/SUSPENSION

COMPONENT LOCATION ··························· 12-2 SHOCK ABSORBER ···································· 12-13

SERVICE INFORMATION ···························· 12-3 SHOCK lINKAGE ···················· ···················· 12-28

TROUBLESHOOTING ............... ................... 12-6 SWINGARM ................................................ 12-33

REAR WHEEL ··············································· 12-7

12-1
REAR WHEEL/ SUSPENSION
COMPONENT LOCATION
After '04 model shown:

44 N·m (4.5 kgf·m, 33 Ibf·h)

88 N'm
(9.0 kgf·m, 65 Ibf.ft)

44 N·m (4.5 kgf·m, 33 Ibf·ft)

3.9 N·m (0.4 kgf·m, 2.9 Ibf.ft)

52 N'm
(5.3 kgf·m , 38 110 '.n'_~_ _ _ _o.

\ 52N'm
(5.3 kgf·m, 38 Ibf.ft)

\
\
«Q,~

52 N·m (5.3 kgf·m, 38 Ibf.ft)

12 N'm (1.2 kgf·m, 9Ibf.ft)

12-2
 REAR WHEEL/SUSPENSION
SERVICE INFORMATION
GENERAL
• When servicing the rear wheel, support the motorcycle using a safety stand or hoist.
• For optimum suspension performance and linkage component service life, the swingarm and shock linkage pivot bear·
ing (along with related seals and bushings) should be disassembled, cleaned, inspected for wear and lubricated with
multipurpose grease NLGI NO.2 (molybdenum disulfide additive) every 3 races or after 7,5 hours of running.
• A contaminated brake disc or pad reduces slopping power. Oiscard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• Optional rear wheel sprockels, drive chain, shock springs and spring preload pin spanners are available. Refer to page
1-27 for detail.
• Refer to page 13-3 for brake system information.

SPECIFICATIONS
Unit: mm (in)
STANDARD SERVICE- LIMIT
ITEM
, ,====:=:_ __
Cold tire pressure 100 kPa (1.0 kg.!(cm2, 14 psi)
Axle runout 0.2010.0081 -
Wheel rim runout Radial 2.0 (0.08)
;--Axial 2.0 (0.08)
Wheel hub-to-rim distance ___-===~~,. 48.00 (1.89)
Drive d-Iain slack - - C - C25 _ 35 ii
p ="'·3I8"'"1-

;=r-
Drive chain sizeltink 010 520DMA2 - 116
Drive d-Iain slider thickness 5 (0.2)
Drive chain ten-
sioner roller 0.0.
Upper '04,
After '04:
_-===t~35 (1.4~1- = = 1
39 (1:-5)
I After
r
lOW " '04, . 25 (1.0)
'04:
---- 31 (1.2)
Shock absorber D.m~pe~,~g~.~,~p~,~e~,,~u~,~e'"
981 kPa (10.0 kgf:ci1l1:-;42 psi)
Damper compressed gas Nitrogen gas
Damper rod compressed force-l-:'~8~,,i"_ n,
kg (39.90 - 48.72 Ibf)

posit~;o~n~~====
at 10 mm compressed
- Spring direction
Spring installed
length
'04:
I
Narrow wound end of coil facing down
266.5 (;;'~0~,4~9~1~~=~
After '04~66.0 ;i0.47)
High speed compression damping adjuster standard 1-1/6 - 1-1/2 turns out from full in
~="-.--
-
~
low speed compression damping ~: 7 - 11 clicks out from full in
_ adjuster standard position
Rebound damping adjuster s."
position _
After '04:
..~n~d~'='~d~_t~'O~4~'",
After '04: f
. 8 - 12 clicks out from full in
18 - 22 clicks out from full in
20 - 24 clicks out from full in

TORQUE VALUES
Rear axle nut 127 N·m 113.0 kgf·m, 94lbf·ft) U·nut
Rear spoke nipple 3.9 N'm (0.4 kgf·m, 2.9 fbf·ft)
Rear rim lock 13 N·m ( 1.3 kgf·m, 9Ibf·ft)
Rear brake disc bolt/nut 16 N'm (1.6 kgf·m, 12 Ibf.ft)
Final driven sprocket nut 32 N·m (3.3 kgf·m, 24 Ibf·ft) U-nut
Rear wheel bearing retainer 44 N·m (4.5 kgf·m, 33 IbHt)
Swingarm pivot nut 88 N·m (9.0 kgf·m, 65 Ibf·ft)
Shock arm nut (swingarm side) 52 N·m (5.3 kgf·m. 38 Ibf.ft) U-nut
Shock arm nut (shock link side) 52 N'm (5.3 kgf·m, 38 IbHt) U-nut
Shock link nut (frame side) 52 N·m (5.3 kgf·m. 38 Ibf.ft) U-nut
Shock absorber mounting nut 44 N·m (4.5 kgf·m, 33 IbUt)
Shock absorber spring lock nut 29 N'm (3.0 kgf·m, 22 Ibf.ft)
Drive d-Iain roller bolt 12 N·m (1.2 kgf·m, 9Ibf·ft)
Drive chain guide mounting nUl 12 N·m (1.2 kgf·m, 9lbf·hl U-nut
Drive chain slider screw 3.9 N·m (0.4 kgf·m, 2.9 Ibf.ft) Apply a locking agent to the threads
Rear brake hose guide screw 1.2 N·m (0.12 kgf·m, 0.91bHtl
Shock absorber damper rod end nut 26 N·m (2.7 kgf.m, 20 Ibf·ft) Stake
Shock absorber damping adjuster 29 N·m (3.0 kgf·m, 22 Ibf·ftl Stake

12-3
REAR WHEEL/SUSPENSION
TOOLS
Spoke wrench, 6.6 mm Pin spanner Retainer wrench body
070MA-KZ30100 07702-0020001 07710-0010401

,-{

(two required)

-~j ~;;~~-0050'OO
ng
or 89201·KS6·81Q

I Reta;ne, w,eooh, 48 , 15 mm Bearing remover head, 25 mm ,emov", ,h,n

1"17VMA-KZ40100 07746-0050800

l o
0' 07HMA-KS70100 (U,S,A, only)

Driver
07749-0010000
L
Attachment, 24 x 26 mm
07745·0010700
Attachment. 42 x 47 mm
07746-0010300

- Attachment, 28 x 30 mm
07946·1870100
--l Pilot, 17 mm
07746-0040400
Pilot, 20 mm
07746-0040500

12-4
 REAR WHEEL/SUSPENSION
Pilot, 25 mm Pilot, 22 mm Pilot, 19 mm
07746·0040600 07746-0041000 07746-0041400

Attachment, 30 mm 1.0. Lock nut wrench, 20 x 24 mm Spherical bearing driver

07746-0030300 07716-0020100 07945-KA30200

M
LJ Not available in U.S.A.

Oil seal driver Slider guide, 16 mm Slider guide attachment

07TMD-MACOlOO 07PMG-KZ40100 07MAG·SP00102

l '"' .',Y" "'. F\

'-

~TMD-MAC010A (U.S.A. only) Not available in U.S.A. Not available in U.S.A.

12-5
REAR WHEEL/SUSPENSION
TROUBLESHOOTING
Soft s uspension
• Weak shock absorber springs
• Incorrect suspension adjustment
• Oil leakage from damper unit
• Low tire pressure
Stiff suspension
• Oamaged shock absorber mounting bearings
• Bent shock absorber damper rod
• Damaged swing arm pivot
• Bent swingarm pivot
• Incorrect suspension adjustment
• High tire pressure
Steers to one side or does not track straight
• Benl rear axle
• Axle alignment/chain adjustment nol equal on both sides
Rear wheet wobbling
• Benl rim
• Worn or damaged rear wheel beari ngs
• Faulty rear tire
• low tire pressure
• loose or broken spokes
• Worn or damaged swingarm bearings
Wheel hard to turn
• Brake drag
• Faulty wheel bearings
• Benl axle

12-6
 REAR WHEEL/SUSPENSION
REAR WHEEL
REMOVAL
Support the motorcycle securely using a hoist or
equivalent.
Remove the axle nut. washer and adjusting block.

Push the rear wheel forward.

Derail the drive chain from the driven sprocket.
Remove the axle from the left side and remove the
rear wheel.

Remove the side collars.

INSPECTION
AX LE

I.:
Set the axle on V-blocks and measure the runout.
The actual runout is 112 of the total indicator read-
ing. AXLE
SERVICE LIMIT: 0.20 mm (0.008 in)

12-7
REAR WHEel/SUSPENSION
WHEEL BEARING
Turn the inner race of each bearing with your finger.
Bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the wheel Remove and discard the bearings if the races do not
bearings In pairs turn smoothly and quietly, or if they fit loosely in the

/~
hub.

WHEEL BEARING

WHEEL RIM RUNOUT

Check the rim runout by placing the wheel in a true-
ing stand.
Spin the wheel slowly and measure the runout
using a dial indicator.
The actual runout is 1/2 of the total indicator read-
ing.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Check the spokes and tighten any that afe loose.

DISASSEMBLY
Remove the bolts, nuts and brake disc.
Remove the right dust seal.

Remove the driven sprocket bolts, nuts, washers

and driven sprocket.
Remove the left dust seal.

12-8
 REAR WHEEl/SUSPENSION
Unstake the Remove the bearing retainer using the special tools
r9/amer w,/h drill as shown.
before removmg If
TOOLS:
Retainer wrench body 07710-0010401
Retainer wrench, 48 x 15 mm 07YMA-KZ40100 or
07HMA-KS70100
(U .S.A . only)

Install the bearing remover head into the bearing.

From the opposite side. install the bearing remover
shah and drive the bearing out of the wheel hub.
Remove the distance collar and d rive out the other
bearing.
TOOLS:
Bearing remover head, 25 mm 07746-0050800
Bearing remover shaft 07746-0050100
• Never install the oil bearings; once the bearings
have been removed, t he bearing must be
replaced with a new one .
• Replace the bearings in pairs.

ASSEMBLY

16 N·m (1.6 kgf·m, 12 Ibf.h) 32 N·m (3.3 kgf·m, 24 Ibf·ft)

BRAKE DISC

DRIVEN SPROCKET

BEARING RETAINER
LEFT OUTER BEARING

RIGHT WHEEL BEARING

~/
.~ .r;;"
DISTANCE COLLAR
'-l@~ (
\C?@
fI.vm
LEFT INNER BEARING LEFT DUST SEAL

12-9
REAR WHEEL/SUSPENSION
Wheel cenrer Place the rim on the work bench with its directional
adjustment IS nec- arrow going counterclockwise. 48.00 mm
essary when new Place the hub in the center of rim. and begin lacing (1.890 in)
spokes are with new spokes.
Insralled
Adjust the hub position so that the distance from
the hub left end surface to the side of rim is 48.00 I
mm (1.890 in) as shown. I
Tighten the spokes in 2 or 3 progressive steps to the I

~ i' ~l
specified torque.
TOOL:
Spoke wrench, 6.6 mm 070MA-KZ30100
_.--.J, _ _ _ _ . _ _
TORQUE: 3.9 N·m (0.4 kgf·m. 2.9 IbUt) ,

Install the rim lock, rim band, tube and tire.

SEITING RUBBER VALVE
Torque the rim lock to the specified torque.
TORQUE: 13 N·m (1.3 kgf·m , 9Ibf.tt)

VALVE NUT

Pack the new bearing cavities with grease.

Replace rhe wheel Drive in a new left inner and outer bearings using
bearmgs m PiNS the special tools as shown.
00 not reuse old
TOOLS:
bearrngs
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 25 mm 07746-0040600
Install the distance collar, then drive the new right
wheel bearing in using the same tools.

Apply grease to the bearing retainer and install it

into the hub using the special tools.

TOOLS :
Retainer wrench body 07710-0010401
Retainer wrench, 48 x 15 mm 07VMA-KZ40100 or
07HMA-KS70100
IU.S.A . only)

TORQUE: 44 N·m 14.5 kgf·m, 33 IbUt)

12-10
 REAR WHEEL/ SUSPENSION
Peen the edge of the retainer.
PEEN

Install the driven sprocket.

Install the bolts, washers and nuts, then tighten the
nuts to the specified torque.
TORQUE: 32 N·m (3.3 kgf·m, 24 Ibf.ft)

Apply grease to the new left dust seal lips. then

install it.

Install the brake disc with its "MIN TH. 3.5 mm" r.~:-:;:-;
mark facing out.
Install the bolts and nuts, then tighten the nuts to
the specified torque.
TORQUE : 16 N·m (1 .6 kgf·m. 12 IbUt)
Apply grease to the new right dust seal l ips, then
install it.

INSTALLATION
Apply grease to the inside of the side collars.
Install the side col lars.

12-11
REAR WHEEL/ SUSPENSION
If removed, install the rear brake caliper bracket
onto the slide rail of the swingarm. SLIDE RAIL CALIPER BRACKET

Place the rear wheel into the 5wingarm.

Apply thin layer of grease to the axle.
Install the axle from the left side.
Install the drive chain over the driven sprocket.

If the master link retaining clip was removed, install

it on the drive chain with the closed end of the clip
in the direction of wheel rolation.

Install the adjusting block, washer and loosely

install the axle nut.
Adjust the drive chain slack (page 3·12).
Tighten the axle nut to the specified torque.
TORQUE: 127 N·m (13.0 kgf·m , 94 Ibf.tt)
Snug the adjusting bolts against the chain adjusters
and tighten the lock nuts.

12-12
 REAR WHEEL/SUSPENSION
SHOCK ABSORBER
REMOVAL
Support the motorcycle secu rely and raise the fear
wheel off the ground by placing a work stand under
the engine.
Remove the seat (page 2-3).
Remove the sub-frame (page 2-5),
If you plan to disassemble the shock absorber,
loosen the spring lock nut and adjusting nUl.
Remove the shock absorber lower mounting bolt
and nut.

Remove the shock absorber upper mounting bolt!

nut and shock absorber.

DISASSEMBLY
Measure the spflflg Hold the shock absorber in a vise by the upper
length for Ins/aIJa- mount, protected on both sides by piece of wood. " - ADJUSTING NUT
II()(J laler
loosen the lock nut and adjusting nut.
TOOL:
Pin spanner, 4 mm 07702-0020001 or
89Z01-KS6 -810
(two required)

Slide the rubber stopper down the damper rod and

remove the spring seat stopper, spring seat and
spring .

12-13
REAR WHEEL/ SUSPENSION
BLADDER REPLACEMENT
• Replace the bladder when oil leaks around the
chamber cap or oil spills oul when releasing the
nitrogen from the reservoir .
• Perform this procedure before draining the oil
from the damper.
Depress the valve core to release the nitrogen from
the reservoir.

Remove the valve core.

CHAMBER CAP VALVE CORE

To avoid damagmg Put a suitable tool on the valve cap and push it in by
rhe fh'eads of Ihe lightly tapping on the 1001 with a plastic hammer SUITABLE TOOL
gas valve, Install/he until you have good access to the stop ring.
valve CiJp before
Depress the chamber cap just the minimum amount
depressmg the
necessary to stop ring access. VALVE CAP
chamber cap

Two small screwdrivers and a shop towel are

required to remove the stop ring. SCREWDRIVERS

t
To avoid damagmg The stop ring groove in the reservoir is ramped
the mSlde s urface toward the inside to give the stop ring a square
of Ihe reservoIr. shoulder on which to seat securely. SHOP
cover Ihe screw- TOWEL
To remove the stop ring, first push one end of the
drrl/flf with shop
stop ring out of its groove, then slip the second
tCJVtteI
screwdriver between the stop ring and the reservoir
to act as a ramp.

STOP
RING

12-14
 REAR WHEEL/ SUSPENSION
Now, use the other screwdriver to pull the stop ring
~,
completely out.
Check the stop ring groove for burrs. Remove any I CJ

t
burrs with the fine emery cloth before pulling the .-. C-
damper rod Qut of the case.
Hold the shock absorber in a vise protected with

---
stop towel or soft jaws.
Using a suitable squeeze bottle. fill the reservoir
with recommended shock oil.
Recomm ended shock o il:
Pro Honda HP Fork Oil 5W
,
'1'c;(\
Slowly pump the damper rod until no air bubbles SHOCK J
appear in the valve core hole, then pull the damper L _ _ _ __ _ __
rod all the way.
install the valve core securely_
VALVE CORE
Remove the chamber cap and bladder following the
procedure below:
CHAMBER CAP
,. Wrap the shop towel around the chamber cap.

\~
Compress the damper rod slowly, to force the
chamber cap out.
• The chamber cap will removed with hydraulic
pressure so its force can be significant consider·
ing the air in the bladder.
• Wear protective clothing and a face guard to pro·
tect your eyes and face in case the chamber cap
pops out quickly and forcibly.

Do 1101 overtighten 2. Place the damper in a vise with soft jaws with the
the '1,se. Damage damping adjuster facing up, being careful not to SHOCKOIL~
to the shock body distort the damper body. Remove the damping
will result adjuster.
3. Fill the damper with Pro Honda HP Fork Oil 5W
through the damping adjuster hole, while slowly
pulling the damper rod out.
The damper must 4. Reinstall the damping adjuster after filling the
be kepI uprigh/IO damper.
prevem 011 from 5. Place the damper with the reservoir chamber cap
leakmg out of the
facing up.
damper
6. Repeat steps 1 to 5 until the chamber cap is
removed from the reservoir.
Remove the bladder from the chamber cap.

NOTICE CHAMBER CAP

BLADDER
• Do nor use any sort of tool to remove the blad·
der, because it may damage the chamber cap.
• Replace the bladder with a new one. Do not
reuse the removed one.
Attach the new bladder to the chamber cap.

12-15
REAR WHEEL/ SUSPENSION
If the bladder becomes distorted during installation,
depress the valve core to reform it.

~\ \
~.

NO GOOD GOOD
Clean the inside the reservoir and fill it with Pro 1 - 2 mm (0.04 - 0.08 in)
Honda HP Fork oil 5W.

Recommended shock oil:

Pro Honda HP Fori< Oil 5W
Apply a light coating of shock oil to the lip of the
bladder, and press the chamber cap into the reser -
voi r to about 1 - 2 mm (O.04 - 0.08 in ) below the
stop ring groove.

Install the stop ring in the groove of t he reservoir ~======.'-'-.-===========~

securely. Temporarily fill t he reservoir with air EQU\A L HEIGHT jHAMBER CAP
slowly until the chamber cap seats against the stop
ring.

[ NOTICE [
Be sure the stop ring is seated in the ring groove al/
the way around or the chamber cap can come apart
lVliJ
when riding the motorcycle.
Then make sure that chamber cap face is level wi t h

~SEAVOIR
the reservoir face.

[ NOTICE [
If the chamber cap does nor seat fully, the chamber L _ _ _ _ _ _ _ __ _ __ _ _ _ _ _ _-'
cap may fly out when filling the reservoir with nitro·
gen.
Release the air from the reservoir by depressing the
valve core.
Bleed the air f rom the shock absorber bladder (page
12-14).
Fill the reservoir with nitrogen to the specified pres-
sure (page 12-25).

12-16
 REAR WHEEl/SUSPENSION
DAMPER DISASSEMBLY
Pomt the valve Depress the valve core to release the nitrogen from
away from you to the reservoir (page 12-17). ADJUSTER
prevent debris get·
Remove the damping adjuster using the special
Img In your eves
tool.
Before disposal of
Iha shock: absorber, TOOL:
release the Mrogen Lock nut w rench, 20 )( 24 mm 0 77 16-0020100
by pressing the
valve core. Then
remove the valve
from the shock
absorber reservoir.

Drain most of the shock oil from the damper and

reservoir, by pumping the damper rod in and out
several times.

Clamp the shock absorber in a vise by the damper

case protected on both sides by pieces of wood .
Remo ve the end plate and tape or tie it to the rubber
stopper so it won't get in the way.

Push in the damper seal until you have good access

to the stop ring.
Two small screwdrivers are required to remove the
stop ring.
The stop ring groove in the damper case is ramped
towards the inside to give the stop ring a square
shoulder on which to seat securely.

12-17
REAR WHEel/SUSPENSION
To remove the stop ring, first push one end of the
SlOP ring Qut of its groove, then slip the second
screwdriver between the stop ring and the damper
case 10 act as a ramp.
Now, use the other screwdriver to pull the stop ring
completely Qut.
Burrs will damage Check the stop ring groove for burrs. Remove any
rhe dllmper rod piS- burrs with fine emery doth pulling the damper rod
ron rmg Qut of the case.

Carefully pull the damper rod assembly QuI of the

damper case.

DAMPER CASE

PISTON RING REPLACEMENT

Inspect the piston ring.
If the piston ring is damaged, cut the piston ring and
replace the piston ring and C-ring under the piston
ring with a new one.

___ - a·RING

PISTON RING

Place the slider guide attachment over the piston

and install a new O-ring and piston ring onto place
with your finger. ....lSI!? D-RING

TOOL:
Slider guide attachment 07MAG·SP00102
not available in
U.S.A.
Compress the piston ring against the ring groove,
and seat the piston ring into the ring groove.

GUIDE ATIACHMENT

12-18
 REAR WHEEL/SUSPENSION
DAMPER ROD DISASSEMBLY
• To keep lint or dirt from getting onto damper rod
parts, do not wear gloves while working on the
damper rod .
• Be ca reful to file the end nut by hand so that the
a.D. of the rod end is about 10 rnm (0.4 in). Be
careful not to over-file.
Unstake the damper rod end nut with a file as r-,----,,------ - - - - - -- - - - ,
shown. 30° at first then gradually
angle to 45°
10 mm (0.04 in)

FILE

Place the damper in a vise protected with a piece of

wood or shop towei, being careful not to distort the
lower mount.
Turn the end nut back-and-forth in 1/4 tu rn incre-
ments until it loosens, then rotate another 1/4 turn
and repeat the back-and-forth until nut loosens
completely.
• If the damper rod is cracked or damaged when
removing the end nut, replace the damper rod
assembly with a new one.
• Remove all burrs from the end of the damper
rod. Lean thoroughly with solvent. If the threads
cannot be repaired, replace t he rod.

Hold the lower shock mount in a vise with soft jaws,

a piece of wood, or shop towel.
DIE
Remove the burrs from the damper rod end with a
file and correct the threads with a die.
DIE: 12 x 1.5 mm
Make sure that fll- Clean the damper rod with solvent after correcting
mgs are not stuck In the threads.
the damper rod 1.0.
SHOP TOWEL

Remove the valve stopper, washers, rebound valves

and piston from the damper rod.
WASHERS REBOUND VALVES

~
• Use a piece of mechanic's wire to keep the
valves in the correct order.
• Keep dust and abrasives away from all damper
rod parts
• Thoroughly clean the valves in solvent and blow
them dry with compressed air if they have been
disassembled and separated.
• Be careful not to get solvent on the O-ring and VALVE STOPPER
piston ring.
• The valve arrangement and number of valves
shown is typical and may not represent this
model exactly. PISTON

12-19
REAR WHEEL/ SUSPENSION
Remove the compression valves and valve stopper.
COMPRESSION VALVES

VALVE STOPPER

Chase the threads with a die and clean with oil.

TAPE
Back out damping adjuster and back flush with sol-
vent.
Wrap the top threads of the damper rod with tape.
Remove the rod guide case from the damper rod.
Remove the end plate, rubber stopper and rubber
seat from the damper rod.

ROD
ROO GUIDE INSPECTION
Inspect the rebound rubber and dust seal lips for
wear or damage and replace the rod guide case DUST SEAL
with a new one if necessary.
Visually inspect the rod guide case metal.
If the metal is worn so thai the copper surface
appears, replace the rod guide case with a new one.

REBOUND RUBBER METAL

Remove the O-ring from the rod guide case and
replace it with a new one. ROD GUIDE CASE

12-20
 REAR WHEel/ SUSPENSION
DAMPER ROD INSPECTION
Inspect the damper rod sliding surface for damage
or distortion.

iF
8 mm (0.3 in) 8 mm (0.3 in)

SLIDING SURFACE

DAMPER ASSEMBLY

END NUT

DAMPING ADJUSTER

~Q~
ROD GUIDE CASE

SPRING SEAT

SPHERICAL BEARING . / END PLATE

@~ ~t~~~~~EAT
ry /' RUBBER STOPPER

DAMPER CASE
~ DAMPER ROD
LOCK NUT

/ ~b
SPRING ADJUSTER

BLADDER / \
\=-'
CHAMBER CAP RUBBER SEAT
SPRING VALVE STOPPER
REBOUND VALVES COMPRESSION VALVES

Before assembly, wash all parts with solvent and

WASHERS
blow them dry with compressed air.
Be sure that there is no dust or lint on any of the
parts.
Never assemble valves which may have become
dusty or otherwise contaminated during the disas-
sembly process. Disassemble them, thoroughly
clean them with solvent and blow them dry with
compressed air before assembly. VALVE STOPPER

I NOTICE I
• Use added care to avoid getting solvent on the
piston ring and D-ring.
• The valve arrangement and number of valves VALVE STOPPER
may differ from those shown.

12-21
REAR WHEEL/SUSPENSION
Install the rubber seat, rubber stopper and end
plale. AU IBBEA STOPPER

PLATE
Install the special tool onto the damper rod.
SLIDER
TOOL:
Slider guide, 16 rnm 07PMG-KZ40100
not available in
U.S.A.
Carefully install the rod guide case with the rebound
rubber facing up, over the damper rod.
• The rod guide case oil seal is filled with grease.
• Be careful not to remove grease from the seal.
• Be careful not to damage the dust seal lip o r turn
it inside out.

ADD
The valve arrang e- Install the valve stopper and compression valves
mOM and number onto the damper rod. CO M PRESSION VALVES
of valves may vary
trom rhose shown
VALVE STOPPER

Install the piston onto the damper rod.

REBOUND VALVES
Install the rebound valves with their polished sur-
faces facing down.
Install the washers and valve stopper.
• Note the installation direction of the piston
valves.
• Be careful not to bind the valves when installing
the piston onto the damper rod. Also, check that
they are concentric with the damper rod. VALVE STOPPER

12-22
 REAR WHEEl/SUSPENSION
Hold the lower shock mount in a vise with soft jaws,
piece of wood or shop towel. END NUT
Install and tighten a new end nut to the specified
torque.
TORQUE: 26 N·m 12.7 kgf·m , 20 Ibf.ft )

Stake the end of damper rod in

shown to secure the end nut. .h'ee pi"., " I END NUT

Coat the damper rod with Pro Honda HP Fork 011 5W

or equivalent. Check the rod guide case by sliding it
up and down fully to be sure there is no restriction.

1
Coat the damper case inner surface, piston ring and
RING
O-ring with Pro Honda HP Fork Oil 5W or equivalent,
and insert the damper rod assembly carefully.
Install the stop ring into the groove in the damper
case.
After assembling, check that the stop ring is seated
in the groove of the damper case completely. You
should not be able to pull it out of the damper case.

12-23
REAR WHEEL/ SUSPENSION
Do nor overtighten Hold the shock absorber gently in a vise by the
the I'!se and dlSton damper case, protected on both sides by pieces of
the damper case wood. ~;!,i,~
Drive the end plate squarely and evenly into the
damper case with a plastic hammer.

Fill the damper case and reservoir with Pro Honda SHOCK OIL _ _ _ _ ~
HP Fork Oil 5W through the damping adjuster hole.

Recommended shock oil :

Pro Honda HP Fork Oil 5W

Make sure the fad Slowly pump the damper rod until there are no bub-
gUIde case IS bles in the oil thai overflows from the damper case.
seatedagatnst the
Remove the damper unit from the vise.
SlOp ring by pulling
the damper rod out
all the way

Do not let oil flow

out of the reservoir
Position the damper the damping adjuster hole fac-
ing up. Turn the damper unit as shown to bleed the
,-----SHOCK
- -----========:.:;
OIL
air from the reservoir completely.
When bleeding air from the reservoir, be careful to
hold the damper at the angles shown so the filler
hole points up.
Temporarily charge the reservoir with 49 kPa (0.5
kgf/cm 1, 7,' psi) of air slowly to inflate the bladder
inside.

NOTICE
• Check for any oil that may leak out of the valve
while pressurizing. Replenish oil as necessary.
• Be sure that the reservoir pressure is correct with L _ _ _ _-'---'--_ _ _-"-_ _
an accurate pressure gauge.
Fill the damper with Pro Honda HP Fork Oil 5W up to
the damping adjuster hole neck.
Apply oil to the new O-rings and install them to the
damping adjuster.
Dip the damping adjuster in clean shock oil.
Slowly install the damping adjuster.

12-24
 REAR WHEEL/SUSPENSION
Tighten t he damping adjuster to t he specified
torque .

TOOL:
lock nut w rench, 20 x 24 mm 07716-0020100

TORQUE: 29 N 'm (3.0 kgf·m , 22 Ibf.ft )

lA.,PINIG ADJUSTER
Stake the damping adjuster as shown.

Wipe off all oil from the damper rod; oil left on the
damper rod can lead to premature failure of the oi l
seal.
Check for oil leak.
Release the air that was in the reservoir precom-
pression.
Fill the reservoir with 98 1 kPa (10.0 kgf/cm ~, 142 psi)
of nitrogen gas.

AWARNING
The shock absorber is fitted wi t h a gas-filled
reservoi r. Use only nitrogen gas to pressurize
the shock absorber. The use of an unstable gas
can cause a fire or explosion resulting in seri-
o us injury.

Install the valve cap.

" VALVE CAP

Install the spring with the wider end sliding against

the adjusting nut. SPRING STOPPER
Install the spring seat and spring seat stopper.
Loosely tighten the adjusting nut and lock nut.

12-25
REAR WHEEL/SUSPENSION
Turn the shock absorber lower mount so that the
rebound adjuster screw is on the same side of the
shock 85 the reservoir as shown.

·SAME SIDE

One tum of Ihe Turn the spring adjusting nut until the spring length
ad/us/lfIg nUlmeasurement recorded at disassembly is reached
changes Ihe spring or until the spring length is as specified below. STANDARD LENGTH
lengrhbyl.5mm
(GOO m) Standard spring length :
'04: 266.5 mm (10.49 in )
After '04: 266.0 mm (10.47 in )

Hold the adjusting nut and tighten the lock nut.

TORQUE: 29 N 'm (3.0 kgf·m , 22 Ibf.tt)
Use this standard spring length as a baseline. See
the Owner's Manual for detailed instructions on
adjusting preload and damping sening for rider
weight and steering damping for riding conditions
and rider skill.
SPHERICAL BEARING REPLACEMENT
Check the spherical bearing for wear or damage.
If it is worn or damaged, it must be replaced. DUST SEALS
Remove the dust seals.

(»

Press the spherical bearing to get the clearance nec·

essary to remove the stop ring. SPHERICAL BEARING DRIVER

TOOL: STOP RING

Spherical bearing driver 07946· KA30200
not available in
U.S.A .

12-26
 REAR WHEEl/SUSPENSION
Press the spherical bearing out of the upper mount.
SPHERICAL
TOOL: BEARING
DRIVER
Spherical bearing driver 07946-KA30200
not available in
U.S.A.
_ +_SPHERICAL
- BEARING

Apply multi-purpose grease NLGI No.2 (Molybde-

num disulfide additive) to the new spherical bear- SPHERICAL
ing. BEARING
DRIVER
Dflve the bearmg In Press a new spherical bea ring into the upper mount.
evenly, do not allow
II lilt.
TOOL
Spherical bearing driver 07946·KA30200
not available in
U.S.A.

SPHERICAL
BEARING

Install a new stop ring into t he groove of t he upper ~==================~

mount securely. SPHERICAL
BEARING
Press the spherical bearing into the upper mount DRIVER
until it seats against the stop ring.
TOOL:
Spherical bearing driver 07946-KA30200
not available in
U.S.A.

SPHERICAL
STOP RING BEARING

Be sure to Install Apply grease to the lip of the new dust seals and
the correct dust install them. DUST SEALS
sea/In each side.

(@

12-27
REAR WHEEL/SUSPENSION
INSTALLATION
Set the shock absorber onto the shock arm with the
rebound adjuster facing to the right.
Install the lower mounting bolt by aligning the cut-
out of the bolt with the stopper on the shock
absorber.
Install and tighten the lower mounting nut.
TORQUE: 44 N ·m (4.5 kgl·m , 33 Ibf·h)

Install and tighten the shock absorber upper mount-

ing nut/boll.

TORQUE: 44 N'm (4.5 kgl·m, 33 IbUt)

Install the sub-frame (page 2-5),

SHOCK LINKAGE
REMOVAL
Remove the nut and drive chain roller.

Remove the following:

- shock absorber lower mounting bolVnut
- shock arm bolt/nut (shock link side)
- shock arm bolt/nul (swingarm side)
- shock arm
- shock link bolt/nut (frame side)
- shock link

12-28
 REAR WHEEL/SUSPENSION
OISASSEMBL V
Remove the side collars, pivot collar and dust seals
SIDE COLLAR
from the shock link. DUST SEALS

~
SHe)CK LINK

PIVOT COLLAR SIDE COLLAR

Remove the pivot collars and side collars from the

shock arm (swingarm side, shock link side). SIDE COLLARS

~Q

SHOCK SIDE COLLARS

Remove the dust seals and washers (swingarm

g;
WASHER PIVOT COLLAR
side, shock link side).

l;~OO'~
Remove the dust seals, side collars and pivot collar
(shock absorber side),

INSPECTION
o!A DUST SEALS

Check the dust seals and collars for wear, damage

SIDE COLLARS DUST SEALS
or fatigue.

~
Check the needle bearings for damage or loose fit.
Check the shock arm for cracks o r damage.
If the needle beari ngs are damaged, replace them.
'>iOo

PIVOT COILLA.RS

12-29
REAR WHEEL/ SUSPENSION
Check the dust seals and collars for wear, damage
SIDE COLLAR
or fatigue.
Check the needle bearings for damage or loose fit.
Check the shock link for cracks or damage.
If the needle bearings are damaged, replace them .

PIVOT COLLAR BEAR INGS

BEARING REPLACEMENT
SHOCK ARM NEEDLE BEARING
Press the needle bearing (shock link side, swingarm
side) out of the shock arm using the special tools DRIVER
and a hyd raulic press.

TOOLS:
Driver 07949·3710001
Attachment, 24 x 26 mm 07746-0010700
Pilot, 20 mm 07746-0040500
Attachment, 30 mm 1.0. 07746-0030300

Press the needle bea ring (shock absorber side) out

of the shock arm using the special tools and a
hydraulic press.

TOOLS: ATTACHMENTI
Driver 07749-0010000 PILOT
Attachment, 24 I( 26 mm 07746-0010700
Pilot, 17 mm 07746-0040400
Attachment, 30 mm 1.0. 07746-0030300

Fill up the new needle bearings and inside of shock

arm with multi-purpose grease.
Press the needle Press the new needle bea rings into the shock link
beanngs Into the side pivot so that the needle bearing surface is 6.0 -
shock arm with the 6.5 mm (0.24 - 0.26 in) below the end of the shock
marked side facmg arm surface.

'"' TOOLS:
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Pilot , 20 mm 07746-0040500
6.0 - 6.5m~
(0.24 - 0.26 in )

12-30
 REAR WHEEL/ SUSPENSION
Fill up the new needle bearings and inside of shock

Press the needle

arm with multi-purpose grease.
Press the new needle bearings into the swingarm
bearmgs mto the side pivot so that the needle bearing surface is 4.4-
4.4 - 4.7 mm
(0.17-0.19 i:J.
shock arm with the 4.7 mm (0.17 - 0.19 in) below the end of the shock
marked side faCing arm surface.

'"' TOOLS:
t
Driver
Attachment, 24 x 26 mm
Pilot, 20 mm
07749·0010000
07746·0010700
07746-0040500
t
4.4-4.7 mmt
(0.17 - 0.19 in)

Pack a new needle bearing with mUlti -purpose

grease.
'04 Press a new needle bearing into the shock absorber
side pivot so that t he needle bearing surface is 2.0-
2.2 mm (0.08 - 0.09 in) below the end of the shock SPECIFIED
arm surface. DEPTH

After '04 Press a new needle bearing into the shock absorber
side pivot so that the needle bearing surface is 3.0-
3.2 mm (0.12 - 0.13 in) below the end of the shock
arm surface.
TOOLS:
Driver 07749-0010000
Attachment, 24 x 26 mm 07746·0010700
Pilot, 19 mm 07746-0041400
SHOCK LINK NEEDLE BEARING
Drive the needle bearings out of the shock link from
DRIVER
the opposite side using a suitable tool. 4.4 -4.7 mm
Press the needle Press the needle bearings (shock link side) out of (017 - 0 19 in) ~
bearmgs mto the the shock arm using the special tools and a hydrau-
shock link with the lic press.

J:
marked side facmg
Fill up the new needle bearing and inside of shock
,m link with mUlti-purpose grease.
Press the new needle bearings into the shock link
pivot so that the needle bearing suriace is 4.4 - 4.7
mm (0.17 - 0.19 in) below the end of the shock link
surface.
4.4 - 4.7 mm
!
TOOLS:
Driver shaft 07749·0010000 (0.17 - 0.19 in)
Attachment, 28 x 30 mm 07946-1870100
Pilot, 20 mm 07746·0040500

ASSEMBLY
Apply multi-purpose g rease NLGI No.2 (molybde·
num disulfide additive) to the shock arm. shock link
dust seal lips and collars. DUST SEAL
Make su re that the needle bearing rollers are in
position before installing.
Number of needle rollers
Shock link : 32
Shock arm: shock link side: 32
swingarm side: 32
shock absorber side: 27
Install the dust seals, pivot collar and side collars to
the shock link.
~
PIVOT COLLAR

12-31
REAR WHEEl/SUSPENSION
Install the dust seals and washers 10 the shock arm
(shock link side),
Install the dust seals to the shock arm (swinga rm WAS~~
side).
Aher '04 InSIi3111he Install the pivot collar, side collars and dust seats to
side collars (shod:
absorber Side} with
Its smaller 0.0. side
lacing Pivot colJar
the shock arm (shock absorber side).

o
DUST SEALS

Install the pivot coliars and side collars to the shock

arm (swingarm side, shock link side), ~ SIDE COLLARS

~
"J

/
SHOCK ARM

INSTALLATION
Apply oil to the shock arm and shock link nut
threads and flange surface. BOLT/NUT

loosely install the following:

- shock link
- shock link bolVnul
- shock arm
- shock arm bolUnu t (swingarm side)
- shock arm bolVnut (shock link side)
Install the lower mounting bolt by aligning the cut-
out of the bolt with the stopper on the shock
absorber.

Tighten all nuts to the specified torque.

TORQUE:
Shock link nut: 52 N'm (5.3 kgf·m , 38 Ibf.ft)
•
Shock ann nut:
SHOCK ARM
swingann side: 52 N ·m (5.3 kgf·m, 38 Ibf.ft)
shock link side: 52 N'm (5.3 kgf·m , 38 Ibf.ft)
Shock absorber lower 44 N 'm (4.5 kgf·m, 33 Ibf.ft)
mounting nut:

12-32
 REAR WHEEL/SUSPENSION
Install the drive chain roller and tighten the bolt to
the specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9Ibf.ft)

SWINGARM
REMOVAL
Raise the rear wheel off the ground by placing a
work stand under the engine.
Remove the rear wheel (page 12-7).
Remove the brake pedal (page 13-24).

Remove the shock arm bolt and nut (swingarm ....- "7
side).

Remove the screws and brake hose guide.

12-33
REAR WHEEL/ SUSPENSION
Do nor dJsconnecl Remove the rear brake caliper/bracket from the slide
rhe hydraulIC I/Oe rail on the swing arm. SLIDE CALIPER BRACKET
and do not suspend
the brake caliper
from the brake
hose.

Remove the swing arm pivot nut .

Remove the swingarm pivot bolt and swingarm.

DISASSEMBLY
Check the chain slider and chain guide for wear or
damage (page 3-13). SLIDER

Remove the boilS, nuts and chain guide.

Remove the screws and chain slider.

DRIVE CHAIN GUIDE

12-34
 REAR WHEEL/SUSPENSION
Remove the following ;
- side collars
- dust seals
- washers
- th rust needle bearings
- collars

Check the dust seals and coliars for wear, damage

or fatigue.
Check the needle bearings and thrust needle bear-
ings for damage o r loose fit.
Check the swinga rm for cracks or damage.
Replace them, if necessary.

BEARING REPLACEMENT
Press the needle bearing out of the swi ngarm pivot
using the special tools and a hyd raulic press.
DRIVER

TOOLS:
Driver 07949·3710001
Atta chment, 24 x 26 mm 07746-0010700
Pilot, 22 rnm 07746-0041000
Attachment, 30 mm 1.0. 07746-0030300

Pack new needle bearings with m ult i-pu rpose

grease.
11.0 - 11.5 mm
Press the needle Press the new needle bearings into the swi ngarm (0.43 - 0.45 in)
bearmgs mto the pivot so that the needle bearing surface is 11.0 -
swmgarm piVO t 11.5 mm (0.43 - 0.45 in) below the end of the swing-
With the marked arm pivot surface.
Side facmg out
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07746-1870100
Pilot, 22 mm 07746-0041000

12-35
REAR WHEEL/SUSPENSION
ASSEMBLY
3.9 N-m (0.4 kgf·m, 2.9 Ibf.ft) CHAIN SLIDER
1.2 N·m (0.12 kgf-m, O.9 Ibf·h)

SWINGARM BEARING

OUST SEAL

COLLAR

CHAI N GUIDE SLIDER

12 N·m (1.2 kgf-m, 9Ibf.ft)

Fill up the new dust seals, washers and bearing with , - - - - - - - -- - - -- - - - - ,

mu It'I-purpose grease. .~""II DUST SEAL --
.....!!mrPIj
Install the following: WASHERS
- washers
- thru st needle bearings
- dust seals
- collars
- side collars
........
BEARING

Inslall the chain slider with it s hole and tab on the

5wingarm.
Install the drive chain slider mounting bolt holes i"!!~~:'~~~
with the bosses on the swingarm .

ALIGN

12-36
 REAR WHEEL/SUSPENSION
Clean and apply a locking agent to the screw
threads.
Install and tighten the screws to the specified
torque.
TORQUE: 3.9 N·m (0.4 kgf·m , 2.9 Ibf.ft)

DRIVE CHAIN SUDER

Install the chain guide.

Install and tighten the bolts and nuts to the specified BOLTS/N UTS
l
torque.
TORQUE: 12 N 'm (1.2 kgf·m , 9Ibf.ft)
"

DRIVE I GUIDE

INSTALLATION
Apply thin coat of grease to the swing arm pivot bolt
sliding surface
Install the swingarm onto the f rame.
Install the swingarm pivot bolt to the frame and
swingarm pivot from the right side.

Install and tighten the swingarm pivot nut to the

specified torque.

TORQUE: 88 N·m (9.0 kgf·m. 65 Ibf.ft)

12-37
REAR WHEEL/ SUSPENSION
Do nor twlSf the Install the rear brake caliper to the slide rail on the
brake hose swingarm. SLIDE RAIL CALIPER BRACKET

Install the brake hose guide.

Tighten the brake hose guide screws to the speci-
fied torque.
TORQUE: 1.2 N-m (0.12 kgf·m , O.9Ibf.ftl

Apply oil to the shock arm nut (swingarm si de)

threads and seating surface. BOLT/NUT
Install the shock arm bolt and nut, l ighten the nul to (SWINGARM SIDE)
the specified torque.
TORQUE: 52 N·m (5.3 kgf·m , 38 Ibf.ft)

Install the rear wheel (page' 2- 1').

12-38
 13. HYDRAULIC BRAKE

COMPONENT LOCATION ........................... 13-2 FRONT MASTER CYLINDER ······················ 13-10

SERVICE INFORMATION ............................ 13-3 REAR MASTER CYLINDER ············ ············ 13-14

TROUBLESHOOTING .................................. 13-4 FRONT BRAKE CALlPER ···························· 13-17

BRAKE FLUID REPLACEMENT! AIR REAR BRAKE CALlPER····················· ·········· 13-20

BLEEDING ............................................. ....... 13-5
BRAKE PEDAL ············································ 13-24
BRAKE PAD / DiSC ········································ 13-8

13-1
HYDRAULIC BRAKE
COMPONENT LOCATION
1.5 N'm (0.15 kgf·m, 1.lIbf.ft)

5.9 N·m (0.6 kgf·m, 4.3 IbHt)

~~
""~~. 9.8 N'm (1.0 kgf·m,
7 Ibf.ft)

34 N'm (3.5 kgf·m, 25 fbf·h) ~~

34 N·m (3.5 kgf·m,
25Ibf.ft)
5.9 N·m (0.6 kgf·m, 4.3 Ibf.ft)

5.9 N'm (0.6 kgf·m, 4.3 IbUt)

-
18 N·m ("8 kgf·m,13Ibf·ft)

2.0 N·m (0.2 kgf·m, 1.4 Ibf·h)

A
1.5 N·m (0.15 kgf·m, 1.1 Ibf·h)

'-?l.....- - 30 N·m (3.1 kgf·m,22Ibf·ft) 34 N·m 13.5 kgl·m, 25 Ibfhl

i~
34 N·m (3.5 kgf·m, 25Ibf·ft)

18 N·m 11.8 Ibf.ft)

'04: 25 N·m (2.6 kgf·m, 19Ibf·ft)

AFTER '04: 36 N·m (3.7 kgf·m, 27 Ibf·h)

13·2
 HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL

ACAUTION
Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health .
• Avoid breathing dust particles .
• Never use an air hose or brush to clean brake assemblies. Use and OSHA·approved vacuum cleaner.
--
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
• Avoid spilling brake fluid on painted. plastic or rubber parts. Place a fag or shop towel ovef these parts whenever the
system is serviced.
• Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal.
• Bleed the hydraulic system if it has been disassembled or if the brake feels spongy.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
ftuid; they may not be compatible.
• Always check brake operation before riding the motorcycle.

SPECIFICATION
Unit: mm (in)
ITEM STANDARD SERV I: E UMJT .
Front Specified brake fluid DOT 4
Brake pad wear indicator 1.0 (0.04)
Brake disc thickness 3.0 (0.12) 2.5 (0.10)
Brake disc runout
Master cylind~'~'~'~.D'.--­
_+_0_.15 10.006)=:3
+ --i',lO",O
;c (0.433)
Caliper cylinder 1.0. 27.00 (1.063)
Rear Specified brake fluid DOT 4
r----srake pad wear indicator 1.010.04)
Brake disc thickness 4.0 (0.16) 3.5 (0.14)

Ti
Brake disc runout 0.15 (0.006)

----= ~
Master cyli,Cncdc,c,'iI."D'.-- - 9.52 (0.375)
Caliper cylinder 1.0. 22.65 (1.892)
= ----==1
TORQUE VALUES
Brake hose oil bolt 34 N·m (3.5 kgf·m, 25Ibf.ft)
Brake lever pivot bolt 5.9 N·m (0.6 kgf.m, 4.3 IbOt)
Brake lever pivot nut 5.9 N'm (0.6 kgf·m, 4.3 Ibf·ft)
Brake lever adjuster lock nut 5.9 N·m (0.6 kgf·m, 4.3 Ibf·ft)
Front master cylinder reservoir cover screw 1.5 N'm (0.51 kgf·m, 1. 1 Ibf.ft)
Rear master cylinder reservoir cover bolt 1.5 N·m (0.15 kgf·m, l.llbf·ft)
Front master cylinder holder bolt 9.8 N·m ( 1.0 k9f·m, 7 Ibf·ft)
Front caliper mounting bolt 30 N·m (3. 1 kgf·m, 22 Ibf·ft) Apply a locking agent to the
threads
Caliper bleed valve 5.9 N'm (0.6 kgf·m, 4.3 Ibf·ft)
Rear master cylinder mounting bolt 13 N ·m (1.3 kgf·m, 9 IbUt)
Front caliper pin bolt 23 N·m (2.3 kgf.m, 17 Ibf.ft) Applya loelcing agent to the
threads
Front caliper bracket pin bolt 23 N·m (2.3 kgf·m, 17 lbf·ft) Apply a locking agent to the
threads
Brake caliper pad pin 18 N·m (1.8 kgf·m, 13Ibf·ft)
Brake caliper pad pin plug 2.0 N·m (0.2 kgf·m, 1.4Ibf·ft)
Rear caliper pin bolt 27 N·m (2.8 kgf·m, 20 Ibf·ft)
Rear caliper bracket pin bolt 13 N·m (1.3 kgf·m, 9Ibf.ft) Applya locking agent to the
threads
Brake pedal pivot bolt '04: 25 N·m (2.6 kgf·m, 19 Ibf·ft)
After '04: 36 N·m (3.7 kgf·m, 27Ibf·ft)
Rear master cylinder joint lock nut 5.9 N·m (0.6 kgf·m, 43 Ibf·ft)

13-3
HYDRAULIC BRAKE
TOOL
Snap ring pliers
07914·SA50001

TROUBLESHOOTING
Brake lever/ pedal soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pad/disc
• Worn caliper piston seal
• Worn master cylinder piston cups
• Worn brake pad/disc
• Contaminated caliper
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Contaminated master cylinder
• Bent brake lever/pedal
Brake lever hard
• Clogged/restricted brake system
• Sticking/worn caliper piston
• Caliper not sliding properly
• Clogged/restricted fluid passage
• Worn caliper piston seal
• Sticking/worn master cylinder piston
• Bent brake lever/pedal
Brake drags
• Contaminated brake padfdisc
• Misaligned wheel
• Clogged/restricted brake hose joint
• Warped/deformed brake disc
• Caliper not sliding properly
• Clogged/restricted brake hydraulic system
• Sticking/worn caliper piston
• Clogged master cylinder port

13-4
 HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
• 00 not allow foreign material to enter the system
when filling the reservoir.
• Avoid spilling fluid on painted. plastic, or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE :
• The pedal brake line air bleeding procedure is
performed in the same manner as in the lever
brake line air bleeding procedure.
• Once the hydraulic system has been opened, or if
the brake feels spongy, the system must be bled .
• When using a commercially available brake
bleeder, follow the manufacturer's operating
instructions.

BRAKE FLUID DRAINING

Make sure that the master cylinder is parallel to the
ground, before removing the reservoi r cover and
cap.
Front Remove the screws, reservoir cover and diaphragm.

Rear. Remove the bolts, reservoir cover and diaphragm.

Connect a bleed hose to the caliper bleed valve.

Loosen the bleed valve and pump the brake lever
(pedal).
Stop operating the brake when no more f luid flows
out of the bleed valve.

13-5
HYDRAULIC BRAKE
BRAKE FLUID FILLINGI AIR BLEEDING
• Use only DOT 4 brake fluid from a sealed con-
tainer.
• Do nol mix different types of fluid. They are not
compatible.
Fill the master cylinder with DOT 4 brake fluid from
a sealed container. UPPER LEVEL LINE

Rear Remove the bolts and rear brake caliper guard .

If (Jlf 11mB'S the Connect a commercially available brake bleeder to

bleeder from the bleed valve.
8round the bleed Operate the brake bleeder and loosen the bleed
valve Ihreads. seal valve.
/he threadS w,rh If an automatic refill system is not used, add fluid
leflon tape when the fluid level in the reservoir is low.
Perfor m the bleeding procedure until the system is
completely flushed/bled.
Close the bleed valve and operate the brake lever
(pedal). If it still feels spongy. bleed the system

~
again.

If the brake bleeder is not available, perform the fol-

/\
lowing procedure.
Pressurize the system with the lever until there are
no air bubbles in the fluid flowing out of the reser·
voir small hole and lever (pedal) resistance is felt.

13-6
 HYDRAULIC BRAKE
Connect a bleed hose to the bleed valve.
Do nor release rne l. Pump the brake lever or pedal several times,
brake lever unr,1 rne then squeeze the brake lever or pedal all the way
bleed valve /'las and loosen the bleed valve 112 turn. Wait several
been closed seconds and then close the bleed valve.
2. Release the brake lever or pedal slowly until the
bleed valve has been closed.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding the air completely, t ighten the bleed
valve to the specified torque.
TORQUE: 5.9 N·m (0.6 kgf·m , 4.3 IbUt)

Fill the reservoir to the upper level with DOT 4 brake

fluid from a sealed container. UPPER LEVEL LINE

Fronr Install the diaphragm and reservoir cover.

Tighten the reservoir cover screws to the specified
torque.
TORQUE: 1.5 N·m (0.15 kgf·m , 1.1Ibf.ft)

Rear Install the diaph ragm and reservoir cover being

careful not to bend the diaphragm while installa-
tion.
Tighten the reservoir cover bolts to the specified
torque.
TORQUE: 1.5 N·m (0.15 kgf·m , 1.1Ibf·ft )

13-7
HYDRAULIC BRAKE
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Always replace the brake pads in pairs to assure
even disc pressure.
Check the fluid level Push the caliper pistons all the way in by to allow
In the mas/erey/m· installation of new brake pads .
del reservoir as thiS
operatIOn causes
the fluid level /0
",.

Front Remove the pad pin plug and the pad pin.

Rear Remove the pad pin.

Front Remove the brake pads.

Rear Remove the brake pads and O-ring from the pad
pin.

13-8
 HYDRAULIC BRAKE
Instal! the new brake pads to the pad retainer
securely.

Front- Push the brake pads against the pad spring , then
install the pad pin.
Tighten the pad pin to the specified torque.
TORQUE: 18 N'm (1 .8 kgf·m, 13 IbUt)

Install and tighten the pad pin plug to the specified

torque.

TORQUE: 2.0 N·m (0.2 kgf·m , 1.4 Ibf·ft)

After replacement, operate the brake lever to seat
the caliper pistons against the pads.

Rear Set a new O-ring in the groove of the pad pin.

Push the brake pads against the pad spring, then
install the pad pin.
Tighten the pad pin to the specified torque.
TORQUE: 18 N·m (1 .8 kgf·m , 13 Ibf·ft )
After replacement, operate t he brake pedal to seat
the caliper piston against the pads.

13-9
HYDRAULIC BRAKE
BRAKE DISC INSPECTION
Remove the brake disc cover (page 13-20).
Visually inspect the brake disc for damage or cracks.
Measure the brake disc thickness at several points
with a micrometer.
SERVICE LIMITS:
Front: 2.5 mm (0.10 in)
Rear : 3.5 mm (0.14 in)

Replace the brake disc if the smallest measurement

is less than service limit.

Check the brake disc for warpage with a dial indica-

tor.

SERVICE LIMIT: 0. 15 mm (0.006 i n )

Check the wheel bearings for excessive play, if the
warpage exceeds the service limit.
Replace the brake disc if the wheel bearings are nor-
mal.

FRONT MASTER CYLINDER

REMOVAL
Drain the brake fluid from the hydraulic system
(page 13-5).
Remove the brake hose oil bolt, sealing washers
and brake hose eyelet.

Remove the boilS from the master cylinder holder

and remove the master cylinder assembly.

13·10
 HYDRAULIC BRAKE
DISASSEMBLY
Remove the dust cover.
Remove the pivot boltfnut and brake lever assem- PIVOT BOLT/NUT
bly.

BRAKE
Remove the boot.
Remove the snap ring from the master cylinder
body using the special tool as shown.
TOOL:
Snap ring pliers 07914-SA50001

BOOT

Remove the master piston, washer and spring.

Clean the master cylinder, reservoir and master pis-
MASTER CYLIN DER
•
ton in clean brake fluid.
MASTER PISTON

SPRING
o
WASHER
INSPECTION
Check the piston boot, primary cup and secondary
cup for fatigue or damage.

PRIMARY CUP

° 0
SECONDARY CUP

13-11
HYDRAULIC BRAKE
Check the master cylinder for abnormal scratches.
MASTER CYLINDER
Check the master cylinder piston for abnormal
scratches.

ASSEMBLY
BOOT

SNAP RING _ _ ~-,; :r@; JASHER SPRING

MASTER PISTON ~
5.9 N·m (0.6 kgf·m, 4.3 Ibf·tt)
MASTER CYLINDER

--

BRAKE LEVER
5.9 N'm (0.6 kgf'm, 4.3 IbUt)
fi!~
I
I
DUST COVER 5.9 N·m 10,6 kgf·m, 4.3 Ibf.ft)

Keep the piston, cups, spring, snap ring and boot as

a set; do nOI substitute individual parts. MASTER CYILINDEF

Do nor allow the Coat all part with clean brake fluid before assembly.
plsron cup /Ips fO Dip the piston in brake fluid.
tum inSide out
Install the spring to the piston.
Install the piston assembly into the master cylinder.
I MASTER PISTON

I CUPS
C")
WASHER

13-12
 HYDRAULIC BRAKE
Be certain the snap Install the snap ring into the g roove in the master \
ring is firmly seared cylinder.
In th e groove
TOOL:
Snap ring pliers 01914-SA50001
Apply silicone grease to the inside of the boot.
..-'iiSiII

, BOOT

Apply silicone grease to the brake lever pivot bolt

sliding surface. DUST COVER ..-'iiSiII PIVOT BOLT/NUT
Install and tighten the pivot bolt to the specified
torque,
TORQUE: 5.9 N'm (0.6 kgf·m. 4.3 Ibf.ft)
Install and tighten the pivot nut to the specified
torque.
TORQUE: 5.9 N·m (0.6 kgf·m, 4.3 Ibf.ft)
Install the dust cover.

BRAKE
INSTALLATION
Place the master cylinder assembly on the handle·
bar. MASTER c, ""'u,"
Align the end of the master cylinder with the punch
mark on the handlebar
Install the master cylinder holder with it "UP" mark ..~~~. .
facing up. - -I",,;;'
Install and tighten the upper bolt first, then tighten
the lower bolt.
TOROUE: 9.8 N'm (1.0 kgf·m , 7 Ibf·ft )

"UP"
MARK

Align the brake hose eyelet between the stoppers

on the master cylinder.
Connect the brake hose with the oil bolt and new
sealing washers.
Tighten the oil boll to the specified torque.
TORQUE: 34 N'm (3 .5 kgf·m , 25 Ibf.ft)
Fill and bleed the hydraulic system (page 13-6).

OIL BOLT

13-13
HYDRAULIC BRAKE
REAR MASTER CYLINDER
REMOVAL
Drain the brake fluid f rom the hydraulic system
(page 13-5).
Remove t he brake hose oil boll, sealing washers
and brake hose.

Remove the brake pedal pivot bolt (page' 3-24).

Remove the cotter pin and joint pin.

Remove the rear master cylinder mounting bolts

and master cylinder.
MASTER CYLINDER M-,l!jNTING BOLTS

DISASSEMBLY
Remove the boot.
Remove the snap ring from the master cylinder
body using the special tool as shown.
TOOL: SNAP RI NG
Snap ring pliers 07914-SA50001

13-14
 HYDRAULIC BRAKE
Remove the push rod, master piston and spring.
Clean the inside of the cylinder with brake fluid.

PUSH ROD

INSPECTION
Check the piston boot, primary cup and secondary
cup for fatigue or damage. PRIMARY CUP

SECONDARY CUP

Check the master cylinder for abnormal scratches.

MASTER CYLINDER
Check the master cylinder piston for abnormal
scratches.
MASTER PISTON

13-15
HYDRAULIC BRAKE
ASSEMBLY

MASTER CYLINDER

MASTER PISTON

Y
PUSH ADD
ASSEMBLY

Keep the piston, cups, spring, snap ring and boot as

Do not allow the

Piston cup /Ips to
tum Insce OUI
a set; do not substitute individual parts.
Coat all part with dean brake fluid before assemblV.
Dip the piston in brake fluid.
I MASTER PISTON

/'-!
Install the spring to the piston.
Install the piston assembly into the master cylinder.
Apply grease to the piston contact area of the push
rod.
Install the push rod into the master cylinder. SPRING V.,..
I CUPS PUSH~oo
Be certam the snap Install the snap ring into the groove in the master
rmg IS firmly seated cylinder.
In the groove
TOOL:
Snap ring pliers 07914-SAS0001 SNAP RING

Install the boot.

13-16
 HYDRAULIC BRAKE
INSTALLATION
Instal the rear master cylinder and tighten the
mounting boils to the specified torque. MASTER CYLINDER MOUNTING BOLTS
,
TORQUE: 13 N 'm 11.3 kgf-m , 9Ibf.ft)

Connect the brake pedal to the push rod lower joint.

Install the joint pin and secure it with a new cotter
pin.

Install the brake hose with the oil bolt and new seal-
ing washers.
Push the eyelet joint against the stopper, then
lighten the oil bolt to the specified torque.
TORQUE: 34 N·m (3 .5 kgf·m, 25 Ibf.ft)
Fill and bleed the hydraulic system (page 13-6).

FRONT BRAKE CALIPER

REMOVAL
Drain the brake fluid from the hydraulic system
(page 13-5).
Remove the oil bolt, sealing washer and brake hose
eyelet jOint.

13-17
HYDRAULIC BRAKE
Remo ve the caliper mounting boils and then
remove the caliper and bracket as an assembly_
Remove the brake pads (page 13-8),

DISASSEMBLY
Remove the caliper bracket from the caliper body.
CALIPER BRIICKIET CAILlP"R PIN BOOT
Remove the brake pad spring from the caliper body.
Remove the brake pad retainer from the caliper
bracket. RETAINER _~~
Remove the caliper pin and bracket pin bools.

PAD SPR:lNo BRACKET PIN BOOT

If necessary, lightly apply compressed air to the cal -

iper fluid inlet to get the piston out.
Do not use h'gh Place a shop rag under the caliper to cushion the
pressure i;/lf or brmg piston when it is expelled.
the nozzle roo close Use the air in short spurts.
the rnlet

Be careful nOllO Push the dust seals and piston seals in and lift them
damage the piston out.
slldmg surface
Clean the seal grooves, caliper pistons and caliper
piston sliding surfaces with clean brake fluid.

DUST SEALS
•

13-18
 HYDRAULIC BRAKE
INSPECTION
Check the caliper cylinder and pistons for scoring, (:Y~IN[)EF"
scratches or damage. CALIPER

.,,~
CAUPER PISTONS
ASSEMBLY

PAD RETAINER

CALIPER PISTONS

PISTON SEALS

5.9 N·m (0.6 kgf·m,

4.3 Ibf.ft)

~
CAUPER BRACKET

DUST SEALS

PAD SPRING
BRACKET PIN BOOT

Coat new piston seals with clean brake fluid.

Coat new dust seals with silicone grease. e l PISTON
Install the piston seals and dust seals into the SEALS
grooves of the caliper body.
Coat the caliper pistons with clean brake fluid and
install them into the caliper cylinder with their
closed ends facing the caliper.

I .~
CAUPER PISTONS

13-19
HYDRAULIC BRAKE
Install the brake pad retainer onto the caliper
bracket. CALIPER BR.OCt<ET CAUPER PIN BOOT

Note lhe installation Install the pad spring into the caliper body. ...-'iSitI
dllecflon of the pad
Apply silicone g rease to the boot inside.
spnng
Install the caliper pin boot and bracket pin boot.
When assembling Assemble the caliper an bracket.
the caliper and
bracJ<.el. set the
boor mto the slrde
pm groove

PAD SPRING BRACKET PIN BOOT

INSTALLATION
Install the brake pads (page 13-8).
Install the caliper/bracket assembly to the fork leg.
Clean and apply a locking agent to the caliper
mounting bolt threads.
Install and tighten the mounting bolts to the speci-
fied torque.
TORQUE: 30 N ·m (3. 1 kgf'm , 22 Ibf·h )

Install the brake hose eyelet to the caliper body with

new sealing washers and oil bolt.
Push the brake hose eyelet to the stopper on the cal-
iper, then tighten the oil bolt to the specified torque.
TORQUE: 34 N·m (3.5 kgf·m , 25 Ibf·ftl
Firt and bleed the hydraulic system (page 13-61.

REAR BRAKE CALIPER

REMOVAL
Drain the brake fluid from the hydraulic system
(page 13-5).
1ic:",':PER
Remove the bolts and caliper guard plate.
loosen the brake hose oil bolt, sealing washers and
brake hose eyelet joint.
Remove the rear wheel (page 12-7).

13-20
 HYDRAULIC BRAKE
Remove the brake hose oil bolt, sealing washers
and brake hose eyelet joint. BRAKE CAllIP"R
Slide the brake caliper backward and pull it off of
the slide rail on the swingarm.
Remove the brake pads (page 13-8),

DISASSEMBLY
Remove the bolts and brake disc cover.
BOLTS

~ DISC COVER

Remove the caliper bracket from the caliper body.

RETAINER CALIPER PIN BOOT
Remove the brake pad spring from the caliper body.
Remove the brake pad retainer from the caliper
bracket.
Remove the caliper pin and bracket pin boots.

CALIPER BR,ACI"T BRACI(ET PIN BOOT

If necessary, lightly apply compressed air to the cal-
iper fluid inlet to get the piston out.
Do nor use tll{}hPlace a shop fag under the caliper 10 cushion the
pressure IJIf Of bongpiston when it is expelled.
the nollie 100 close Use the air in short spurts.
the ".Iel

13-21
HYDRAULIC BRAKE
Be careful not to Push the dust seal and piston seal in and lift them PISTON SEAL
damage the PIston out.
slldmg surface Clean the seal grooves, caliper piston and caliper
piston sliding surface with clean brake fluid.

INSPECTION
Check the caliper cylinder and pistons for scoring,
scratches or damage.

CALIPER PISTON

ASSEMBLY

CALIPER BRACKET CALIPER GUARD

BRACKET PIN BOOT

PAD RETAINER

CALIPER PIN BOOT

CALIPER BODY

DISC COVER

PAD SPRING CALIPER PISTON

~~ PISTON SEAL
DUST SEAL

13-22
 HYDRAULIC BRAKE
Coat new piston seal with clean brake fluid.
Coat new dust seal with silicone grease.
Install the piston seal and dust seal into the grooves fI~
of the caliper body. DUST SEAL
Coat the caliper piston with clean brake fluid and
install it into the caliper cylinder with their closed
end facing the caliper.

PISTON SEAL

CALIPER PISTON

Install the brake pad retainer onto the caliper

CAl"",, " PIN BOOT
bracket .
Note rhe InstaliaflOn Install the pad spring into the caliper body.
drr8ctIOn of rhe pad
Apply silicone grease to the boot inside.
sprmg
Install the caliper pin boot and bracket pin boot.
When assemblIng Assemble the caliper an bracket.
the caliper and
bracker, set Ihe
boor Into the slIde
pm groove CALIPER BR"CKI"

~ BR"CKIET PIN BOOT

Clean and apply a locking agent 10 the disc cover

bolt threads.
CWa BOLTS
Install the brake disc cover and tighten the bolts.

~ DISC COVER

INSTALLATION
Temporarily install the brake hose eyelet to the cali-
BRAKE CALIPER
per body with new sealing washers and oil bolt.
Install the brake pads (page 13-8).
Install the caliper/bracket assembly onto the swing-
arm by aligning the bracket tab with the slide rail on
the swingarm.

13-23
HYDRAULIC BRAKE
Instailihe rear wheel (page 12-11).
Push the brake hose eyelet to the stopper on the cal-
iper, then tighten the oil bolt to the specified torque.
TORQUE: 34 N·m 13.5 kgf·m . 25 Ibf·tt)
Fill and bleed the hydraulic system (page 13-6),
Install the caliper guard plate and tighten the
mounting bolts securely_

BRAKE PEDAL
REMOVAL
Remove the rear brake pedal pivot bolt, washer and
return spring.

Remove and discard the cotler pin.

Remove the joint pin.
Remove the brake pedal.

INSTALLATION
Inslall the brake pedal joint and secure it with a new
cotter pin.

13-24
 HYDRAULIC BRAKE
Hook the brake pedal return spring to the pedal and-
frame.
Apply grease to the sliding surface of the brake
pedal and pivot bolt.

Place the washer between the brake pedal and

frame as shown.
L

Install and tighten the brake pedal Pivot bolt to the

specified torque.

TORQUE :
'04: 25 N ·m (2.6 kgf·m , 19Ibf.ft)
After '04: 36 N·m (3.7 kgf·m , 27Ibf·ft)

13-25
MEMO
 14. IGNITION SYSTEM/ALTERNATOR

SYSTEM DIAGRAM ..................................... 14-2 IGNITION PULSE GENERATOR ················· 14-14

SERVICE INFORMATION ............................ 14-3 ALTERNATOR ····························· ············· ··· 14-15

TROUBLESHOOTING .................................. 14-5 IGNITION TIMING ······································ 14-18

IGNITION SYSTEM INSPECTION ............... 14-6 ENGINE STOP BUTTON ···························· 14-19

ECM (ENGINE CONTROL MODULE) ········ 14-10 REGULATOR/ RECTIFIER ('04) ··················· 14-20

IGNITION COIL··········································· 14-11 THROTTLE POSITION SENSOR

INSPECTION ............................................... 14-21 . .
ALTERNATOR COIL··································· 14-13

14-1
IGNITION SYSTEM/ ALTERNATOR
SYSTEM DIAGRAM
'04 model shown:

ENGINE CONTROL MODULE (ECM )

ENGINE STOP BUnON

REGULATOR/RECTIFIER
('04 ONLY)

IGNITION PULSE
GENERATOR

ALTERNATOR

54 N·m (5.5 kgf·m, 40 Ibf.tt)

14-2
 IGNITION SYSTEM I ALTERNATOR
SERVICE INFORMATION
GENERAL
• When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 14-5.
• The ignition timing odes nOI normally need to be adjusted since the Engine Control Module (ECM) is factory preset.
• The Engine Control Module (ECM) may be damaged if dropped . Also, if the connector is disconnected when current is
flowing, the excessive voltage may damage the module.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.

SPECIFICATION

Spark plug
'::o.a~~~iE:~[Opti=;oPtional
Spark plug gap
ITEM

~~Elndard ___--=====:-~ __jB~R'99E~G'-iiIN~G~KQI;:;=~ r

BR9EV (NGK)
0.5
SPECIACATION

.L
0.6 mm (0.020
W~2'"7"E"'S"RC<.V'I"'DENSO)
W27ESR-G (DENSO)
0.024 in)
Ignilion coil
resistance
primarY~i;;y~~g~gp;;~
I Secondary with plug cap
__--.:t::----==_ _ _~O.4 - 0.6knn 15 - 22
(a120 "C/6a OF) tseConda ry without plug cap
Ignition coil peak voltage ~~@~2~~~~~--t
Ignition pulse generator resistance (at 20 "e/68 OF)
Ignilion pulse generator peak \/oltage
_______
- = ====:J0[,:7 V minimum
10 - 17 kn
Cl~O"O180V minimum
- 280 11
_ __ _ _

Alternator charging coil resistance '04: 0.5 - 4.0 n

(a t 20 °C/68 "F)
Alternator exciter coil resislanc,o.:--i-After '04: Yellow Blue: Blue - White:
(at 20 C/68 F) 120-1800 24-44n
Alternator exciter coil peak voltag,e--Jf-'A~'ee,'~'Oo4,:_ 20 V minimum (Yellow - Blue and Blue White)
Ignition timing ("F" mark) '04: 30 ± 2° BTOC!3,OOO rpm
After '04: _ _~3~3.~7~±=2 " BTOC/4,OOO rpm

TORQUE VALUES
Alternator cover bolt 2.0 N·m (0.2 kgf.m, 1.4 Ibf·ftl
Flywheel nut 54 N·m (5.5 kgf·m, 40 Ibf·ft)

14-3
IGNITION SYSTEM! AL TERNA TOR
TOOLS
Peak voltage adaptor Ignition Mate peak voltage tester Universal holder
07HGJ-Q020100 MTP07·Q286 (U.S.A. only) 07725-0030000

(Not available in U.S.A.) with com·

mercially available digital multime-

l ter (impedance 10 Mruminimum, +

or Peak voltage tester (U.S.A. only)

Flywheel puller
07733-0010000
L

or 07933-0010000

14-4
 IGNITION SYSTEM / ALTERNATOR
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
- faulty spark plug
- loose spark plug cap or spark plug wire connection
- water got into the spark plug cap (affecting the ignition coil secondary voltage)
IGNITION SYSTEM
No spark at plug

Unu sual condition Probable cause (ch eck i n numerical order)

Ignilion coil low peak voltage. 1. Incorrect peak voltage adaptor connections (system is
primary normal if measured voltage is over the specifications
voltage with reverse connection).
2. The multimeter impedance is too low; below 10 Mnt
DCV.
3. Cranking speed is too slow (operating force of the kick-
starter is weak).
4. The sampling timing of the tester and measured pulse
were not synchronized (system is normal if measured
voltage is over the standard voltage at least once).
5. Poorly connected connectors or an open circuit in igni-
tion system.
6. Faulty alternator coil ('04).
7. Faulty exciter coil (After '04; measure the peak voltage).
8. Faulty ignition coil.
9. Faulty regulator/rectifier or condenser ('04).
10. Faulty ECM or ICM (in case when above No. 1 ~ 9 are
normal) .
No peak voltage. 1. Incorrect peak voltage adaptor connections (system is
normal if measured voltage is over the specifications
with reverse connection),
2. Short circuil in the engine stop bunon wire.
3. Faulty engine stop bunon.
4. loose or poorly connected ECM or reM connectors.
5. An open circuit or loose connection in Green wire.
6. Faulty alternator coil ('04),
7. Faulty exciter coil (After '04; measure the peak voltage).
8. Faulty ignition pulse generator (measure the peak volt-
age).
9. Faulty regulator/rectifier or condenser (,04).
10. Faulty ECM or ICM (in case when above No.1 ~~""
normal).
Peak voltage ,c,'""
nooc,m
= , T',' bC,'t'oCoc---t-·,-, C,c,"ulty
' spark plug or leaking ignition coil secondary cur-
spark jumps at plug. rent amperage.
2. Faulty ignition coil.
low peak voltage 1. The multi meter impedance is too low; below 10 Mnt
DCV.
2. Cranking speed is too slow (operating force of the kick-
starter is weak).
3. The sampling timing of the tester and measured pulse
were not synchronized (system is normal if measured
voltage is over the standard voltage at least once).
4. Faulty exciter coil (in case when above No. t - 3 are nor-
mal).
No peak voltage 1. Faulty peak voltage adaptor.
2. Faulty exciter coil.

I
I 'go't'oo p,',e
generator
low peak voltaCgCeC,- - - - - - - +--<,c,~T"hCe~mc':i'''tI~mCe'''''e'C'"'impedance is too low; below 10 Mru
DCV.
2. Cranking speed is too slow (operating force of the kick-
starter is weak).
3. The sampling timing of the tester and measured pulse
were not synchronized (system is normal if measured
voltage is over the standard voltage at least once).
4. Faulty ignition pulse generator (in case when above
No.1 - 3 are normal).
~No peak voltage. t. Faulty peak voltage adaptor.
I 2. Faulty ignition pulse generator.

14-5
IGNITION SYSTEM! ALTERNATOR
IGNITION SYSTEM INSPECTION
• If there is no spark at the spa rk plug, check all
connections for loose or poor contact before
measuring each peak vollage.
• If using the peak voltage adaptor, use a commer-
cially available digital mullimeler with an imped-
ance of 10 MruDCV minimum .
• The display value differs depending upon the
internal impedance of the multi meter.
Connect the peak voltage adaptor to the digital mul- , - -- -- - - - -=Dc'G='TC
ACL--:-
MCUCLCTC'OMC'=T='=R
::-l
limeter, or use the peak voltage tester (U.S.A. only). (impedance 10 MntDCV
If usmg the peak TOOLS: minimum)
IIO/rage lesrer Ign itio nMate pe ak voltage lester MTP07-0286
IU S.A onlyl. fol- (U.S.A. only) or
low the manufac- Pea k voltage a da pto r 07HGJ-0020100
turers Ins/rUC/lOn (Not available in
U.S.A.)
w ith commerci ally available dig ital multimeter
(imped ance 10 M O/ OCV min imum )

PEAK VOLTAGE ADAPTOR

IGNITION COIL PRIMARY PEAK

VOLTAGE
• Check all system connections before inspection.
If the system is disconnected, incorrect peak volt·
age might be measured.
• Check cylinder compression and make sure the
spark plug is installed correctly.
Remove the fuel tank (page 2-6).
'04 MODEL SHOWN:
Disconnect the spark plug cap from the spark plug.
Connect a good known spark plug to the spark plug
cap and g round the spark plug to the cylinder head.

14-6
 IGNITION SYSTEM! ALTERNATOR
With the ignition coil primary w ire connected, con·
'04 MODEL: BLACKNELLOW CONNECTOR
nect the peak voltage adaptor or peak vo ltage tester
to the ignition coil.

TOOLS:
Ignition Mate peak voltage tester MTP07·0286
(U.S.A . only) or
Peak voltage adaptor 07HGJ·0020100 •
(Not available in
U.S.A .)
with commercially available digital multimeter
(impedance 10 M nlOCV minimum)

CONNECTION:
BodV ground (+) - Black / yellow terminal H PEAK VOLTAGE ADAPTOR

Shift the transmission into neutral.

AVOId rouchmg the Crank the engine wi th kickstarter and read ignition
spark plug or fester coil primary peak \loltage.
probes /0 prevent
eleclflC shock
PEAK VOLTAGE: 100 V minimum
If the peak vo ltage is abnormal , check for an open
circuit or poor connection in the Black/yellow wire
or ground wire.
If defects are not found in the harness, refer to the
troubleshooting chart (page 14-5).
Refer to the illustration fo r arrangement of the con - r Ac,cTcEcRc,cO-4-, - - cB
cL-A
-C' --
KN
-'-'E
cL-LcOcW
c cC
" "'
OcNcN
cEcC=TO
""'R-'
nector and ignition coil of the model after '04. MODEl IFF""'c':';;:~,<,

V I

,
f

PEAK VOLTAGE ADAPTOR

14-7
IGNITION SYSTEM! ALTERNATOR
EXCITER COIL PEAK VOLTAGE
(AFTER '04)
• Check that the spark plug is installed correctly. 8P (BLACK) CONNECTOR
Remove the number plate (page 2·4).

~\1
~

Disconnect the leM BP (Black) connector. .-I

I / Y'Q3: . ' \ "
X - ~~ I
Connect the peak voltage adapter or peak voltage

!('1f
tester probes to the connector terminals of the wire
harness side.
I V I
TOOLS:
IgnitionMate peak voltage tes ter MTP07·0286
) J
(U .S.A. only) o r
I\>- ~ ; -' 1/
1 I

~ ~
Peak voltage adaptor 07HGJ·0020100
(Not available in ...L ,
U.S.A.'
with commercially available digital multimete r PEAK VOLTAGE ADAPTOR
P
(impedance 10 M O/Dev minimum)

CONNECTION:
High: Yellow (+, - Blue H
Low : Blue (+, - White H
Shift the transmission into neutral.
Crank the engine with the kickstarter and read the
peak voltage.
PEAK VOLTAGE : 20 V minimum
If the peak vohage measured at the leM connector is
abnormal, recheck the following:
Remove the fuel tank (page 2-6).
3P (BLACK) CONNECTOR
Remove the alternator 3P (Black) connector from \ vi'
the frame, then disconnect the 3P (Black) connector. , "-
Connect the peak voltage adapter or tester probes .... -,' '>
to the terminals of the alternator side and recheck
the peak voltage.
If the peak voltage measured at the ICM 8P (Black)
connector is abnormal and peak voltage at the alter·
nator 3P connector is normal, check for poorly con·
nected connector o r a broken wire harness.
If the peak voltage is abnormal at both connectors,
follow the checks described in the troubleshooting
(page 14-5). If all items are normal. the exciter coil is
faulty. See page page 14-15 for alternator replace·
=='"
PEAK VOLTAGE ADAPTOR
ment.

14-8
 IGNITION SYSTEMIALTERNATOR
IGNITION PULSE GENERATOR PEAK
VOLTAGE
• Check that the spark plug is installed correctly.
'04:
Remove the number plate (page 2·4).
BP (B LACK) CONNECTOR
Disconnect the ECM 8P (Black) and 4P (Black) con - 4P (BLACK) CONNECTOR
nectors.
Connect the peak voltage adaptor or peak voltage
tester probes to the connector terminals of the wire
harness side.
TOOLS:
IgnitionMate peak voltage tester MTP07·0286
(U.S.A. only) or
Peak voltage adaptor 07HGJ·0020100
(Not available in
U.S.A .)
with commercially avaitable digital rnultimeter
(impedance 10 M Q/DCV minimum)
PEAK VOLTAGE ADAPTOR

CONNECTION :
Blue/ yellow tanninal (+) - Green H
Shift the transmission into neutral.
Crank the engine with the kickstarter and read the
peak voltag8.
PEAK VOLTAGE: 0.7 V minimum

If the peak voltage measu red is abnormal, recheck

the following:
Disconnect the alternator 4P (Black) connect or.
Connect the peak voltage adapter or tester probes 4P(BLACK) CONN ECTOR
to the terminals of the ignition pulse generator side
and recheck the peak voltage.
=
CONNECTION :
Blue/ yellow tenninal (+J- Green/ white H

If the peak voltage measured at the ECM 8P (Black)

o..
and 4P (Black) connectors is abnormal and peak
voltage at the alternator 4P connector is normal,
check for poorly connecte d connector or a broken
wire harness.
If the peak voltage is abnormal at both connectors,
follow the checks described in the troubleshooting PEAK VOLTAGE ADAPTOR
(page 14·5). If all items are normal, the ignition L _ _______________---.J
pulse generator is faulty. See page page 14- 15 for
alternatorlignition pulse generator replacement.

14-9
IGNITION SYSTEM/ALTERNATOR
AFTER '04:
Remove the number plate (page 2-4),
8P CONNECTOR
Disconnect the leM SP (Black) and 4P (Black) con-
nectors.
Connect the peak voltage adaptor or peak voltage L
tester probes to the connector terminals of the wife
harness side.
: V )
TOOLS:
Ignitio nM ate pea k voltage t ester MTP07-0286
(U.S.A. o nly) or
)
Peak voltage ad aptor 07HGJ·0020100
(Not available in
U.S.A .)
wit h co mmercially available digital multimeter
PEAK VOLTAGE ADAPTOR
(imped ance 10 M O/DCV m inimum )

CONNECTION:
Blu e/ye llow terminal I+J - Green /white H
Shift the transmission into neutral.
Crank the engine with the kickstarter and read the
peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured is abnormal, recheck
the following:
Remove the fuel tank (page 2-6),
Remove the ignition pulse generator 2P (Black) con·
nector from the frame. then disconnect the 2P
(Black) connector.
Connect the peak voltage adapter or tester probes
to the terminals of the ignition pulse generator side
and recheck the peak voltage.
CONN ECTION :
Blue/yellow t ermin al (+' - Green/ whit e (-)
If the peak voltage measured at the ICM 8P (Black)
and 4P (Black) connectors is abnormal and peak
voltage at the ignition pulse generator 2P connector
is normal, check for poorly connected connector or PEAK VOLTAGE ADAPTOR
a broken wire harness.
If the peak voltage is abnormal at both connecto rs,
follow the checks described in the troubleshooting
(page 14·5). If all items are normal, the ignition
pulse generator is faul ty. See page page 14-15 for
alternator/ignition pulse generator replacement.

ECM (ENGINE CONTROL MODULE)

REMOVALIINSTALLA TION
Remove the number plate (page 2-4).
8P (BLACK) CONNECTOR
Disconnect the ECM 4P (Black) and 8P (Black) con -
4P (BLACK) CONNECTOR
nectors.
Remove the ECM from the rubber case. Y '\
Installation is in the reverse order of removal.

14-10
 IGNITION SYSTEM/ ALTERNATOR
IGNITION COIL
INSPECTION
'04:
Remove the fuel tank (page 2-6),
PRIMARY WIRE TERMINAL
Remove the spark plug cap.
Remove the ignition coil upper mounting bolt.
Disconnect the ignition coil primary wire connector.
Measure the ignition primary coil resistance
between the primary wire terminal and ground ter-
minal.
STANDARD: 0.4 - 0.6 n (20 cC/ 68 CF)

If the resistance is Qut of range, replace the ignition

coil.

GROUND TERMINAL

Measure the ignition secondary coil resistance

between the primary wire terminal and spark plug
;=======::':~P~R:'::M:CACR:Y:;:CW:;'~R':;E=T:;E;:::;R~M~'~NCACL~
cap.

STANDARD: 15 - 22 kn (20 " C/ 68 cFJ

SPARK PLUG CAP

If the resistance is out of range, remove the spark

plug cap from the spark plug wire and measure the
~======::::===========~
PRIMARY WIRE TERMINAL
ignition secondary coil resistance between the pri.
mary wire terminal and spark plug wire.

STANOARD : 10 - 17 kO (20 aC/ 68 OF)

If the resistance is out of range, replace the ignition

coil.

SPARK PLUG WIRE

AFTER '04:
Remove the fuel tank (page 2-6).
Disconnect the ignition coil primary wire connector.
Measure the ignition primary coil resistance
bet ween the primary wire t erminal and ground ter·
minal.
, Q '
STANDARD: 0.4 - 0.6 n (20 °e/68 OF)

If the resistance is out of range, replace the ignition 1

coil.

GROUND TERMINAL

14-11
IGNITION SYSTEM I AL TERNA TOR
Disconnect the spark plug cap.
GROUND TERMINAL
Measure the ignition secondary coil resistance
between the ground terminal and spark plug cap.
STANDARD: 15 - 22 kn (20 cC/68 "F)

If the resistance is out of range, remove the spark

""
~~~~~~~~~~~~;G;R~O~U~N~D~W~'~R~E=~
\

plug cap from the spark plug wire and measure the
ignition secondary coil resistance between the pri.
mary wire terminal and spark plug wire.

STANDARD: 10 - 17 kn (20 ~C /68 "F)

Q
If the resistance is Qut of range, replace the ignition
coil.

,
REMOVAL/INSTALLA TION
'04:
Remove the fuel tank (page 2-6).
BOLTS WIRE BAND
Remove the spark plug cap.
Remove the wire band and release the spark plug
wire from the O-ring.
Disconnect the ignition coil primary wire.
Remove the bolts and ignition coil.
Installation is in the reverse order of removal.

IGNITION COIL O-RING

AFTER '04:
Remove fuel tank (page 2-6).
IGNITION COIL BOLTS CONNECTOR

,:r,,\\;;::t.h
Remove the spark plug cap.
Disconnect the ignition coil primary wire connector.
Remove the bolts, ground terminal and ignition coil.
Installation is in the reverse order of removal.
\ , 'f,~ \ :i'
"
,,' ~..,.) c
~,

.:
."
SPARK PLUG
CAP

14-12
 IGNITION SYSTEM/ALTERNATOR
ALTERNATOR COIL
CHARGING COIL INSPECTION ('04)
Remove the right radiator shroud (page 2-4).
4P (NATURAL) CONNECTOR
Disconnect the regulator/rectifier 4P (Natural) con-
nector.
Measure the resistance between Ihe Yellow and
White terminals of the wire harness side.
CONNECTION: Yellow - White

STANDARD: 0.5 - 4.0 n (20 QC/ 68 OF) ••

If the resistance is out of range, disconnect the alter-

nator 4P (Black) connector and measure the resis-
~==~~~~4~P~I~B~L~A~C~K~)~C~O~N~N~E~C~T~O~R;=~
tance at Ihe 4P (Black) terminals of Ihe alternator
side.
If the resistance measured at the alternator 4P
(Black) connector is normal, check for an open cir-
cuit or poor connection in Yellow and White wire.
If defects are not found in the harness, refer to Ihe
troubleshooting chart (page 14-5).

EXCITER COIL INSPECTION

(AFTER ' 04)
Remove the fuel tank (page 2-6).
Remove the alternator 3P (Black) connector from
the frame, then disconnect the 3P (Black) connector.
Measure the resistance between the exciter coil ter -
minals of the wire harness side.
STANDARD:
Hig h (Yellow - Blue): 120 - 180 n (20 QC/ 68 OF)
l ow (Blue - White): 24 - 44 0 (20 eC/ 68 CF)
If the resistance is out of range, replace the stator
(page 14- 15).

3P (BLACK) CONNECTOR

14-13
IGNITION SYSTEM! ALTERNATOR
IGNITION PULSE GENERATOR
INSPECTION
'04:
Remove the number plate (page 2-4),
4P(BLACK) CONNECTOR
Disconnect the ECM SP (Black) and 4P (Black) con-
8P (BLACK) CONNECTOR
nectors.
Measure the resistance between the Blue!yellow
and Green terminals of the wire harness side.
CONNECTION :
Blue/ yellow (+) - Green (-)

STANDARD: 180 - 280 n (20 "C/ 68 OF)

~
If the resistance is Qut of range, disconnect the alter-
nator 4P (Black) connector and measure the resis-
~==~;~=4~P:I ~B~L~AC~K=1C~O~N~N~E~C~T~O~R~==!
tance at the 4P (Black) terminals of the ignition
pulse generator side.

CONNECTION:
Blue/ yellow (+) - Green /white (-)

STANDARD: 180 - 280 n (20 " C/68 CF)

If the resistance measured at the alternator 4P
(Black) connector is normal, check for an open cir-
cuit in Blue/yellow and Green/white wire or poorly
connected connector.
If the resistance is abnormal at both connectors, the
ignition pulse generator is faulty. See page page 14- L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---'
15 for alternator/ignition pulse generator replace-
ment.

CONNECTION:
Blue/ yellow (+) - Green/ white (-)
If the resistance is out of range, recheck the fo l low-
ing:
Remove the fuel tank (page 2-6).
Remove the ignition pulse generator 2P (Black) con-
nector. then disconnect the 2P (Black) connector.
Measure the resistance between the Blue/yellow
and Greenlwhite terminals of the sensor side.
CONNECTION:
Blue/yellow (+ ) - Green/ white H

STANDARD: 180 - 280 n (20 C/68 OF)

If resistance is out of specification, replace the alter-
nator (page 14- 15).

14-14
 IGNITION SYSTEM/ ALTERNATOR
ALTERNATOR
REMOVAL
'04 Disconnect the alternator 4P (Black) connector.

After '()4 Remove the fuel tank (page 2-6), then remove the r--------:c:cc::-c:::::c:=C""C-::::=-;:--,
alternator 3P (Black) and ignition pulse generator 2P \ ~
~p (BLACK) CONNECTOR
(Black) connector from the frame. l'
Disconnect the alternator 3P (Black) and ignition ~~' ~"'~" _,
pulse generator 2P (Black) connectors. "'"'" _ .......-; ..:::,., \

~<;Jtf '
~' ...... "

Z:~!~ti~~ )

'()4 only_ Remove the left radiator mounting bolts (page 5-9),
BOLTS
Remove the wire bands and releas e the alternator
wire from the wire clamp on the RC valve cover.
Remove the bolts and alternator cover.

WIRE BANDS ALTERNATOR COVER

Remove the gasket.

14-15
IGNITION SYSTEM! ALTERNATOR
Hold the flywheel with the universal holder, then
remove the nut and washer.

TOOL:
Universal holder 07725-0030000

Remove the flywheel using the flywheel puller.

TOOL:
Flywheel puller 07733·0010000 o r
07933-0010000

Remove the grommet, woodruff key, bolts and sta-

tOf.

INSTALLATION
Clean any oil from the tapered portion of the crank-
shaft and flywheel.
Install the woodruff key to the groove on the crank-
shaft.
Install the stator and tighten the bolts securely.
Install the grommet to the groove on the left crank-
case. ;;Iii;~

14-16
 IGNITION SYSTEM/ALTERNATOR
When you replaced Install the flywheel to the crankshah, aligning the 'f
the flywheel, stator groove on the flywheel and woodruff key.
or ECM(lCM),
Install the washer and nut.
ched; and ad/usl
Hold the flywheel with the universal holder and
the ognltlon timing
tighten the nut to the specified t orque.
{page 14~18}

TOOl:
Universa l holder 07725-0030000

TORQUE: 54 N·m (5.5 kgf.m , 40 Ibf.ft)

Install the new gasket.

Install the ahernator cover and tighten the bolts to

the specified torque.

TORQUE: 2.0 N' m (0.2 kgf·m, 1.4 Ibf.ft)

Route the alternator wire properly, clamp it with
wire clamp on the RC valve cover.
Secure the alternator wire with wire bands.

WIRE BANDS ALTERNATOR COVEA

'04 Connect the alternator 4P (Black) connector.

14-17
IGNITION SYSTEM / ALTERNATOR
After '04 Connect the alternator 3P (Black) and ignition pulse
generator 2P (Black) connectors.
Install the alternator 3P (Black) and ignition pulse
generator 2P (Black) connectors to the frame hook.
Install the fuel tank (page 2-7).

2P (BLACK) CQNNECTOR

IGNITION TIMING
• Read the manufacturer' s instructions for timing
light operation. BOLTS

Warm up the engine to normal operating temepera-

ture.
Stop the engine,
Disconnect the throttle position sensor connector
(page 4-10).
Remove the bolts and alternator cover.

ALTERNATOR COVER

Check thai the stator index mark is aligned with the

index mark on the crankcase.
;===========::;;;;:::======::;
Attach the timing light and tachometer.
Start the engine and hold it at 3,000 rpm (After '04:
4,000 rpm) while pointing the timing light towards
the index mark.

o
ORIGINAL INDEX MARK

If the stator's original index mark aligns between :===================~

the " F" marks, the engine is timed correctly. TEMPORARY
INDEX MARK
Remove the testing equipment and reassemble the
motorcycle.
If the stator's original index mark does not align
between the "F- marks, scribe a temporary index
mark on the stator setting plate that will align
o "F" MARK
between the " F" marks at 3,000 rpm (Aher '04: 4,000
rpm). CRANKCASE
MARK
I"\~J0t-~~
0,
"-
SETTING PLATE

14-18
 IGNITION SYSTEM/ ALTERNATOR
Stop the engine and do the following.
BOLT HOLE TEMPORARY
• This procedure is to be done aher replacing the A~~I INDEX MARK
ECM, ignition pulse generator/stator assembly or
flywheel.
• If you have checked the ignition timing as a trou-
bleshooting method and the marks did not align,
inspect the ECM, ignition pulse generator and
stator, before performing this procedure.
Remove the stator mounting bolts, setting plate
screw and setting plate.
Elongate the setting plate mounting bolt hole, then
reinstall it with its temporary index mark aligned
with the index mark on the crankcase.
SETTING PLATE SETTING PLATE
Install and tighten the stator mounting bolts and
setting plate screw. Make a new mark here MOUNTING BOLT

Recheck the ignition timing.

The stator setting plale index mark should now
align between the "F" marks on the flywheel.
Repeat the steps if the ig nition timing is not correct.
Grind off the old index mark. SETTING
n~~~c!::: SCREW

CRANKCASE
MARK RemOlle the old mark

ENGINE STOP BUTTON

INSPECTION
Remolle the number plate (page 2-4) .
4P (BLACK) CONNECTOR
'04 Disconnect the ECM BP (Black) and 4P (Black) con-
nectors.
Ahef'04 Disconnect the ICM BP (Black) connector.
Check for continuity at the Blacklwhile and Green
terminals of the wire harness side with the engine
stop button pressed.
There should be no continuity when the button is
not pushed.

Disconnect the engine stop button connectors.

CONNECTORS

14-19
IGNITION SYSTEM/ALTERNATOR
Check the engine stop button for continuity with the
ENGINE STOP BUTTON
button pressed.
There should be continuity when the button is
pressed and no continui ty when released .

REGULATOR/RECTIFIER ('04)
INSPECTION
VOLTAGE INSPECTION
Remove the number plate (page 2-4),
8P (BLACK) CONNECTOR
Disconnect the ECM 8P (Black) connector.
Measure the voltage at the ECM 8P (Black) connec-
tor of the wire harness side.
Crank the engine with kickstarter several times at a
few seconds interval.
CONNECTION: Red (+' - Green (-)
STANDARD: 5 V minimum
If the voltage measured is below 5 V, check the cir-
cuit inspection.
If the voltage measured is over 12 V all the time,
replace the regu lator/recti fie r unit.

CIRCUIT INSPECTION
Remove the fuel lank (page 2-6),
8P(BLACK) CONNECTOR
Disconnect the regulator/rect ifier 4P (Black) connec- 4P (NAT URAL) CONNECTOR
tor.
Check for continuity between the ECM BP (Black)
connector of the wire harness side and the regula-
tor/;rectifier 4P connector of the wire harness side.
CONNECTION : Red - Red
Green - Green
STANDARD: Continuity
If there is no continuity, check for poorly connected
connectors or a broken wire harness.
If there is continuity, replace the regulator/rectif ier.

REMOVAL/ INSTALLATION
Remove the fuel lank (page 2-6),
Disconnect the regulator/recti fier 4P (Natural) con-
nector.

14-20
 IGNITION SYSTEM/ ALTERNATOR
Remove the regulator/rectifier wire from the wire
band.

Remove the condenser from the tab on the frame.

Remove the regulator/rectifier wire from the wire
clamp.
Remove the bolt, clamp and regulator/rectifier unit.
Installation is in the reverse order of removal.
Route the wires properly (page 1-18),

THROTTLE POSITION SENSOR

INSPECTION
'04:
8P (BLACK) CONNECTOR
Remove the number plate (page 2-4 ).
;y
Disconnect the ECM 8P (Black) connector.
Measure the resistance between the Blue/green and
Yellow/red wire terminals of the wire harness side
connector.
STANDARD : 4 - 6 kfl (20 "C/68 OF)

AFTER '04:
4P (BLACK) CONNECTOR
Remove the number plate (page 2-4).
Disconnect the ICM 4P (Black) connector.
Measure the resistance between the Blue/green and
Yellow/red wire terminals of the wire harness side
connect or.
STANDARD: 4 - 6 kO (20 °C/68 OF)

14-21
IGNITION SYSTEM/ALTERNATOR
'04:
8P(BLACKICONNECTOR
Check that the resistance between the Blue/green 4P (BLACK) CONNECTOR
and Yellow/blue wire terminals varies from 0 10
about 5 kO with the t hrottle position while operating
the throttle grip.
fully closed - Fully open position :
Res istance increases
Fully open - Fully clo sed position :
Res istance decreases

AFTER '04:
<
j
Check that the resistance between the Blue/green
and Yellow/blue wire terminals varies from 0 to
abo ut 5 kO: wi t h the thro ttle position w hile operating
the throttle g rip.
Fully closed - Fully open position :
Resistance increases
Fully open - Fully closed position :
Resistance decreases r

If both measu rements are abnorma l, recheck the

'04 MODEL SHOWN:
following:
Remove the right radiator shroud (page 2-4) _
Disconnect the throttle position sensor (TPS) 3P
(Natural) connector.
Measu re t he resistance between the Blue/green and
Yellow/red wire term inals of the sensor side con-
••
nector.
STANDARD: 4 - 6 kn (20 cC/ 68 <IF)

3P (NATURAL) CONNECTOR

Check that the resistance between the Blue/green

'04 MODEL SHOWN:
and Yellow/blue w ire terminals varies from 0 to
about 5 kn with the throttle position while operating
the throttle g rip.

Fully closed - Fully open position :

Resistance increases
Fully open - Fully closed position :
Resistance d ecreases
If the measu rements at t he ECM (lCM ) connector(s)
are abnormal and the measurement at the TPS con-
nector is normal, check for poor connected of the
connectors or a broken wire harness.
If both measurements are abnormal, replace the 3P (NATURAL) CONNECTOR
TPS (page 4-20) ,

14·22
 15. WIRING DIAGRAMS

WIRING DIAGRAMS .. ·································· 15-2

15-1
WIRING DIAGRAMS
WIRING DIAGRAMS
'04:

.••- ~

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15-2
 WIRING DIAGRAMS
AFTER '04:

_.r;:.: I ~ ~ !:

...••
~

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ur...•
m~
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0030Z-KSR-7100

15-3
MEMO
 16. TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO POOR PERFORMANCE AT LOW AND IDLE
START, """ """ """ "" """ "'" "'" "'" """ "" "" 16·2 SPEED " " " " " ,."".,," " ' " "" '" "" "" "" "', "," "", 16·5

ENGINE LACKS POWER ,,"""''''''''',,'''''''''' 16·3 POOR PERFORMANCE AT HIGH SPEED ",, 16·6

POOR HANDLING '" "'" "" "" "" '" "'" '" "'" "", 16·7

16-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Carburetor Inspection
Check the fuel flow to carburetor.
Is fuel reaching the carburetor?
NO _ . Clogged fuel hose or fuel strainer scre en
• Sticking float valve
• Clogged fuel tank breather hose
YES - GO TO STEP 2.
2. Spark Test
Perform a spark test.
Is there a good spark?
NO _. Faulty spark plug
• Fouled spark plug
• Faulty ignition control module
• Broken or shorted spark plug wire
• Broken or shorted ignition coil
• Faulty igniting pulse generator
• Faulty alternator coil
• Faulty engine stop button
• Loose or disconnected ignition system wires
YES - GO TO STEP 3.
3. Cylinder Compression Inspection
Test the cylinder compression.
Is the compression normal?
NO - . Stuck piston ring
• Worn cylinder and piston rings
• leaking/damaged cylinder head gasket
• Faulty reed valve
• Cylinder head flaw
• Compression leak past crankcase
YES - GO TO STEP 4.
4. Engine Start Condition
Start by following the normal procedure.
Does the engine start but then stop?
YES _ . Improper choke operation
• Carburetor incorrectly adjusted
• Intake pipe leaking
• Improper ignition timing (faulty ignition coil or ignition pulse generator)
• Crankcase leaking
• Fuel contaminated
NO - GO TO STEP 5.
5. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug in good condition ?
NO _ . Flooded carburetor
• Damaged starter valve seal
• Clogged air cleaner

16·2
 TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspection
Raise wheel off the ground and spin bV hand.
Does the wh ee/ spin freely?
NO _ . Brake dragging
• Worn or damaged wheel bearings
• Drive chain too tight
YES - GO TO STEP 2.
2. Tire Pressure Ins pection
Check the tire pressure.
Is the tire pressure correct?
NO - Faulty lire valve
YES - GO TO STEP 3.
3. Clutch Ins pection
Accelerate rapidly from low to second.
Does the engine speed change accordingly when clutch is released?
NO _ . Clutch slipping
• Worn clutch discs/plates
• Warped clutch discs/plates
• Weak clutch spring
YES - GO TO STEP 4.
4. Engine Performance Inspection
Accelerate lightly_
Does the engine speed increase?
NO - . Carburetor choke is on
• Clogged air cleaner
• Restrict ed fuel flow
• Clogged exhaust chamber
• Pinched fuel f ill cap breather
• Excessive carbon build-Up on the exhaust valve
YES - GO TO STEP 5.
5. Ignition Timing Inspection
Check the ignition timing.
Is the ignition timing norma17
NO _. Faulty Engine Control Modu le (ECM)
• Faulty ignition pulse generator
YES - GO TO STEP 6.
6. Cylinder compression Inspection
Test the cylinder compression.
Is the compression normal?
NO _ . Faulty reed valve
.. Worn cylinder and piston rings
• leaking/damaged head gasket
• Flaws in cylinder head, cylinder or crankcase
YES - GO TO STEP 7.
7. Carburetor Inspection
Check the carbu reto r for clogs.
Is the carburetor clogged?
YES _ .o Carburetor dirty
.. Dirt getting past air cleaner
NO - GO TO STEP 8.

16-3
TROUBLESHOOTING
8. Spark Plu g Inspection
Remove and inspect the spark plug_
Is the spark plug in good condition?
NO _ . Plug not serviced frequently enough
• Incorrect spark plug heat range
• Incorrect fuel/oil mixture
YES - GO TO STEP 9.
9. Over Heating Inspection
Check for engine over healing.
Is the engine over heating ?
YES _ . E)(cessive carbon build-up in combustion chamber
• Use of poor quality fuel
• Clutch slipping
• Lean fuel mixture
• Wrong type of fuel
NO - GO TO STEP 10.
10. Engine Knocking Inspection
Accelerate or run at high speed.
Does the engine knock?
YES _. Worn piston and cylinder
• Wrong type of fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advanced !faulty engine control module)
• lean fuel mixture
NO _. Engine does not knock

16-4
 TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Ignition Timing Inspection
Check the ignition liming.
Is the ignition timing normsl?
NO _. Im proper ignition timing (Faulty engine control module)
• Faulty alternator
YES - GO TO STEP 2.
2. Carburetor Air Screw Inspection
Check the carburetor air screw adjustment.
/5 the air screw correct?
NO - (page 4-5)
YES - GO TO STEP 3.
3. Intake Manifold Leaking Inspection
Check for leaks in the intake manifold.
Is there leaking?
YES _ . Loose insulator clamp
• Damaged insulator and reed valve
NO - GO TO STEP 4.
4. Spark Test
Perform a spark test.
15 there 8 good spark?
NO _. Faulty carbon or wet fouled spark plug
• Faulty Engine Control Module (ECM)
• Faulty ignition coil
• Broken or shorted spark plug wire
• Faulty engine stop button
• Faulty ignition pulse generator
• Faulty alternator
YES - GO TO STEP 5.
5. Throttle Position Sensor Inspection
Check for throttle position sensor.
Is the throttle position sensor correct?
NO - Faulty throttle position sensor
YES - GO TO STEP 6.
6. Inspect The RC Valve System
Check for AC valve system.
Is the RC valve system correct?
NO _ . Faulty RC valve
• Excessive carbon build-up on the flap valves or valve shaft
YES - No problem

16-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1, Ignition Timing Inspection
Check the ignition timing.
Is the ignition timing normal?
NO _. Faulty Engine Control Module (ECM)
• Faulty alternator
YES - GO TO STEP 2.
2. Fuel line Inspection
Disconnect the fuel tube at the carburetor.
Does the fuel flow freely ?
NO _ . Clogged fuel line
• Clogged fuel fill cap breather
• Clogged fuel valve
• Clogged fuel filter
YES - GO TO STEP 4.
3. Air Cleaner Inspection
Remove the air deaner and check for dirty.
Does the air cleaner dirty?
YES - Not cleaned frequently enough
NO - GO TO STEP 4.
4. Carburetor Inspection
Remove the carburetor and check for clogged jets.
Are the jets clogged?
YES - Contaminants in the fuel
NO - GO TQ STEP 5.
5. RC Valve System In spection
Check the RC valve system.
Is the system correct7
NO - Damaged RC valve system
YES - GO TO STEP 6.
6. Carburetor Setting Inspection
Install a large carburetor main jet.
Does the engine condition improve7
NO - Jet size wrong. rejet in the opposite direction
YES - Tune for special conditions

16-6
 TROUBLESHOOTING
POOR HANDLING
Steering is heavy
• Steering bearing adjustment nut too tight
• Damaged steering head bearings
Eithe r w heel is wobbling
• Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Swing arm pivot bearing excessively worn
• Bent frame
• loose swingarm pivot bolt
The motorcycle pulls t o one side
• Front and rear wheel not aligned
• Bent fork
• Bent swing arm
• Bent axle
NOTE :
• Follow these recommendation, the motorcycle must be adjusted as follows;
- Fork: compression damping at standard position, at standard fork oil quantity and viscosity, and air
pressure zero.
- Shock: nitrogen pressure 142 psi, compression and rebound damping standard position, and
spring preload adjusted so the bikes sags correctly with rider seated - see Owner's manual for
spring preload adjustment
• Make only one change in the preferred sequence of adjustment.
Fro nt End Oversteers; It Cuts Too Sharply (such as in sand )
• Increase the fork oil capacity
• Use stiffer fork spring
Fro nt End Underst eers; It Washes Out Or Pu shes (such as on at tight track with hard gro und )
• Lower the fork oil capacity
• Use satter fork spring
Front End Hunts At High Speed; It W anders Under Power
• Increase the fork oil capacity
• Increase shock preload
Front End Shakes Under Heavy Braking
• Decrease shock preload
• Increase shock rebound damping
• Increase the fork oil capacity
Front End Hops Over Bumps In Sm ooth Turns
• Change to lighter fork oil
• Decrease the fork oil capacity
• Decrease for compression damping
• Use satter fork spring
Rear End Ho ps Over Bumps While Accelerating
• Decrease shock preload
• Decrease shock compression damping
Rear End Gets Poor Traction White Accelerating Aw ay From A Corner
• Decrease shock preload
• Decrease shock compression damping

16-7
MEMO
 17. INDEX
AlA CLEANER .. ................ ................ .................... ············ 3-6 FUEL TANK ··· ................................................. ······ .. ······ .. 2-6
AlA CLEANER HOUSING ................ ... ... ........ ...... ... ...... . 4-24 GEARSHIFT UNKAGE ... .. ........ .... ....... ......... .. ............. ... 9-21
ALTERNATOR ·· ..... ..... ..... ····· .. ··· ········ .... .. ···· ·· .......... ·.. 14- 15 GENERAL SPECiFiCATIONS ·.. ······· ······················ .. ·.. ······' ·4
ALTERNATOR COIL ................................... ...... ......... 14-13 GOVERNORNALVE LINKAGE (AFTER '04) .......... ··· .... 8- 17
BRAKE FLUID ...................................................... ·········· 3-15 HANDLEBAR· ··· .. ···· ··· ········ .... ······· .... ····· .... ···· ........ ······· 11 -27
BRAKE FLUID REPLACEMENT/AIR BLEEDING··········· 13-5 HYDRAULIC BRAKE SPECiFiCATIONS ·· ·· · ····· ·· 1-10
BRAKE PAD WEAR ··· ........ ..... .. . .............. ................ .... 3- 16 IGNITION COil .... ·.. .. ....... ....... ...... 14-1 1
BRAKE PAD/DiSC ······· ·· ·· ··· .. ········ ···················· ···· ·········· 13·8 IGNITION PULSE GENERATOR·· ··········· .. ·.. ····· .... ······· 14-1 4
BRAKE PEDAL .. ........... ................ ................ 13-24 IGNITION SYSTEM INSPECTION ............................... 14-6
BRAKE SySTEM ······· .. ..... .......... ·· ···· ··· ············· 3-17 IGNITION SYSTEM/ALTERNATOR
CABLE & HARNESS ROUTING ............... .. ....... ....... .... 1-18 SPECiFiCATIONS .. · .. ·.................... .. .......... · ...... ·........ .. ·'-10
CARBURETOR ADJUSTMENT, MAJOR ······ ········· ·.... ···· 4-5 IGNITION TIMING ····.... ········· .. ····················· .. ············· 14-18
CARBURETOR ADJUSTMENT, MINOR .. ·...................... 4-5 KICKSTARTER ............................................................... 9- 17
CARBURETOR ASSEMBLY/INSTALLATION ............... 4-15 LUBRICATION & SEAL POINTS ······· .. ······ ···················· 1-16
CARBURETOR REMOVAUDISASSEMBLY········ .. ··· .. ··· 4·10 LUBRICATION SYSTEM SPECIFICATIONS ................... 1-6
CARBURETOR TUNING INFORMATION CHART .... ·.. .. · 4-7 MAINTENANCE SCHEDULE ...... .... ........... .. .. ·· .. ·.......... ·3-4
CLUTCH ......... ........................................ ................... ..... 9-10 MODEL IDENTIFICATION ····· .. ·········· .. ··· .. ········· .. ······· .... · ' -2
CLUTCH SYSTEM ................................. ............ .. .......... 3-17 NUMBER PLATE ·.. ····· .. · .. .. ····· .. .. .. ··· ................ .. .. 2·4
CLUTCH/ KICKSTARTER /GEARSHIFT LINKAGE NUTS, BOLTS, FASTENERS .... .................... ·........ ···· .. 3-22
SPECIFICATIONS .. ....... .......... ........ ........ ....... ................ 1-7 OPTIONAL PARTS .. .... ·· .. ...... · .. · .... ........... ...... ........ .... · 1-25
COMPONENT LOCATION RADIATOR .................... .. ................ .. .. .. ··5·9
ClUTCH/KICKSTARTER/GEARSHIFT LINKAGE ....... 9·2 RADIATOR COOLANT ········ .. ······· .. ···· .. ·· .... ··· .. ·.. ········ ······3·9
COOLING SySTEM ·.... ··· ········· .... ··· ······ .... · .. ···· ····· .. ·.. ·· 5-2 RADIATOR SHROUD .... ······ .. ····· ···· .. ······· .. ······· .... ······· .. ···2-4
CRANKCASE/CRANKSHAFTrrRANSMISSION .. .... 10-2 RC VALVE CABLE ('04) ·· ............ ...... · .. ·........ ·.. .. ·.. ·...... ·.. 8-21
CYLINDER HEAD/CYLINDER/PISTON ....................... 7-2 REAR BRAKE CALIPER ............ · ...... ·...... ................ .. .. 13-20
ENGINE REMO VA U INSTALLATION ......................... 6-2 REAR MASTER CYLINDER .. · .. ···· .... ·· .. ··· .... ·· .... ······ .... ·13-14
FRONT WHEE USUSPENSION/STEERING · ...... .. ·.... 11 -2 REAR WHEEL .. ··· .. ........ .... .... ...... .............. .. .. ·· .......... ··· 12-7
FUEL SYSTEM ...... ...... .... .. .... ........... .. ....... ··· .. .... .... .. · 4-2 REAR WHEEUSUSPENSION SPECIFICATION S .. ...... .... 1-9
HYDRAULIC BRAKE ........ ....... ........ ......... ......... .. .... 13-2 REED VALVE .. ....... ........ ............ .. .. .. ·· 4-2 1
IGNITION SYSTEM/ALTERNATOR·· .............. ·...... ·.. 14-2 REGULATOR/RECTIFIER 1'04 j .. ·· ................ · ........ ·.... ·.. 14-20
RCVALVE .............. · .. .............. .... ........... .. .... .......... .. .. 8·2 RIGHT CRANKCASE COVER .. ·· .... .... 9·5
REAR WHEEUSUSPENSTION ····· ······· ······· ·.. · .. ·· ······ 12-2 SEAT······ .... ··· ·· ·······,·, ·············· .... ········ .. ,· ................ ,..... .... 2-3
CONTROL CABLES ........ ...... ........... ..... ........ ... ... ........... 3-19 SERVICE INFORMATION
COOLANT REPLACEMENT .. ······· ·················· .. ···· .. ·········· 5-8 CLUTCH/KICKST ARTE R/GEARSHIFT LIN KAGE··· .... · 9-3
COOLING SYSTEM ..... ..... ......... ................ ··· ········ ········ 3-9 COOLING SYSTEM .. ········· .. ·, ··· ··· .... ,,····· .. ······· .. ,······ .. ·5-4
COOLING SYSTEM SPECiFiCATIONS · .. ...... ·.. ·· .. · ........ .. 1-6 CRANKCASE/CRANKSHAFTfTRAN SMtSSION ....... 10-3
CRANKCASE ASSEMBly .......... · ........ ....... ............... 10-19 CYLINDER HEAD/CyLINDER/PiSTON··· ·· .. ··········· ··· ·.. 7-4
CRANKCASE BEARING REPLACEMENT .... ......... ...... 10-13 CYLINDER/PISTON .. .............................................. ·.. ·8-4
CRANKCASE SEPARATION ......................................... 10-7 ENGINE REMOVAU INSTALLAT10N·· ··················· ·· ·.. 6·3
CRANKCASE/CRANKSHAFTITRANSMISSION FRAME/eODY PANE l S/EXHAU ST SYSTEM .... .... .... 2-2
SPECIFICATIONS ........... ...... .. .... .. .... .... .. .. .... ...... .... .. ....... l -8 FRONT WHEEUSUSPENSION/ STEERIN G .... · 11-3
CRANKSHAFT INSTALLATION · ....... ........ ....... ......... 10-16 FUEL SYSTEM ..... ..... .......... .................. ...................... 4-3
CRANKSHAFT REMOVAL ... ........... .... ....................... 10- 11 HYDRAULIC BRAKE ·.. ······· .... ·· .. ·· .... · ···· .. ······ 13-3
CYLINDER HEAD .. ·· .. ········· .... ···· ··· ··· ·.... ······· ·· .... ·· .. ······· ·· · 7·6 IGNITION SYSTEM/A LTERNATOR .... ·.... ··· .. ·...... · .... 14-3
CYLINDER HEAD DECARBONIZING .... ...... ................ 3-10 MAINTENANCE ............... ...... ............. .. ...... · .. ·3-2
CYLINDER HEAD/CYLINDER/PISTON REAR WHEEUSUSPENSTION · .................... 12-3
SPECIFICATIONS .......... ................. ............................... 1-7 SERVICE RULES ........................... ·.. ··········· .. ··· .. ···· .. ······1-2
CyLINDER/PiSTON .... · .............. · ....... .......... ...... ......... .. ·7-8 SERVO MOTOR 1'04) .. .. ............. .. ...... ,........................ ·8- 15
DRIVE CHAIN······· .. ········· ····· ···· .. ········· .... ··· ···· ·· ···· .... ···· ··3· 12 SHOCK ABSORBER · ...... ....... ... ....... ... " .... ..... ,........... , 12- 13
DRIVE CHAIN ROLLER .... ...... ........... .... ....................... 3-14 SHOCK LINKAGE .. ···· ...... · .......... ·12-28
DRIVE CHAIN SUDER .... ···· ·.. ·.. · .. ··············· .. ·· 3-13 SIDE COVERS ............ .. ........................................ 2-3
DRIVE/DRIVEN SPROCKET ·········· ·· ··················· .. ·········· 3-14 SPARK PLUG ........... .. ................. .. .................. ··3-8
ECM (ENGINE CONTROL MODU LE) .......... ..... 14-10 STANDARD TORQUE VALUES .. ........ .. .... · 1· 11
ENGINE & FRAME TORQUE VALUES .. · .. · .. .......... ·.. · .. · 1-11 STEERING HEAD BEARINGS .......... ·.................... · ...... ·3-23
ENGINE INSTALLATION .... .. ......... ······ ·············· .. ··· .. ····· 6-6 STEERING STEM ......................................................... 11 -34
ENGINE REMO VA L ..................................... ...... ......... ···6-4 SUB·FRAME ·· .......... · ............................................. .... .... 2-5
ENGINE STOP BUTION .............. .... ...... .... ..·14·19 SUSPENSION ......................... ............. .. ........ .... 3·2 1
EXHAUST DEPOSIT DRAINING ('04) ...... ...... ·.. ·.... .... ·· .. · 8-7 SWINGARM .... ...... ..... ····· ·· .. ···· ·· .. ···· ··· .. ········· .... 12-33
EXHAUST PiPE·· ········ .. ·· .. ·········· .. · .. ·········· .... ·.. ···· .. ··· .. ··· ··2-7 SWIN GARMISHOCK LINKAGE·.... ······ .. ······· .. ··· .. ·· .... ···· 3-22
EXHAUST VALVE .. ······· ···· ·.. ······ .. ·.. ··············· .. ·· .. ····· .. ····· 8-7 SYSTEM TESTING .... .... .................................... ,", .......... 5-7
EXHAUST VALVE DECARBONiZiNG··· ······ ········ .. ··· .. ··· 3-10 THROTILE OPERATION ·· .... .............. ·· .......... · .... ·3-6
EXPANSION CHAMBER/SILENCER .. ...... .. .. .. 3-20 THROTILE POSITION SENSOR ..... .. ....... .... ................. 4-20
FORK .. .... ·.... ···· ...... ........ ·· ...... .... ···· .............. ...... ........ 1' -12 THROTIlE POSITION SENSOR INSPECTION .......... 14-21
FRONT BRAKE CALIPER ........................................... 13-17 TRANSMISSION ASSEMBLY/INSTA LLATlQN ··· .... ··· 10-17
FRONT MASTER CyLINDER ·· .. · .... ·.... ·.... ·.. · ............... 13· 10 TRANSMISSION OIL ·· .... ······· .. ·· ···3-11
FRONT WHEEL .... .......... ........ ..................... ...... ....... ... 11-7 TRANSMISSION REMOVAUDISASSEMBLY ·········· .. ·· 10-9
FRONT WHEEU SUSPENStON/STEERING TROUBLESHOOTING
SPECIFICATIONS ............. .... ......... ·· .. ·· .. · .. ··· .. ·.. ············· 1-9 CLUTCH/KICKST ARTE AlG EARSHIFT LI NKAGE········ 9-4
FUEL SYSTEM SPECI FICATIONS .... ·.. ··· ........ ··· .. · .. ........ ' -6 COOLING SYSTEM .. ............. .. ........................ .. .. 5-6

17-1
INDEX
TROUBLESHOOTING HYDRAULIC BRAKE .. ...... .... ....... ... ........ .. ......... ··· .. · 13-4
CAANKCASE/CAANKSHAFTfTAANSMISSION ···· ·· 10·6 IGNITION SYSTEM/ALTERNATOR ................... ····· · 14-5
CYLINDER HEAD/CYLINDER/PISTON ··········7-5 POOR HANDLING .............................................. ······16-7
CYLINDER/PISTON ....... ..... ....... ·········8-5 POOR PERFORMANCE AT HIGH SPEED······· ·········16·6
ENGINE DOES NOT START OR IS HARD TO POOR PERFORMANCE AT LOW AND IDLE
START·· ·········· ·· .... ·· 16-2 SPEED···· .. · .. ······ .. ·.. · ............................... ·· .. ··16·5
ENGINE LACKS POWER·· ····· ······ .. ·· 16-3 REAR WHEEUSUSPENSTION ·················· .. · ········ .... 12·6
FRAMEiBODY PANELS/EXHAUST SYSTEM ............ 2-2 WATER PUMP·· .... ········ .... ····· ·· .. ········· .. ········ .. ·········· .... ··5·11
FRONT WHEEUSU$PENSIQN/ STEERING ·············· 11 -6 WHEELSIT1RES ·.... ······· .... ········ .... ······ .... ···· .. ·.... ···· ........ ·3·22
FUEL SYSTEM ······ ···· 4-4 WIRING D1AGRAMS ........................ · .............. ·...... ·...... ·15·2

17-2