A Few Words About Safety: How To Use This Manual

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HOW TO USE THIS MANUAL

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

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
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How To Use This Manual
This manual describes the service procedures for the ANF110MS-D.
Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removal/installation of components that may be
required to perform service described in the following sections.
Section 4 through 20 describe parts of the motorcycle, grouped according to location.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
If you don't know the source of the trouble, go to Troubleshooting section.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: January, 2012
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SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Honda Moly 60 (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.
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CONTENTS
GENERAL INFORMATION 1
FRAME/BODY PANELS/EXHAUST SYSTEM 2
MAINTENANCE 3
IGNITION SYSTEM 4
ELECTRIC STARTER SYSTEM 5
FUEL SYSTEM 6
LUBRICATION SYSTEM 7
CYLINDER HEAD/VALVES 8
CYLINDER/PISTON 9
ALTERNATOR/STARTER CLUTCH 10
CLUTCH/GEARSHIFT LINKAGE 11
CRANKSHAFT/TRANSMISSION/KICKSTARTER 12
ENGINE REMOVAL/INSTALLATION 13
FRONT WHEEL/BRAKE/SUSPENSION/STEERING 14
REAR WHEEL/BRAKE/SUSPENSION 15
HYDRAULIC BRAKE 16
BATTERY/CHARGING SYSTEM 17
LIGHTS/METERS/SWITCHES 18
WIRING DIAGRAM 19
INDEX
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MEMO
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1. GENERAL INFORMATION
SERVICE RULES ··········································1-2 CRANKSHAFT/TRANSMISSION/

KICKSTARTER SPECIFICATIONS ·············· 1-7
MODEL IDENTIFICATION ····························1-2
FRONT WHEEL/SUSPENSION/
GENERAL SPECIFICATIONS ······················1-4 STEERING SPECIFICATIONS ····················· 1-8
IGNITION SYSTEM SPECIFICATIONS ········1-5 REAR WHEEL/BRAKE/SUSPENSION

SPECIFICATIONS········································· 1-8
ELECTRIC STARTER SYSTEM
SPECIFICATIONS ·········································1-5 HYDRAULIC BRAKE SPECIFICATIONS····· 1-8
FUEL SYSTEM SPECIFICATIONS···············1-5 BATTERY/CHARGING SYSTEM

SPECIFICATIONS········································· 1-9
LUBRICATION SYSTEM
SPECIFICATIONS ·········································1-5 LIGHTS/METERS/
SWITCHES SPECIFICATIONS····················· 1-9
CYLINDER HEAD/
VALVES SPECIFICATIONS··························1-6 TORQUE VALUES ········································ 1-9
CYLINDER/PISTON SPECIFICATIONS ·······1-6 LUBRICATION & SEAL POINTS ··············· 1-13
CLUTCH/GEARSHIFT LINKAGE CABLE & HARNESS ROUTING················· 1-15

SPECIFICATIONS ·········································1-7
EMISSION CONTROL SYSTEMS ·············· 1-24
ALTERNATOR/STARTER CLUTCH
SPECIFICATIONS ·········································1-7 MANUAL CLUTCH SYSTEM······················ 1-25
1-1
GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design
specifications may cause damage to the motorcycle.
2. Use the special tools designed for 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, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-15).
DESTINATION CODE
Throughout this manual, the following code is used to identify individual types for each region.
DESTINATION CODE REGION

CA CAMBODIA
MODEL IDENTIFICATION
1-2
GENERAL INFORMATION
SERIAL NUMBERS
The Vehicle Identification Number (V.I.N) [1] is stamped on the seat stay as
shown.
[1]
The engine serial number [1] is stamped on the lower left side of the
crankcase.
[1]
The carburetor identification number [1] is stamped on the right side of the
carburetor body. [1]
1-3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,919 mm
Overall width 709 mm
Overall height 1,080 mm
Wheelbase 1,227 mm
Seat height 760 mm
Footpeg height 272 mm
Ground clearance 135 mm
Curb weight 100 kg
FRAME Frame type Back bone type
Front suspension Telescopic fork
Front axle travel 81 mm
Rear suspension Swingarm
Rear axle travel 82 mm
Rear damper One side operation tube type
Front tire size 70/90-17 M/C 38P
Rear tire size 80/90-17 M/C 50P
Tire brand IRC Front NR69
Rear NR69
VEE RUBBER Front V357F
Rear V357R
CST Front C-6016
Rear C-6016R
Front brake hydraulic disc brake
Rear brake Mechanical leading trailing
Caster angle 26°30’
Trail length 68 mm
Fuel tank capacity 3.7 liter
ENGINE Bore and stroke 50.0 x 55.6 mm
Displacement 109.1 cm3
Compression ratio 9.0: 1
Valve train 2 valve, single chain driven SOHC
Intake valve opens at 1 mm lift 5° BTDC
closes at 1 mm lift 30° ABDC
Exhaust valve opens at 1 mm lift 34° BBDC
closes at 1 mm lift 0° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper element
Crankshaft type Assembled type
Engine dry weight 22.6 kg
Cylinder arrangement Single cylinder inclined 80° from
vertical
CARBURETOR Carburetor Type Piston valve type
Throttle bore 18 mm
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Automatic centrifugal type
Transmission Constant mesh, 4-speed
Primary reduction 4.059 (69/17)
Final reduction 2.642 (37/14)
Gear ratio 1st 2.615 (34/13)
2nd 1.555 (28/18)
3rd 1.136 (25/22)
4th 0.916 (22/24)
Gearshift pattern Left foot operated return system
(rotary system; only when the
motorcycle is not running)
- N - 1 - 2 - 3 - 4 (- N)
1-4
GENERAL INFORMATION
ITEM SPECIFICATIONS
ELECTRICAL Ignition system DC-CDI
Starting system Kickstarter with electric starter
motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened/single phase, half
wave rectification
Lighting system Alternator
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spark plug NGK CPR6EA-9S
DENSO U20EPR9S
Spark plug gap 0.80 – 0.90 mm
Ignition coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 10° BTDC at idle
ELECTRIC STARTER SYSTEM SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT
Starter motor brush length 7.0 mm 3.5 mm
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Carburetor identification number PB7UL
Engine idle speed 1,400 ± 100 min-1
Throttle grip freeplay 2 – 6 mm
Main jet #90
Slow jet #35
Float level 11.7 mm
Air screw initial opening See page 6-11
PAIR control valve specified vacuum 60 kPa
LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm
Engine oil capacity At draining 0.75 liter –
At disassembly 1.0 liter –
Recommended engine oil Honda “4-stroke motorcycle oil” or an –
equivalent motor oil
API classification: SG or higher
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Oil pump rotor Tip clearance – 0.15
Body clearance 0.15 – 0.21 0.26
Side clearance 0.03 – 0.09 0.15
1-5
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm
Cylinder compression 824 kPa (120 psi) at
–
400 min-1
Cylinder head warpage – 0.05
Valve, Valve clearance IN/EX 0.10 ± 0.02 –
valve guide Valve stem O.D. IN 4.975 – 4.990 4.965
EX 4.955 – 4.970 4.945
Valve guide I.D. IN/EX 5.000 – 5.012 5.03
Stem-to-guide clearance IN 0.010 – 0.037 0.065
EX 0.030 – 0.057 0.085
Valve guide projection IN/EX 9.1 – 9.3 –
Valve seat width IN/EX 0.90 – 1.10 1.6
Valve spring free length IN/EX 30.67 (1.207) 29.70
Rocker arm/ Rocker arm I.D. IN/EX 10.000 – 10.015 10.10
shaft Rocker arm shaft O.D. IN/EX 9.972 – 9.987 9.91
Rocker arm-to-shaft
IN/EX 0.013 – 0.043 0.044
clearance
Camshaft Cam lobe height IN 32.194 – 32.434 32.16
EX 31.990 – 32.230 31.96
Cam chain Push rod O.D. 11.985 – 12.000 11.94
tensioner Spring free length 111.3 109
CYLINDER/PISTON SPECIFICATIONS
Unit: mm
Cylinder I.D. 50.005 – 50.015 50.05
Out-of-round – 0.10
Taper – 0.10
Warpage – 0.05
Piston, piston Piston mark direction “IN” mark facing toward the intake side –
rings Piston O.D. 49.980 – 49.995 49.91
Piston O.D. measurement point 10 mm from bottom of skirt –
Piston pin bore I.D. 13.002 – 13.008 13.03
Piston pin O.D. 12.994 – 13.000 12.98
Piston-to-piston pin clearance 0.002 – 0.014 0.075
Piston ring-to-ring Top 0.015 – 0.045 0.08
groove clearance Second 0.015 – 0.045 0.08
Piston ring end gap Top 0.10 – 0.25 0.5
Second 0.10 – 0.25 0.5
Oil (side rail) 0.20 – 0.70 1.1
Cylinder-to-piston clearance 0.010 – 0.035 0.10
Connecting rod small end I.D. 13.016 – 13.034 13.05
Connecting rod-to-piston pin clearance 0.016 – 0.040 0.07
1-6
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm
Manual clutch Disc thickness 2.00 – 2.20 1.82
Plate warpage – 0.20
Clutch spring 5.01 4.63
free height
Clutch outer I.D. 16.991 – 17.009 17.049
guide O.D. 22.959 – 22.980 22.940
Primary driven gear I.D. 23.000 – 23.021 23.07
Mainshaft O.D. at clutch outer
16.966 – 16.984 16.87
guide
Centrifugal clutch Clutch drum I.D. 104.0 – 104.2 104.3
Clutch weight lining thickness 1.5 1.0
One-way clutch drum I.D. 42.000 – 42.020 42.04
One-way clutch roller O.D. 4.990 – 5.000 4.97
Primary drive gear I.D. 19.030 – 19.058 19.11
Crankshaft O.D. at primary drive
18.967 – 18.980 18.92
gear
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm
Starter driven gear boss O.D. 45.660 – 45.673 45.2
CRANKSHAFT/TRANSMISSION/KICKSTARTER SPECIFICATIONS
Unit: mm
Crankshaft Connecting rod side clearance 0.10 – 0.35 0.60
Connecting rod radial clearance 0 – 0.008 0.05
Runout – 0.10
Transmission Gear I.D. M2, M3 17.000 – 17.018 17.04
C1 18.000 – 18.018 18.04
C4 20.000 – 20.021 20.04
Bushing O.D. C1 17.966 – 17.984 17.94
Bushing I.D. C1 15.000 – 15.018 15.04
Gear-to-bushing
C1 0.016 – 0.052 0.10
clearance
Mainshaft O.D. M3 16.966 – 16.984 16.95
Countershaft O.D. C1 14.966 – 14.984 14.95
Gear-to-shaft clearance M3 0.016 – 0.052 0.09
Bushing-to-shaft
C1 0.016 – 0.052 0.09
clearance
Shift fork/ Shift fork I.D. 34.075 – 34.100 34.14
Shift drum Shift fork claw thickness 4.85 – 4.95 4.60
Shift drum O.D. Right 33.950 – 33.975 33.93
Left 23.940 – 23.980 23.92
Kickstarter Pinion I.D. 20.000 – 20.021 20.08
Spindle O.D. 19.959 – 19.980 19.94
1-7
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm
Minimum tire tread depth – To indicator
Cold tire pressure Driver only 200 kPa (29 psi) –
Driver and passenger 225 kPa (33 psi) –
Axle runout – 0.20
Wheel rim runout Radial – 2.0
Axial – 2.0
Wheel hub-to-rim distance See page 14-7
Fork Spring free length 294.3 300.2
Spring direction With the tightly wound coil side facing
–
down
Pipe runout – 0.20
Recommended fork fluid Honda ultra cushion oil 10 –
Fluid level (full bottom) 78 –
Fluid capacity 62 ± 1 cm3 –
REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Unit: mm
Axial – 2.0
Wheel hub-to-rim distance (page 14-11) –
Drive chain Size – link DID 420AD – 104RB
KMC 420JB – 104
Slack 30 – 40 –
Brake Brake drum I.D. 110.0 – 110.2 111.0
Brake pedal freeplay 20 – 30 –
HYDRAULIC BRAKE SPECIFICATIONS

Unit: mm
Recommended brake fluid DOT 3 or DOT 4 –
Brake pad wear indicator – To the groove
Brake disc thickness 3.3 – 3.7 3.0
Brake disc runout – 0.30
Master cylinder I.D. 11.000 – 11.043 11.055
Master piston O.D. 10.957 – 10.984 10.945
Caliper cylinder I.D. 33.96 – 34.01 34.02
Caliper piston O.D. 33.878 – 33.928 33.87
1-8
GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Battery brand GTZ4V/YTZ4V
Capacity 12 V – 3.0 Ah
Current leakage 20 mA max.
Voltage (20°C) Fully charged 13.0 – 13.2 V
Needs charging Below 12.4 V
Charging Normal 0.3 A/5 – 10 h
current Quick 3.0 A/0.5 h
Alternator Capacity 0.120 kW/5,000 min-1
Charging coil resistance (20°C) 0.3– 1.0 Ω
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight (High/Low) 12 V – 35/35 W
Position light 12 V – 3.4 W x 2
Brake/tail light 12 V – 18/5 W
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Meter light 12 V – 1.7 W x 2
Turn signal indicator 12 V – 3.4 W x 2
High beam indicator 12 V – 1.7 W
Gear position indicator 12 V – 1.7 W x 4
Neutral indicator 12 V – 1.7 W
Fuse Main 10 A
Sub 7.5 A
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m) N·m (kgf·m)
5 mm bolt and nut 5.2 (0.5) 5 mm screw 4.2 (0.4)
6 mm bolt and nut 6 mm screw 9.0 (0.9)
(Include SH flange bolt) 10 (1.0) 6 mm flange bolt
8 mm bolt and nut 22 (2.2) (8 mm head, small flange) 10 (1.0)
10 mm bolt and nut 34 (3.5) 6 mm flange bolt
12 mm bolt and nut 55 (5.6) (8 mm head, large flange) 12 (1.2)
6 mm flange bolt (10 mm head) and nut 12 (1.2)
8 mm flange bolt and nut 27 (2.8)
10 mm flange bolt and nut 39 (4.0)
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m)
Throttle cable lock nut 1 8 – See page 2-14
Exhaust pipe joint nut 2 8 27 (2.8)
Exhaust pipe stud bolt 2 8 – See page 2-16
Chain case cover bolt 4 6 7 (0.71)
Muffler cover screw 2 6 9 (0.92)
1-9
GENERAL INFORMATION
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
Oil drain bolt 1 12 24 (2.4)
Valve adjusting lock nut 2 5 9 (0.92) Apply oil to the threads and
seating surface.
Oil centrifugal filter cover bolt 3 5 5 (0.51) Apply locking agent to the
threads: See page 3-9
Clutch adjuster lock nut 1 8 12 (1.2)
Spark plug 1 10 16 (1.6)
Air cleaner housing cover screw 5 5 1.1 (0.11)
IGNITION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Timing hole cap 1 14 1.5 (0.15)
THREAD TORQUE
ITEM Q'TY REMARKS
Starter motor cable screw 1 4 2.0 (0.20)
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Inlet pipe band screw 1 – – See page 6-8
Fuel valve screw 2 3 0.88 (0.090)
Air cut-off valve screw 2 4 2.1 (0.21)
Slow jet 1 – 1.5 (0.15)
Main jet 1 – 1.5 (0.15)
Needle jet holder 1 – 2.5 (0.25)
Float chamber screw 2 4 2.1 (0.21)
Float chamber drain screw 1 – 1.5 (0.15)
Fuel strainer cup 1 – 5.9 (0.60)
Throttle cable holder screw 1 5 3.4 (0.35)
Fuel valve lever screw 1 4 2.1 (0.21) Apply locking agent to the
threads.
Inlet pipe mounting bolt 2 6 12 (1.2)
PAIR control valve mounting bolt 2 6 10 (1.0)
PAIR check valve cover screw 2 4 2.1 (0.21)
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Oil pump cover screw 3 5 5 (0.51)
CYLINDER HEAD/VALVES
THREAD TORQUE
ITEM Q'TY REMARKS
Cylinder head cover special bolt 2 6 10 (1.0)
Cylinder head nut 4 7 13 (1.3) Apply oil to the threads and
seating surface.
Cam sprocket bolt 1 8 27 (2.8) Apply oil to the threads and
seating surface.
Cam chain tensioner sealing bolt 1 14 22 (2.2)
Cam chain tensioner arm pivot bolt 1 8 16 (1.6)
1-10
GENERAL INFORMATION
CYLINDER/PISTON
THREAD TORQUE
ITEM Q'TY REMARKS
Cam chain guide roller pin bolt 1 8 10 (1.0)
Cylinder stud bolt 4 7 – (page 9-7)
CLUTCH/GEARSHIFT LINKAGE
THREAD TORQUE
ITEM Q'TY REMARKS
Shift drum stopper arm bolt 1 6 10 (1.0) Apply locking agent to the
threads: See page 11-30
Shift return spring pin 1 8 30 (3.1)
Gearshift cam plate bolt 1 6 17 (1.7) Apply locking agent to the
threads: (page 11-29)
Centrifugal clutch lock nut 1 14 54 (5.5) Apply oil to the threads and
seating surface.
Clutch center lock nut 1 14 54 (5.5) Apply oil to the threads and
seating surface.
Clutch lifter plate bolt 4 6 12 (1.2)
THREAD TORQUE
ITEM Q'TY REMARKS
Flywheel nut 1 10 40 (4.1) Apply oil to the threads and
seating surface.
Starter clutch mounting torx bolt 6 6 16 (1.6) Apply locking agent to the
threads: (page 10-10)
CRANKSHAFT/TRANSMISSION/KICKSTARTER
THREAD TORQUE
ITEM Q'TY REMARKS
Cam chain guide sprocket spindle 1 6 10 (1.0)
ENGINE REMOVAL/INSTALLATION
THREAD TORQUE
ITEM Q'TY REMARKS
Drive sprocket fixing plate bolt 2 6 12 (1.2)
Engine hanger nut 3 10 59 (6.0)
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
Handle bar weight screw 2 6 9 (0.92) SL thread screw
steering stem lock nut 1 26 – For tightening
sequence;See page 14-22
Steering stem top thread 1 26 – For tightening sequence;
See page 14-23
Bottom bridge pinch bolt 4 10 64 (6.5)
Handlebar post mounting nut 1 10 59 (6.0) U-nut
Front axle nut 1 12 59 (6.0) U-nut
Front disc socket bolt 4 8 42 (4.3) ALOC bolt; replace with
new ones.
Front spoke 36 BC2.9 3.2 (0.33)
Fork socket bolt 2 8 20 (2.0) Apply locking agent to the
threads.
Brake hose clamp bolt 1 6 12 (1.2) ALOC bolt; replace with
new ones.
1-11
GENERAL INFORMATION
REAR WHEEL/BRAKE/SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
Rear axle nut 1 12 59 (6.0) U-nut
Rear spoke 36 BC 3.2 3.7 (0.38)
Driven sprocket nut 4 8 32 (3.3) U-nut
Driven flange stud bolt 4 8 – See page 14-12
Rear brake stopper arm nut 2 8 22 (2.2)
Rear brake arm nut 1 6 10 (1.0) U-nut
Shock absorber upper mounting bolt 2 10 24 (2.4)
Shock absorber lower mounting cap nut/
nut 2 10 24 (2.4)
Swingarm pivot nut 1 12 59 (6.0) U-nut
HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TY REMARKS
Caliper bleed valve 1 8 5.4 (0.55)
Pad pin 1 10 17 (1.7)
Front caliper torque pin 1 8 22 (2.2) Apply locking agent to the
threads.
Caliper bracket pin bolt 1 8 17 (1.7)
Caliper mounting bolt 2 8 30 (3.1) ALOC bolt; replace with
new ones.
Brake hose oil bolt 2 10 34 (3.5)
Master cylinder reservoir cap screw 2 4 1.5 (0.15)
Front brake light switch screw 1 4 1.2 (0.12)
Brake lever pivot bolt 1 6 1.0 (0.10)
Brake lever pivot nut 1 6 5.9 (0.60)
Brake hose clamp bolt 1 6 12 (1.2) ALOC bolt; replace with a
new one.
LIGHTS/METERS/SWITCHES
THREAD TORQUE
ITEM Q'TY REMARKS
Ignition switch mounting bolt 2 6 9 (0.92) ALOC bolt; replace with
new ones.
Key shutter assembly socket bolt 1 5 3.9 (0.40) ALOC bolt; replace with
new one.
OTHERS
THREAD TORQUE
ITEM Q'TY REMARKS
Sidestand pivot bolt 1 10 18 (1.8)
Sidestand pivot nut 1 10 44 (4.5,)
1-12
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Engine oil Cylinder bore
Piston outer surface and piston ring grooves
Piston pin hole inner surface
Piston pin outer surface
Piston rings whole surface
Connecting rod small end inner surface
Connecting rod big end 1.0 – 2.0 cm3
IN/EX valve stem sliding surface and stem end
Camshaft whole surface
Cam chain whole surface
Cam sprocket teeth
Rocker arm shaft hole inner surface
Rocker arm shaft whole surface
Rocker arm roller rolling area
Oil pump inner and outer rotor sliding area
Cam chain guide sprocket spindle whole surface
Clutch outer guide outer surface
Clutch discs
Gearshift spindle journal
Shift fork inner sliding surface
Shift drum whole surface
Countershaft shift drum lock plate rotating area
Gear teeth (primary, transmission, kickstarter)
Cam chain tensioner push rod inside 4.0 – 5.0 cc
Starter clutch rolling surface
Starter reduction gear both journal and gear teeth
Starter reduction gear shaft
Each bearing rolling surface
Each O-ring
Locking agent Oil stopper plate bolt threads See page 8-22
Mainshaft bearing set plate bolt threads
Liquid sealant Cylinder head cover rubber seal (semicircular area) See page 8-6
(recommended: Three bond
5211C or SHINETSU-
SILICONE KE45T or Three
bond 1215 or equivalent)
Molybdenum disulfide oil (a Kickstarter pinion gear inner surface
mixture of 1/2 engine oil and Primary drive gear inner surface
1/2 molybdenum disulfide Each transmission rotating gear inner surface
grease) C1 gear bushing whole surface
M4, C3 gear shift fork groove
Cam chain timing sprocket starter gear sliding surface
Left crankshaft starter gear sliding surface
Decompressor cam and arm sliding area
Sealant (Three bond 1215 or Left crankcase mating surface See page 12-17
1207B or LOCTITE or Alternator wire grommet seating surface
equivalent)
Sealant (Three bond 1215 or Alternator wire grommet seating surface
1207B or equivalent)
Adhesive (Cemedine 575 or Cylinder head cover and rubber seal mating point See page 8-6
Three Bond 1194 or
equivalent)
Multi-purpose grease Gearshift spindle oil seal lip
Countershaft oil seal lip
Kickstarter spindle oil seal lip
Degreasing Flywheel and left crankshaft contact areas
1-13
GENERAL INFORMATION
FRAME
MATERIAL LOCATION REMARKS
Urea based multipurpose Steering stem dust seal lips
grease with extreme Upper inner and outer bearing races Apply 3 g minimum
pressure (example: Kyodo Lower inner and outer bearing races Apply 3 g minimum
Yushi EXCELITE EP2, Shell
ALVANIA EP2 or equivalent)
Grease (Shell BEARING Speedometer gear teeth Apply 0.2 – 0.4 g
GREASE HD or equivalent) Speedometer gear inner surface Apply 0.03 – 0.05 g
Speedometer cable pinion shaft Apply 0.02 – 0.03 g
Speedometer cable pinion teeth Apply 0.2 – 0.4 g
Multi-purpose grease Front/rear axle surface
Front wheel dust seal lips
Steering handle lock sliding area
Throttle pipe surface, flange groove and slot Apply 0.1 – 0.2 g
Rear wheel driven flange dust seal lips
Rear wheel hub O-ring
Speedometer cable O-ring
Seat lock sliding area
Kickstarter pedal sliding area
Sidestand pivot sliding surface
Rear brake pedal/centerstand pivot sliding surface
Rear brake panel anchor pin Apply 0.06 – 0.08 g
Rear brake cam sliding surface Apply 0.2 – 0.3 g
Rear brake cam (brake shoe contact area) Apply 0.03 – 0.05 g
Front/rear wheel distance collar
Speedometer gear teeth Apply 3 g
Speedometer gear inner surface Apply 0.5–1.0 g
Speedometer cable inside Apply 1.0 g
Each wheel bearing
Silicone grease Front brake lever pivot bolt sliding surface Apply 0.1 g
Front brake lever-to-master piston contacting surface
Brake caliper bracket pin sliding surface Apply 0.4 g minimum
Brake caliper dust seal
Pad pin O-ring
Brake fluid DOT 3 or DOT 4 Brake master piston, spring and piston cups
Brake caliper piston
Brake caliper piston seal
Honda Bond A or equivalent Handlebar grip rubber inside
Air induction case-to-connecting hose mating area
Lower side cover rubbers
Fork fluid Fork oil seal lips
Fork dust seal lips
Fork cap O-ring
SAE #80 or 90 gear oil or Drive chain
drive chain lubricant Rear brake cam felt seal
1-14
GENERAL INFORMATION
CABLE & HARNESS ROUTING
TURN SIGNAL RELAY
FRONT BRAKE LIGHT LEFT HANDLEBAR
SWITCH WIRE SWITCH WIRE
RIGHT HANDLEBAR
SWITCH WIRE
CHOKE CABLE
THROTTLE CABLE
FRONT BRAKE HOSE HEADLIGHT ASSEMBLY

9P CONNECTOR
SPEEDOMETER CABLE
FRONT BRAKE HOSE

CHOKE CABLE
COMBINATION METER
SUB HARNESS
IGNITION SWITCH
2P CONNECTOR SPEEDOMETER CABLE
1-15
GENERAL INFORMATION
HORN WIRE
COMBINATION METER SUB HARNESS
FRONT BRAKE HOSE
AIR VENT HOSE
AIR SUPPLY HOSE
SPEEDOMETER CABLE
IGNITION SWITCH 2P CONNECTOR
CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR
FRONT BRAKE HOSE

CHOKE CABLE
THROTTLE CABLE
MAIN WIRE HARNESS
AIR VENT HOSE
1-16
GENERAL INFORMATION
AIR SUPPLY HOSE

THROTTLE CABLE
AIR VENT HOSE
CHOKE CABLE
SEPARATE AIR FILTER
MAIN WIRE HARNESS
AIR SUPPLY HOSE
1-17
GENERAL INFORMATION
GROUND MAIN WIRE
TERMINALS HARNESS AIR VENT HOSE
VACUUM
REAR BRAKE LIGHT HOSE
SWITCH WIRE
STARTER MOTOR
2P CONNECTOR
SPARK PLUG WIRE AIR SUPPLY PIPE
ALTERNATOR/IGNITION PULSE GENERATOR

WIRE (Yellow, Blue/Yellow) CONNECTORS
IGNITION COIL WIRE (Black/ GROUND TERMINAL

Yellow, Green) CONNECTORS
1-18
GENERAL INFORMATION
SEPARATE AIR FILTER AIR SUPPLY HOSE
CRANKCASE
BREATHER HOSE REGULATOR/RECTIFIER 4P CONNECTOR
ALTERNATOR/IGNITION PULSE
GENERATOR WIRE (Yellow, Blue/Yellow)
CONNECTORS
CARBURETOR
DRAIN HOSE
GEAR POSITION
SWITCH 6P (Black)
FUEL HOSE CONNECTOR
ALTERNATOR 2P CONNECTOR
1-19
GENERAL INFORMATION
FUEL LEVEL SENSOR WIRE

FUEL FILTER
MAIN WIRE HARNESS
IGNITION CONTROL FUEL HOSES

MODULE (ICM) WIRE
FUEL LEVEL SENSOR 3P
(Black) CONNECTOR
FUEL LEVEL SENSOR WIRE
FUEL HOSES
MAIN WIRE HARNESS IGNITION CONTROL MODULE (ICM)
MAIN WIRE HARNESS
BATTERY WIRE HARNESS

2P/3P CONNECTORS/
WIRE (Red) CONNECTOR
REAR BRAKE LIGHT SWITCH WIRE

(Green/Yellow, Black) CONNECTORS BATTERY WIRE HARNESS
1-20
GENERAL INFORMATION
MAIN WIRE HARNESS

IGNITION CONTROL
MODULE (ICM)
ICM COVER
MAIN WIRE
RUBBER
HARNESS
ICM COVER
RUBBER ICM STAY
REAR
FENDER
IGNITION CONTROL MODULE (ICM)
BATTERY
MAIN FUSE 10 A
SUB FUSE 7.5 A
STARTER RELAY
BATTERY NEGATIVE (–) CABLE BATTERY POSITIVE (+) CABLE
1-21
GENERAL INFORMATION
LEFT FRONT
TURN SIGNAL
LIGHT WIRE
LEFT FRONT
POSITION RIGHT FRONT
LIGHT WIRE POSITION LIGHT WIRE
HEAD LIGHT WIRES

RIGHT TURN
SIGNAL LIGHT
WIRE
HEAD LIGHT ASSEMBLY

9P CONNECTOR
BRAKE/TAIL LIGHT WIRE
RIGHT REAR LEFT REAR

TURN SIGNAL TURN SIGNAL
LIGHT WIRE LIGHT WIRE
BRAKE/TAIL LIGHT UNIT

6P CONNECTOR
1-22
GENERAL INFORMATION
IGNITION PULSE GENERATOR
ALTERNATOR WIRE
1-23
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons (HC). Controlling hydrocarbon emission is very important
because, under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not
react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and
hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by
gas is returned to the combustion chamber through the air cleaner [1], crankcase breather hose [2] and carburetor [3].
EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM)
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases
in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system.
This change of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons
and carbon monoxide into relatively harmless carbon dioxide and water vapor.
This model has the pulse secondary air injection (PAIR) control valve and PAIR check valve. PAIR check valve prevents reverse air
flow through the system. The PAIR control valve reacts to high inlet pipe vacuum and will cut off the supply of the fresh air during
engine deceleration, thereby preventing after burn in the exhaust system.
No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is
recommended.
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law may prohibit the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of
any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate customer or while it is in use; (2) the use of the vehicle after such device or element of design has been removed or
rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
1-24
GENERAL INFORMATION
MANUAL CLUTCH SYSTEM
OUTLINE
This motorcycle adopts a diaphragm clutch spring instead of conventional coil springs.
COMPONENT LOCATION
CLUTCH SPRING CLUTCH CENTER
SPRING SEAT
CLUTCH OUTER
CLUTCH LIFTER PLATE
THRUST WASHER
PRESSURE PLATE
CLUTCH OUTER
CLUTCH DISCS/PLATES
PRESSURE PLATE
CLUTCH SPRING
SPRING SEAT
CLUTCH LIFTER PLATE
CLUTCH CENTER
CLUTCH DISCS/PLATES
1-25
GENERAL INFORMATION
CLUTCH MECHANISM
OPERATION
As the lifter cam plate moves during the gearshift pedal applied and the gearshift spindle is shifting to the next gear position, the
balls on the clutch lifter boss derail from the recesses on the lifter cam plate. This operation lifts the pressure plate, reducing the
pressure applied to the clutch discs/plates and the engine power is not transmitted from the crankshaft to mainshaft.
CRANKSHAFT CLUTCH DISCS/PLATES
CLUTCH SPRING
MAINSHAFT Derailed
GEARSHIFT SPINDLE CLUTCH LIFTER BOSS
LIFTER CAM PLATE
CLUTCH LIFTER PLATE
When the shifting is complete and the balls on the clutch lifter boss are engaged with the recesses on the lifter cam plate, the
pressure plate returns to its original position and the engine power is transmitted from the crankshaft to mainshaft.
CRANKSHAFT
CLUTCH SPRING
Engaged
MAINSHAFT CLUTCH LIFTER PLATE
CLUTCH DISCS/PLATES
1-26
dummytext
2. FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS ·························2-2 LUGGAGE BOX ·········································· 2-10
BODY PANEL REMOVAL CHART ···············2-2 REAR FENDER ··········································· 2-11
SERVICE INFORMATION ·····························2-3 HANDLEBAR COVER ································ 2-12
TROUBLESHOOTING···································2-3 HANDLEBAR REAR COVER ····················· 2-14
FRONT TOP COVER·····································2-4 FOOTPEG BAR ·········································· 2-15
FRONT FENDER ···········································2-5 PASSENGER FOOTPEG HOLDER ··········· 2-15
LOWER SIDE COVER···································2-6 LEFT CRANKCASE REAR COVER ··········· 2-15
CENTER COVER···········································2-6 CHAIN CASE ·············································· 2-16
MAIN PIPE COVER ·······································2-7 EXHAUST PIPE/MUFFLER ························ 2-16
SEAT······························································2-8 CENTERSTAND·········································· 2-17
GRAB RAIL ···················································2-8 SIDESTAND ················································ 2-18
BODY COVER ···············································2-9
2-1
BODY PANEL LOCATIONS
(1)
(3)
(2)
(10) (13)
(6) (9)
(11)
(4)
(8) (12)
(5)
(15)
(7) (14) (17)

(16)
(1) Handlebar top cover (page 2-12) (10) Seat (page 2-8)
(2) Handlebar front cover (page 2-12) (11) Luggage box (page 2-10)
(3) Handlebar rear cover (page 2-14) (12) Rear fender (page 2-11)
(4) Front top cover (page 2-4) (13) Grab rail (page 2-8)
(5) Front fender (page 2-5) (14) Footpeg bar (page 2-15)
(6) Main pipe cover (page 2-7) (15) Passenger footpeg holder (page 2-15)
(7) Lower side cover (page 2-6) (16) Left crankcase rear cover (page 2-15)
(8) Center cover (page 2-6) (17) Chain case (page 2-16)
(9) Body cover (page 2-9)
BODY PANEL REMOVAL CHART

• This chart shows removal order of frame covers.
(1) HANDLEBAR TOP COVER (2) HANDLEBAR FRONT COVER (3) HANDLEBAR REAR COVER
(4) FRONT TOP COVER (5) FRONT FENDER
(8) CENTER COVER (6) MAIN PIPE COVER (10) SEAT (7) LOWER SIDE COVER
(13) GRAB RAIL (9) BODY COVER (11) LUGGAGE BOX
(14) FOOTPEG BAR (15) PASSENGER FOOTPEG HOLDER (12) REAR FENDER
(16) LEFT CRANKCASE REAR COVER (17) CHAIN CASE
2-2
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• Always replace the exhaust pipe gasket after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all of the muffler fasteners. Always tighten the exhaust joint first, then tighten
the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Shock absorber upper mounting bolt 24 N·m (2.4 kgf·m)
Throttle cable lock nut – (page 2-14)
Exhaust pipe joint nut 27 N·m (2.8 kgf·m)
Exhaust pipe stud bolt – (page 2-16)
Chain case cover bolt 7 N·m (0.71kgf·m)
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
2-3
FRONT TOP COVER
REMOVAL/INSTALLATION
Remove the following:
– Two screws [1] from the front side
– Four special screws A [2] from the rear side
– Four special screws B [3] from the rear side
– Two clips [4]
Remove the front top cover [5] by releasing its tabs [6]
from the slots [7] of the main pipe cover.
Remove the two rubbers [8] from the front top cover
stay.
Installation is in the reverse order of removal.
[8] [3]
[2]
[5]
[7]
[1]
[4]
[6]
FRONT LOWER COVER REMOVAL/

INSTALLATION
Remove the screw [1] and front lower cover [2] by
releasing its groove [3] from the tab [4] of the front top
[1]
cover.
[3]/[4] [2]
2-4
FRONT FENDER
FRONT FENDER A
Remove the front top cover (page 2-4).
Remove the two bolts [1], collars [2], speedometer
cable guide [3] and brake hose clamp [4].
Remove the bolt [5], collar [6] and front fender A [7] by
releasing the two hooks [8] from slots [9] of the front
fender B.
[2] [4]
[1]
[7]
[8]
[9]
[5]/[6]
[3]
FRONT FENDER B
– Front wheel (page 14-5)
– Front fender A (page 2-5)
Remove the two bolts [1], collar [2] and front fender B
[3].
[3]
[1]/[2]
2-5
LOWER SIDE COVER
Remove the screw A [1], two screws B [2] and a washer
[3].
Remove the lower side cover [4] by releasing the
following.
– Three grooves [5] from the hooks [6] of the main
pipe cover
– Left side: Tab [7] from the slot [8] of the body cover
– Right side: Tabs [9] from the slots [10] of the body
cover
[8]
[6] RIGHT SIDE:
[5]
[9]
[7]
[10]
[2]
[1]
[4]
[3]
CENTER COVER
Open the seat using the ignition key.
Remove the screw [1], special screw [2] and center
[1] [2]
cover [3] by releasing its tabs [4] from the slots [5] of the
body cover.
Be careful not to Installation is in the reverse order of removal.
damage the tabs. [5]
[4] [3]
2-6
MAIN PIPE COVER
– Center cover (page 2-6)
– Two screws A [1]
– Two screws B [2]
– Four special screws C [3]
– Three special screws D [4]
Release the hooks [5] on the lower side of main pipe
cover [6] from the grooves [7] of the lower side cover
and remove the main pipe cover [8].
[8]
[4]
[2]
[1]
[7]
[3]
[6]
[5]
DISASSEMBLY/ASSEMBLY
Remove the two screws [1] and separate the main pipe
rear cover [2] from the main pipe front cover [3] by
releasing the tabs [4] from the grooves [5].
Assembly is in the reverse order of disassembly.
[1]
[3]
[2]
[5]
[4]
2-7
SEAT
Support the seat Remove the two nuts [1] and the seat [2]. [2]
while removing the
nuts.
[1]
GRAB RAIL
[1] [2]
Remove the four mounting bolts [1] and the grab rail [2].
2-8
BODY COVER
– Grab rail (page 2-8)
Remove the two special screws [1] and a screw [2].
Release the following and remove the body cover [3].
– Boss [4] from the frame grommet [5]
– Holes from the grab rail mounting bosses [6]
– Hook [7] from the rear fender groove
– Left side: Slot [8] from the lower side cover tab [9]
– Right side: Slots [10] from the lower side cover tabs
[11]
LEFT SIDE SHOWN:

[6]
RIGHT SIDE: [11]
[5]
[10]
[7]
[1]
[9] [4]
[2] [8] [3]
Right side only: Remove the two screws [1] and body lower cover [2].
Remove the screws [3] and separate the rear body
cover [4] and center side cover [5] by carefully releasing
the body cover tab [6] from the center side cover groove
[7].
[4] [1]
[2] (Right side only)
[6]
[3]
[5]
[7]
2-9
LUGGAGE BOX
– Battery (page 16-3)
– Seat (page 2-8)
– Right body cover (page 2-9)
Release the battery cable boss [1] from the hole of the
luggage box [2] and disconnect the battery wire harness
connectors [3] and starter motor 2P connector [4].
Remove the three bolts [5] and collars [6].
Raise the luggage box [7] while pulling out the battery
wire harness [8].
Be careful not to Installation is in the reverse order of removal.
pinch the wire
harness between
the luggage box and
frame.
[5]/[6]
[8]
[1]
[2]
[7]
[3] [4]
2-10
REAR FENDER
– Luggage box (page 2-10)
– ICM (page 4-9)
– Brake/tail light unit (page 17-7)
– Fuel tank (page 6-12)
Remove the shock absorber left side upper mounting
bolt [1], then turn the shock absorber [2] backward.
Release the main wire harness [3] from the three wire
guides [4].
Remove the three bolts [5], special bolt [6] and rear
fender [7].
Remove the screw [8] and cover [9].
Remove the spring [10], retainer [11] and key cylinder
[12].
TORQUE:
SHOCK ABSORBER UPPER MOUNTING BOLT 24 N·m (2.4 kgf·m)
[4]
[5]
[3]
[7]
[8]
[9]
[6]
[10]
[1]
[11]
[2]
[12]
2-11
HANDLEBAR COVER
HANDLEBAR TOP COVER
Remove the four screws [1].
Remove the handlebar top cover [2] by releasing the
boss [3] from the grommet [4] and tabs [5] from slots [6]
on the handlebar front cover.
Installation is in the reverse order of the removal.
[5]
[3]
[2]
[1]
[4]
[6]
HANDLEBAR FRONT COVER

Removal/Installation
Pull back the rubber dust covers [1].
[1]
Loosen the lock nut [2].
Loosen the rearview mirrors [3] and remove them. [2]
Loosen the mirror adapters [4] and remove them.
[3]
[4]
2-12
Be careful not to Remove the following:
damage the
– Bolt [1]/collar [2]/rubber [3] on the front side
handlebar front
– Six screws/washers [4]
cover.
Remove the handlebar front cover [5] by releasing the
two bosses [6] from the holes [7] on the handlebar rear
cover and disconnecting the headlight 9P connector [8].
[5] [6]
[7]
[4]
[1]/[2]/[3]
[8]
Disassembly/Assembly
– Special bolt [1]
– Two holders [2]
Remove the headlight assembly [3] by releasing the two
tabs [4] from the slots [5] on the handlebar front cover.
[5]
[2]
[4]
[3]
[1]
2-13
HANDLEBAR REAR COVER
– Front top cover (page 2-4)
– Handlebar front cover (page 2-12)
Disconnect the following connectors
– Front brake light switch connectors (page 18-14)
– Horn connectors (page 18-17)
– Combination meter sub harness 9P/6P connectors
[1].
Disconnect the speedometer cable [2] from the [2]
combination meter assembly. [1]
Release the wire band boss [3] from the frame.
Release the combination meter sub harness from the [4]
cable guides [4].
Disconnect the choke cable [5] from the choke lever.
Remove the two front screws [6] and the rear special
screw [7].
Release the handlebar rear cover [8] from the
handlebar.
Remove the screw [9] and the throttle upper housing
[10] by unhooking the lower housing tab [11]. [3]
Disconnect the throttle cable [12] from the throttle pipe.
Loosen the throttle cable lock nut [13] and pull the cable
out from the throttle lower housing [14].
Remove the handlebar rear cover by pulling the choke
and throttle cables out of its holes [15].
• Apply grease to the throttle pipe flange groove and
throttle pipe slot.
• Install the throttle lower housing by aligning its pin with the hole on the handlebar.
[9] [10]
[15]
[7]
[11] [8]
[6]
Align
[12]
[14]
[13]
10N·m (1.0kgf·m)
0 – 1.25 mm
[5]
2-14
FOOTPEG BAR
Remove the four bolts [1] and footpeg bar [2] while
pushing down the rear brake pedal. [1]
[2]
PASSENGER FOOTPEG HOLDER

Remove the muffler mounting bolt [1], nut [2], washer
[3], collar [4] and mount rubber [5] (right side only). Right side shown: [6]
Remove the two socket bolts [6] and passenger footpeg
holder [7].
[1]/[2]/[3]/
[4]/[5]
[7]
LEFT CRANKCASE REAR COVER

Remove the two bolts [1] and left crankcase rear cover [1]
[2].
[2]
2-15
CHAIN CASE
The upper and Remove the four bolts [1] and the chain case [2].
lower chain cases
Install the drive chain case by aligning its slots [3] with [1]
can be removed/
rail [4] as shown.
installed
individually. Tighten the four bolts to the specified torque.
TORQUE: 7 N·m (0.71kgf·m)
[3] [3]
[4] [4]
[2]
EXHAUST PIPE/MUFFLER
REMOVAL
– Two joint nuts [1]
– Muffler mounting nut [2]
– Muffler mounting bolt A [3]
– Washer [4]
– Collar [5]
– Muffler mounting bolt B [6]
– Exhaust pipe/muffler [7]
– Exhaust pipe gasket [8]
• Always replace the exhaust pipe with a new one.
[5]
[4]
[6]
[2] Tighten the exhaust pipe joint

[7] [8] nuts fast, then tighten the
muffler mounting bolts and nut.
[1]
27 N·m (2.8 kgf·m)
[3]
2-16
EXHAUST PIPE STUD BOLT
Thread two nuts to the stud bolt and tighten them
together, then use a wrench on them to turn the stud
bolt out.
Install and tighten new stud bolts into the cylinder head
to the specified torque.
TORQUE: 11 N·m (1.1 kgf·m)
After tightening the stud bolts, check that the length
from the bolt head to the cylinder head surface is within
specification.
29.5 ± 1.0 mm
MUFFLER COVER
Remove the two screws [1], mounting rubber [2], collar
[3] and muffler cover [4].
[4]
Tighten the muffler cover screw to the specified torque.
[1]/[2]/[3]
CENTERSTAND
Exhausted pipe (page 2-16)
Remove the following: [1]/[2]
[4]
• Pivot nut [1]/washer [2]
• Bolt [3]
• Plate [4]
[3]
2-17
Remove the following: [3]
• Collar [1]
• Pivot bolt [2]
• Swingarm [3]
[1] [2]
Unhook the brake light switch spring [1] and
[2]
centerstand spring [2].
[1]
Remove the cotter pin [1], then remove the centerstand [2]
[1]
pivot [2].
Remove the centerstand [3] and brake pedal.
• Replace the cotter pin with a new one.
• Apply grease to the pivot shaft sliding surface.
• Install the spring in the correct direction.
[3]
SIDESTAND
Remove the sidestand return spring [1], pivot nut [2],
pivot bolt [3] and sidestand [4].
[1]
TORQUE: Sidestand pivot bolt
18 N·m (1.8 kgf·m)
Sidestand pivot nut
44 N·m (4.5 kgf·m)
[2]/[3] [4]
2-18
dummytext
3. MAINTENANCE
SERVICE INFORMATION ·····························3-2 SECONDARY AIR SUPPLY SYSTEM ······· 3-10
MAINTENANCE SCHEDULE························3-3 DRIVE CHAIN ············································· 3-11
FUEL LINE·····················································3-4 BRAKE FLUID ············································ 3-13
THROTTLE OPERATION······························3-4 BRAKE SHOES/PADS WEAR ··················· 3-13
CHOKE OPERATION····································3-5 BRAKE SYSTEM ········································ 3-14
AIR CLEANER···············································3-5 BRAKE LIGHT SWITCH ····························· 3-15
CRANKCASE BREATHER ···························3-5 HEADLIGHT AIM ········································ 3-15
SPARK PLUG················································3-6 CLUTCH SYSTEM ······································ 3-16
VALVE CLEARANCE····································3-7 SIDESTAND ················································ 3-16
ENGINE OIL ··················································3-8 SUSPENSION ············································· 3-16
ENGINE OIL STRAINER SCREEN ···············3-8 NUTS, BOLTS, FASTENERS ····················· 3-16
ENGINE OIL CENTRIFUGAL FILTER ··········3-9 WHEELS/TIRES ·········································· 3-17
ENGINE IDLE SPEED ·································3-10 STEERING HEAD BEARINGS ··················· 3-17
3-1
MAINTENANCE
SERVICE INFORMATION
MAINTENANCE
GENERAL
• Place the motorcycle on a level ground 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 or where the gasoline is stored can cause
a fire or explosion.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the
engine in and open area or with an exhaust evacuation system in and enclosed area.
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug CPR6EA-9S (NGK) U20EPR9S (DENSO)
Engine oil capacity At draining 0.75 liter
At disassembly 1.0 liter
Recommended engine oil Honda “4-stroke motorcycle oil” or an
equivalent
Valve clearance IN/EX 0.10 ± 0.02 mm
Drive chain Size – link KMC 420JB – 104
DID 420AD – 104RB
Slack 30 – 40 mm
Drive chain length at 41 pins (40 links) 508 mm
Recommended brake fluid DOT 3 or DOT 4
Brake pedal freeplay 20 – 30 mm
Tire size (Brand) Front 70/90-17 M/C 38P (IRC: NR69/VEE: V357F/CST:C-6016)
Rear 80/90-17 M/C 50P (IRC: NR69/VEE: V357R/CST:C-6016R)
Cold tire pressure Driver only Front 200 kPa (29 psi)
Rear 225 kPa (33 psi)
Driver and passenger Front 200 kPa (29 psi)
Rear 280 kPa (41 psi)
Minimum tire tread depth Front To indicator
Rear To indicator
TORQUE VALUES
Oil drain bolt 24 N·m (2.4 kgf·m)
Valve adjusting lock nut 9 N·m (0.92 kgf·m) Apply oil to the threads and seating surface
Oil centrifugal filter cover bolt 5 N·m (0.51 kgf·m) Apply locking agent to the threads:
(page 3-9)
Clutch adjuster lock nut 12 N·m (1.2 kgf·m)
Spark plug 16 N·m (1.6 kgf·m)
Rear axle nut 59 N·m (6.0 kgf·m) U-nut
Air cleaner housing cover screw 1.1 N·m (0.11 kgf·m)
Front spoke 3.2 N·m (0.33 kgf·m)
Rear spoke 3.7 N·m (0.38 kgf·m)
3-2
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.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult an authorized Honda dealer.
FREQUENCY WHICHEVER
COMES FIRST
ODOMETER READING (NOTE 1) REFER TO

PAGE
X1,000 km 1 4 8 12
X1,000 mi 0.6 2.5 5 7.5
ITEMS Months 6 12 18
* FUEL LINE I I I 3-4
* FUEL STRAINER SCREEN C C C 6-13
* THROTTLE OPERATION I I I 3-4
* CHOKE OPERATION I I I 3-5
* AIR CLEANER NOTE2 EVERY 16,000 km (10,000 mi) R 3-5
CRANKCASE BREATHER NOTE3 C C C 3-5
SPARK PLUG I R I 3-6
* VALVE CLEARANCE I I I I 3-7
ENGINE OIL R R R R 3-8
** ENGINE OIL STRAINER SCREEN C 3-8
** ENGINE OIL CENTRIFUGAL FILTER C 3-9
* ENGINE IDLE SPEED I I I I 3-10
* SECONDARY AIR SUPPLY SYSTEM I 3-10
DRIVE CHAIN EVERY 500 km (300 mi) I, L 3-11
BRAKE FLUID NOTE4 I I I 3-13
BRAKE SHOES/PADS WEAR I I I 3-13
BRAKE SYSTEM I I I I 3-14
BRAKE LIGHT SWITCH I I I 3-15
HEADLIGHT AIM I I I 3-15
CLUTCH SYSTEM I I I I 3-16
SIDESTAND I I I 3-16
* SUSPENSION I I I 3-16
* NUTS, BOLTS, FASTENERS I I 3-16
** WHEELS/TIRES I I I I 3-17
** STEERING HEAD BEARINGS I I 3-17
* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
Honda recommends that a dealer should road test the motorcycle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replace every 2 years. Replacement requires mechanical skill.
3-3
MAINTENANCE
FUEL LINE
Remove the left body cover (page 2-9).
Check the fuel line [1] for deterioration, damage or [1]
leakage.
Replace the fuel line if necessary.
Install the left body cover (page 2-9).
[1]
THROTTLE OPERATION
Check for smooth throttle grip full opening and
automatic full closing in all steering positions.
If the throttle grip does not return properly, check the
throttle cable routing. 2 – 6 mm
Check for any deterioration or damage to the throttle

cable.
Reusing a If the throttle grip still does not return properly, lubricate
damaged, or replace the throttle cable.
abnormally bent or
With the engine idling, turn the handlebar all the way to
kinked throttle cable
the right and left to ensure that the idle speed does not
can prevent proper
change.
throttle operation
and may lead to a If idle speed increases, check the throttle cable
loss of throttle connection.
control while riding.
Measure the free play at the throttle grip flange.
FREEPLAY:2 – 6 mm
3-4
MAINTENANCE
CHOKE OPERATION
Check for smooth choke lever [1] operation and
lubricate the choke cable if required.
Inspect the cable for cracks which could allow moisture
to enter.
Replace the choke cable if necessary.
[1]
AIR CLEANER
Remove the screws [1] and air cleaner housing cover
[2].
[1] [4]
Remove and discard the air cleaner element [3] in
accordance with the maintenance schedule (page 3-3).
Replace the element any time if it is excessively dirty or
damaged.
Clean the inside of the air cleaner housing and cover.
Make sure the rubber seals [4] in the housing and cover
are in position and in good condition.
Make sure the seals Install the removed parts in the reverse order of
are properly removal.
positioned in the
grooves on air
TORQUE:
cleaner housing AIR CLEANER 1.1 N·m (0.11 kgf·m)
and cover. HOUSING SCREW
[2] [3]
CRANKCASE BREATHER
Service more frequently when ridden in rain or at full
throttle. Service if the deposit level can be seen in the [2]
drain cap.
Check the crankcase breather drain cap [1].
If deposits has collected, remove the clip [2] and
crankcase breather drain cap.
Drain deposits into the suitable container.
Install the crankcase breather drain cap and clip.
[1]
3-5
MAINTENANCE
Remove the left body cover (page 2-9). [1]
Check the crankcase breather hose [1] for deterioration,
damage or leakage.
Install the left body cover (page 2-9).
SPARK PLUG
INSPECTION
Clean around the Disconnect the spark plug cap [1] and remove the spark
spark plug base plug [2].
with compressed air Inspect or replace as described in the maintenance [1] [2]
before removing the schedule (page 3-3).
plug and make sure
Clean the spark plug electrodes with a wire brush or
no debris is allowed
special plug cleaner.
to enter the
combustion Check the insulator for cracks or damage, and the
chamber. electrodes for wear, fouling or discoloration.
Always use the RECOMMENDED SPARK PLUG
specified spark plug CPR6EA-9S (NGK)
on this motorcycle. U20EPR9S (DENSO)
Measure the spark gap between the center and side

electrodes with a feeler gauge.
SPARK PLUG GAP:
0.80 – 0.90 mm
If necessary, adjust the gap by bending the side
electrode carefully.
Install and hand tighten the spark plug to the cylinder
head, then tighten the spark plug to the specified
torque.
Connect the spark plug cap.
3-6
MAINTENANCE
VALVE CLEARANCE
• Inspect and adjust the valve clearance while the
engine is cold (below 35°C).
INSPECTION
– Left lower side cover (page 2-6)
– Spark plug (page 3-6)
– Cylinder head cover (page 8-5)
[1]
Shift the transmission into 3rd or 4th gear.
Always turn the rear Turn the rear wheel counterclockwise little by little, in a
wheel quick motion.
counterclockwise. If Position the cam sprocket so that the cylinder head top
you turn it surface comes between the “l” [1] and “lI” [2] lines on
[2]
clockwise, the the sprocket.
decompressor will
Make sure the piston is at TDC (Top Dead Center) on
operate and correct
the compression stroke.
position cannot be
This position can be obtained by confirming that there is
obtained.
slack in the rocker arms. If there is no slack, turn the
rear wheel again until the correct position is obtained.
Check each valve clearance by inserting a feeler gauge

[1] between the valve adjusting screw and valve stem.
VALVE CLEARANCE:
IN/EX: 0.10 ± 0.02 mm
[1]
ADJUSTMENT
Adjust by loosening the lock nut [1] and turning the [1]
[2]
adjusting screw [2] until there is a slight drag on a feeler
gauge.
Apply engine oil to the lock nut.
Hold the adjusting screw and tighten the lock nut to the
specified torque.
TOOL:
[3] Valve adjusting wrench 07708-0030400

Recheck the valve clearance.
Install the following: [3]
– Spark plug (page 3-6)
3-7
MAINTENANCE
ENGINE OIL
OIL LEVEL INSPECTION
Start the engine and let it idle for 3 – 5 minutes.
Stop the engine and wait 2 – 3 minutes.
Hold the motorcycle in an upright position.
Remove the oil filler cap/dipstick [1] and wipe oil from
the dipstick with a clean cloth. UPPER
Insert the oil filler cap/dipstick without screwing it in, LEVEL
remove it and check the oil level.
LOWER
If the level is below or near the lower level on the
dipstick, add the recommended oil to the upper level. LEVEL
RECOMMENDED ENGINE OIL:

Honda “4-stroke motorcycle oil” or an equivalent
motor oil
[1]
ENGINE OIL CHANGE
Warm up the engine.
Stop the engine, remove the oil filler cap/dipstick and
wipe oil from the dipstick with a clean cloth.
Remove the drain bolt [1] and sealing washer [2].
Drain oil completely.
Install the oil drain bolt with a new sealing washer and
tighten it to the specified torque.
Fill the engine with recommended engine oil.
ENGINE OIL CAPACITY:
0.8 liter
1.0 liter [1] [2]
Check that the O-ring on the oil filler cap is in good

condition, and replace it if necessary.
Install the oil filler cap/dipstick.
Make sure there are no oil leaks.
Check the engine oil level (page 3-8).
ENGINE OIL STRAINER SCREEN

Remove the right crankcase cover (page 11-9).
Remove the oil strainer screen [1] and clean it in non-
flammable or high flash point solvent.
CRANKCASE
Install the oil strainer screen with its tapered side facing SIDE
the crankcase side and thinner edge facing up as
shown.
Install the right crankcase cover (page 11-24).
[1]
3-8
MAINTENANCE
ENGINE OIL CENTRIFUGAL FILTER
CLEANING
Remove the right crankcase cover (page 11-5). [1]
[3]
Remove the three bolts [1], oil centrifugal filter cover [2]
and gasket [3].
[2]
Clean the oil centrifugal filter cover and inside of the
drive plate using a clean lint-free cloth.
Install a new gasket [1] with its sealed side facing the oil [1]
centrifugal filter cover.
Apply locking agent to the oil centrifugal filter cover bolt

[1] threads.
Install the oil centrifugal filter cover [2] and bolts. Coating width 4.5 ± 1.0 mm from tip
Tighten the bolts to the specified torque.
Install the right crankcase cover (page 11-8).
[2] [1]
3-9
MAINTENANCE
ENGINE IDLE SPEED
• Inspect and adjust the engine idle speed after all
other engine maintenance items have been
performed and are within specifications.
• The engine must be warm for accurate engine idle
speed inspection and adjustment.
• Use a tachometer with graduations of 50 min-1 or
smaller that will accurately indicate a 50 min-1
change.
Warm up the engine for about 10 minutes.
[1]
Connect a tachometer according to the tachometer
manufacturer’s operating instructions.
Check the engine idle speed.
IDLE SPEED: 1,400 ± 100 min-1
Turn the throttle stop screw [1] as required to obtain the
specified engine idle speed.
SECONDARY AIR SUPPLY SYSTEM

– lower side cover (page 2-6)
– Main pipe cover (page 2-7)
Check the air supply hose [1] and pipe [2] between the
PAIR control valve and exhaust port for cracks,
deterioration, damage or loose connections.
Check the vacuum hose [3] between the PAIR control
valve and inlet pipe vacuum joint for cracks,
deterioration, damage or loose connections.
[1]/[2]
Check the air supply hoses [3] for deterioration,

damage or loose connections.
Also check that hoses are not cracked, kinked or
pinched.
Make sure that the hoses are not cracked.
Remove and check the air supply hoses.
If there are carbon deposits in the air supply hoses,
check the PAIR check valve (page 6-15).
Install the removed parts in the reverse order of
removal.
[3]
3-10
MAINTENANCE
DRIVE CHAIN
Never inspect and adjust the drive chain while the
engine is running.
DRIVE CHAIN SLACK INSPECTION
Support the motorcycle with its centerstand and shift
the transmission into neutral.
Remove the chain case hole cap [1].
Measure the drive chain slack, on the chain run midway
between the sprockets.
CHAIN SLACK: 30 – 40 mm
Excessive chain slack, 50 mm or more, may damage

the frame.
Install the chain case hole cap.
[1] 30 – 40 mm
ADJUSTMENT
Loosen the rear axle nut [1] and both lock nuts [2].
Turn both drive chain adjusters [3] until the correct drive
chain slack is obtained. [3]
[2] [1]
Make sure the front end of both adjuster plates [1] are
aligned with the same index lines [2] on the swingarm. [5]
[1]
Tighten the rear axle nut to the specified torque while
holding the rear axle bolt [3].
Tighten the both drive chain adjusters [4] and lock nuts
[5] securely.
Recheck the drive chain slack and free wheel rotation.
Check the rear brake pedal freeplay (page 3-14) and
adjust it if necessary.
[2] [3] [4]
3-11
MAINTENANCE
CLEANING, LUBRICATION AND
INSPECTION
Support the motorcycle with its centerstand and shift
the transmission into neutral.
If the drive chain becomes extremely dirty, it should be [2]
removed and cleaned prior to lubrication.
Remove the left crankcase rear cover (page 2-15).
Carefully remove the retaining clip [1] with pliers.
Remove the master link [2] and link plate [3], and
disconnect the drive chain.
Remove the drive chain.
[1] [3]
Clean the chain with non-flammable or high flash point [1]

solvent [1] and wipe it dry.
Be sure the chain has dried completely before
lubricating.
Inspect the drive chain for possible damage or wear. CLEAN
Replace any chain that has damaged rollers, loose
fitting links, or otherwise appears unserviceable.
Installing a new chain on badly worn sprockets will
cause the new chain to wear quickly.
Inspect and replace the sprocket as necessary.
Lubricate the drive chain with #80 – 90 gear oil or drive WIPE AND DRY
chain lubricant. Wipe off any excess oil or chain
lubricant.
Measure the distance between a span of 41 pins (40
links) from pin center to pin center by holding so that all
links are straight.
DRIVE CHAIN LENGTH (41 pins/40 links)

STANDARD: 508 mm
SERVICE LIMIT:518 mm
SPROCKET INSPECTION
Inspect the drive and driven sprocket teeth for wear or
damage, replace them if necessary.
WEAR
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condition, or
the new replacement chain will wear rapidly.
DAMAGE NORMAL
3-12
MAINTENANCE
Install the drive chain onto the sprockets.
Install the master link [1] and link plate [2]. Drive
Install the retaining clip [3] with its open end opposite [1]
the direction of chain travel. Inside
Adjust the drive chain slack (page 3-11).
Install the left crankcase rear cover (page 2-15).
[3] [2]
BRAKE FLUID
Spilled fluid can damage painted, plastic or rubber

parts. Place a rag over these parts whenever the
system is serviced.
• 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.
Turn the handlebar so that the reservoir is level and
check the front brake fluid level through the sight glass [1]
[1].
If the level is near the lower level line [2], check the
brake pad wear(page 3-13).
A low fluid level may be due to wear of the brake pads.
If the brake pads are worn the caliper pistons are
pushed out, and this accounts for a low reservoir level.
If the brake pads are not worn and the fluid level is low,
check the entire system for leaks (page 3-14).
[2]
BRAKE SHOES/PADS WEAR

FRONT BRAKE PADS
Check the brake pads for wear.
Replace the brake pads if either pad is worn to the wear
limit groove [1].
Always replace the For brake pad replacement (page 16-7).
brake pads as a set
to assure even disc
pressure.
[1]
3-13
MAINTENANCE
REAR BRAKE SHOES
Check the wear indicator position when the brake pedal [2] [1]
is applied.
If the indicator plate [1] aligns with the " " [2] mark on
the brake panel, inspect the brake drum (page 15-12).
If the brake drum I.D. is within the service limit, replace
the brake shoes (page 15-11).
BRAKE SYSTEM
HYDRAULIC BRAKE INSPECTION
Firmly apply the brake lever and check that no air has
entered the system.
If the lever feels soft or spongy when operated, bleed
the air from the system (page 15-5).
Remove the handlebar front cover (page 2-12).
Inspect the brake hose [1] and fittings for deterioration,
cracks and signs of leakage.
Tighten any loose fittings.
Replace hoses and fittings as required.
Install the handlebar front cover (page 2-12).
[1]
[1]
BRAKE PEDAL FREEPLAY

Measure the rear brake pedal freeplay at the tip of the
brake pedal.
FREEPLAY: 20 – 30 mm
20 – 30 mm
3-14
MAINTENANCE
Make sure the cut- Adjust the brake pedal freeplay by turning the rear
out of the adjusting brake adjusting nut [1].
nut is seated on the
Recheck the freeplay, then check and adjust the rear
joint pin.
brake light switch (page 3-15).
[1]
BRAKE LIGHT SWITCH

• The front brake light switch on the master cylinder
cannot be adjusted. If the front brake light switch
actuation and brake engagement are not
synchronized, either replace the switch unit or the
malfunctioning parts of the system.
• Adjust the rear brake light switch after the brake
pedal freeplay adjustment.
Check that the brake light comes on just prior to the
brake actually being engaged. [1]
Hold the switch If the light fails to come on, adjust the switch [1] by
body and turn the turning the adjusting nut [2] so that the light comes on at
adjusting nut. the proper time.
Do not turn the
Recheck the brake light switch operation.
switch body while
turning the
adjusting nut.
[2]
HEADLIGHT AIM
Place the motorcycle on the level ground using the
centerstand.
Adjust the headlight Adjust the headlight beam vertically by loosening the
beam as specified bolt [1] and moving the headlight unit, then tighten the
by local laws and bolt.
regulations.
[1]
3-15
MAINTENANCE
CLUTCH SYSTEM
Loosen the clutch adjuster lock nut [1] and turn the
clutch adjuster [2] clockwise one full turn; do not turn [1]
excessively.
Slowly turn the adjuster counterclockwise until
resistance is felt. [2]
Hold the adjuster From this point, turn the adjuster clockwise 1/8 turn,
while tightening the and tighten the lock nut to the specified torque.
lock nut.
• Check for clutch operation after adjustment.
SIDESTAND
Support the motorcycle with its centerstand.
Check the sidestand springs for damage or loss of tension.
Check the sidestand assembly for freedom of movement and lubricate the sidestand pivot if necessary.
SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the forks by operating the front
brake and compressing the front suspension several
times.
Check the entire assembly for signs of leaks, damage
or loose fasteners.
Loose, worn or Replace damaged components which cannot be
damaged repaired.
suspension parts
Tighten all nuts and bolts.
impair motorcycle
stability and control. For fork service (page 14-11).
REAR SUSPENSION INSPECTION
Check the action of the rear shock absorbers by
compressing them several times.
Check the entire shock absorber assembly for signs of
leaks, damage or loose fasteners.
Tighten all nuts and bolts.
For rear shock absorber service (page 15-17).
Check for worn swingarm bushings by grabbing the rear
ends of the swingarm and attempting to move the
swingarm side to side.
Replace the swingarm bushings if any looseness is
noted (page 15-12).
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-9).
Check that all cotter pins, safety clips, hose clamps and
cable stays are in place and properly secured.
3-16
MAINTENANCE
WHEELS/TIRES
Support the motorcycle securely and raise the front wheel off the ground.
Hold the fork leg and move the front wheel sideways with force to see if the wheel bearings are worn.
Check for worn wheel bearings by holding the swingarm and move the rear wheel sideways.
Replace the wheel bearings if any looseness is noted (page 14-8).
Check the tire pressure with a tire pressure gauge when the tires are cold.
RECOMMENDED TIRE PRESSURE AND SIZE:
Unit: kPa (psi)
FRONT REAR
Cold tire pressure
Driver only: 200 (29) 225 ( 33)
Driver and Passenger: 200 (29) 280 (41)
Tire size 70/90-17 80/90-17
M/C 38P M/C 50P
Tire brand IRC: NR69 IRC: NR69
VEE: 357F VEE: 357R
CST:C6016 CST:C6016R
Check the tires for cuts, embedded nails, or other damage.

Check the front and rear wheels for trueness.
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the following limits.
MINIMUM TIRE TREAD DEPTH: To indicator
Inspect the wheel rims and spokes for damage.
Tighten any loose spokes to the specified torque using the special tool.
TOOL:
Spoke wrench, 4.5 x 5.1 mm 07701-0020200
Spoke Wrench 5.8 x 6.1 mm 07701-0020300
TORQUE:
FRONT SPOKE 3.2 N·m (0.33 kgf·m)
REAR SPOKE 3.7 N·m (0.38 kgf·m)
STEERING HEAD BEARINGS

Support the motorcycle securely and raise the front
wheel off the ground.
Check that the handlebar moves freely from side to
side. Make sure the control cables do not interfere with
handlebar rotation.
Check for steering stem bearings by grabbing the fork
legs and attempting to move the front fork forward and
backward.
If the handlebar moves unevenly, binds, or has vertical
movement, inspect the steering head bearings (page
14-20).
3-17
MEMO
dummytext
4. IGNITION SYSTEM
SYSTEM LOCATION·····································4-2 IGNITION SYSTEM INSPECTION ················ 4-5
SYSTEM DIAGRAM ······································4-2 IGNITION COIL ············································· 4-8
SERVICE INFORMATION ·····························4-3 IGNITION CONTROL MODULE (ICM)·········· 4-9
TROUBLESHOOTING···································4-4 IGNITION TIMING ······································· 4-10
4-1
IGNITION SYSTEM
SYSTEM LOCATION
IGNITION SYSTEM
IGNITION SWITCH
IGNITION CONTROL
MODULE (ICM)
MAIN FUSE 10 A
SUB FUSE 7.5A
SPARK PLUG
IGNITION COIL BATTERY

IGNITION PULSE GENERATOR
SYSTEM DIAGRAM
IGNITION
MAIN FUSE SWITCH
10A
R
Bu/Y
Bu/Y
R/Bl
Bl/Y
G
R
IGNITION
PULSE
IGNITION
GENERATOR
COIL
G
Bl : Black
BATTERY IGNITION CONTROL Y : Yellow
SPARK
MODULE (ICM) Bu : Blue
PLUG
G : Green
R : Red
4-2
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and maylead to death.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 4-4.
• The ignition timing does not normally need to be adjusted since the Ignition Control Module (ICM) is factory preset.
• The Ignition Control Module (ICM) may be damaged if dropped. Also if the connector is disconnected when current is flowing,
the excessive voltage may damage the module. Always turn off the ignition switch before servicing.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure the battery
is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark
at the spark plug.
• Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug CPR6EA-9S (NGK) U20EPR9S (DENSO)
Ignition coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 10° BTDC at idle
TORQUE VALUE
Timing hole cap 1.5 N·m (0.15 kgf·m)
4-3
IGNITION SYSTEM
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 (Leaking the ignition coil secondary voltage)
No spark at spark plug
Unusual condition Probable cause (Check in numerical order)
Ignition coil Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/DCV.
primary 2. Cranking speed is too slow. (Battery is undercharged or
voltage operating force of the kickstarter is weak)
3. The sampling time of the tester and measured pulse were
not synchronized. (System is normal if measured voltage is
over the standard voltage at least once.)
4. Poorly connected connectors or an open circuit in the
ignition system.
5. Faulty ignition coil.
6. Faulty ignition control module (ICM) (in case when above
No. 1 – 5 are normal).
No peak voltage. 1. Incorrect peak voltage adaptor connections.
2. Faulty ignition switch.
3. Loose or poorly connected ICM connectors.
4. Open circuit or poor connection in the Red/Black wire of the
ICM.
5. Open circuit or poor connection in the Green wire of the
ICM.
6. Faulty peak voltage adaptor (page 4-5).
7. Faulty ignition pulse generator. (Measure the peak voltage.)
8. Faulty ICM (in case when above No. 1 – 7 are normal).
Peak voltage is normal, but no spark 1. Faulty spark plug or leaking ignition coil secondary current.
jumps at the plug. 2. Faulty ignition coil.
Ignition pulse Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/DCV.
generator 2. Cranking speed is too slow. (Battery is undercharged or
operating force of the kickstarter is weak)
3. The sampling time 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. 1. Faulty peak voltage adapter (page 4-5).
2. Faulty ignition pulse generator.
4-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark at plug, check all connections for [2]
loose or poor contact before measuring peak
voltage.
• Use commercially available digital multimeter with
an impedance of 10 MΩ/DCV minimum.
• The display value differs depending upon the
internal impedance of the multimeter.
• If using Imrie diagnostic tester (model 625), follow
the manufacturer’s instructions.
Connect the peak voltage adaptor [1] to the digital
multimeter [2], or use the Imrie diagnostic tester.
TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100 [1]
with Commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)
IGNITION COIL PRIMARY PEAK

VOLTAGE
• Check all system connections before performing this

inspection. Loose connectors can cause incorrect
readings.
• Check cylinder compression and check that the
spark plug is installed correctly.
Disconnect the spark plug cap [1] from the spark plug. [2]
Connect a known good spark plug [2] to the spark plug
cap and ground the spark plug to the cylinder head as
done in a spark test.
[1]
4-5
IGNITION SYSTEM
Remove the center cover (page 2-6).
[2]
With the ignition coil primary wire connected, connect
the peak voltage adaptor [1] or tester probes to the
ignition coil primary wire terminal [2] and ground.
TOOLS:
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)
CONNECTION:
Black/Yellow (–) – Body ground (+)
Turn the ignition switch “ON”.
Avoid touching the Crank the engine with the starter motor and measure
tester probes to the ignition coil primary peak voltage. (–) Black/yellow
IGNITION COIL
prevent electric
shock.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is abnormal, check each item
following the troubleshooting chart (page 4-4).
(1)
Connect the spark plug cap to the spark plug. BI/Y G
From ICM
(+)
4-6
IGNITION SYSTEM
IGNITION PULSE GENERATOR PEAK
VOLTAGE
• Check all system connection before inspection. If the

system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compression and make sure the
spark plug is installed correctly.
Turn the ignition switch to “OFF”.
Remove the luggage box (page 2-10). [1]
Remove the ICM [1] from the rear fender and
disconnect the ICM 3P connector [2].
Connect the peak voltage adaptor or tester probes to
the ICM 3P connector.
TOOLS:
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum) [2]
CONNECTION: Blue/Yellow (+) – Body ground (–)
Turn the ignition switch “ON”. ICM 3P CONNECTOR
Avoid touching the Crank the engine with the starter motor and measure
tester probes to the ignition pulse generator peak voltage.
prevent electric
shock.
PEAK VOLTAGE: 0.7 V minimum
Bu/Y Bu/Y
If the peak voltage measured at the ICM connector is
abnormal, measure the peak voltage at the ignition
pulse generator wire connector. IGNITION
PULSE
GENERATOR
4-7
IGNITION SYSTEM
Connect the peak voltage tester or adaptor probes to
the wire connector [1] (Blue/Yellow) terminal of the [1]
ignition pulse generator side.
In the same manner as at the ICM connector, measure
the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnormal
and the one measured at the ignition pulse
generator is normal, the wire harness has an open
or short circuit, or loose connection.
• If both peak voltages measure are abnormal, check
each item in the troubleshooting chart (page 4-4).
If all items are normal, the ignition pulse generator is
faulty. See page 4-7 for ignition pulse generator
replacement.
Install the removed parts in the reverse order of IGNITION PULSE GENERATOR WIRE
removal. (Blue/Yellow) CONNECTOR
Bu/Y
IGNITION PULSE
GENERATOR
IGNITION COIL
Remove the center cover (page 2-6).
[1]
Disconnect the ignition coil wire connectors [1]. [2]
Remove the bolts [2] and ignition coil [3] from the frame.
[3]
Disconnect the spark plug cap [1] from the spark plug [2]
and release the spark plug wire from the guide [2].
Pull out the spark plug wire from the center cover side.
Route the wire Installation is in the reverse order of removal.
harness properly
(page 1-15).
[1]
4-8
IGNITION SYSTEM
IGNITION CONTROL MODULE (ICM)
Remove the luggage box (page 2-10).
Turn the ignition switch “OFF”. [1]
Remove the ICM [1] from the frame.
Disconnect the ICM 2P [2] and 3P [3] connectors.
[2]/[3]
POWER/GROUND LINE INSPECTION
Remove the luggage box (page 2-10).
Remove the ICM [1] from the rear fender and [1]
disconnect the ICM 2P connector [2].
Measure the battery voltage between the ICM 2P
connector of the wire harness side and ground.
CONNECTION: Red/Black (+) – Body ground (–)
There should be battery voltage with the ignition switch
“ON”.
If there is no voltage with the ignition switch “ON”, [3] [2]
check the following:
– Wire harness between the battery and ICM
– Ignition switch
– Main fuse 10 A POWER LINE:
Turn the ignition switch “OFF”. IGNITION

MAIN FUSE
Disconnect the ICM 3P connector [3]. SWITCH
10 A
Check for continuity between the ICM 3P connector of R
the wire harness side and ground.

CONNECTION: Green – Body ground R R/Bl
There should be continuity at all time.

G
Route the wire If there is no continuity, check the open circuit in green
harness properly wire.
(page 1-15).
ICM 2P CONNECTOR
GROUND LINE:
G G
ICM 3P CONNECTOR
4-9
IGNITION SYSTEM
IGNITION TIMING
Warm up the engine.
Stop the engine and connect the timing light [1] to the
spark plug wire.
Remove the timing hole cap from the left crankcase [2]
cover using the special tool.
TOOL:
[3]
Timing cap wrench 07709-0010001
Start the engine and let it idle.
IDLE SPEED:1,400 ± 100 min-1
The ignition timing is correct if the “F” mark [2] on the
flywheel aligns with the index notch [3] on the left [1]
crankcase cover.
Apply engine oil to a new O-ring.
Install and tighten the timing hole cap to the specified
torque.
TORQUE: 1.5 N·m (0.15 kgf·m)
4-10
dummytext
5. ELECTRIC STARTER SYSTEM
SYSTEM LOCATION·····································5-2 TROUBLESHOOTING ·································· 5-4
SYSTEM DIAGRAM ······································5-2 STARTER MOTOR ······································· 5-5
SERVICE INFORMATION ·····························5-3 STARTER RELAY········································· 5-9
5-1
SYSTEM LOCATION
STARTER SWITCH
IGNITION SWITCH
STARTER RELAY
MAIN FUSE 10 A
SUB FUSE 7.5 A
IGNITION CONTROL
MODULE (ICM)
STARTER MOTOR
BATTERY
SYSTEM DIAGRAM
IGNITION
MAIN FUSE SWITCH SUB FUSE
10A 7.5A
R R R/Bl
STARTER
RELAY
G
BATTERY
Y/R Bl
R/W
STARTER
SWITCH
Bl : Black
STARTER
Y : Yellow
MOTOR G : Green
R : Red
W : White
5-2
SERVICE INFORMATION
GENERAL
• Always turn the ignition switch “OFF” before servicing the starter motor. The motor could suddenly start, causing serious injury.
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting (page 5-4).
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.
• Refer to the following component information.
– Ignition switch (page 18-12)
– Starter switch (page 18-13)
SPECIFICATION

Starter motor brush length 7.0mm 3.5mm
TORQUE VALUE
Starter motor cable screw 2.0 N·m (0.20 kgf·m)
5-3
TROUBLESHOOTING
Starter motor does not turn
1. Standard Inspection
Check for following:
– Battery condition
– Burned fuse(s)
Are the above items in good condition?
YES – GO TO STEP 2.
NO – Replace or repair the malfunction part(s).
2. Starter Relay Operation
Push the starter switch.
You should hear the relay “CLICK” when the starter switch is depressed.
Is the “CLICK” heard?
NO – GO TO STEP 3.
3. Starter Motor Cable Inspection
Turn the ignition switch “OFF”.
Check for open circuit in starter motor cable.
Is the above cable in good condition?
NO – • Loose or poorly connected starter motor cable and starter motor
• Open circuit in battery negative terminal.
• Open circuit in starter motor Red/White cable between the starter relay and starter motor.
4. Starter Motor Inspection
Apply battery voltage to the starter motor directly and check the operation.
Does the starter motor turn?
YES – • Open circuit in Red wire between the starter relay and battery.
• Faulty starter relay.
NO – Faulty starter motor.
5. Starter Relay Coil Circuit Inspection
Disconnect the starter relay 5P connector.
Turn the ignition switch “ON” and push the starter switch.
Measure the battery voltage between the starter relay 5P connector terminal of the wire harness side.
CONNECTION: Yellow/Red (+) – Green (–)
Does the battery voltage exist?
NO – • Loose or poorly connected connector.
• Open circuit in battery cable between the battery and ignition switch.
• Open circuit in Red/Black and/or Black wire between the ignition switch and starter switch.
• Open circuit in starter relay Yellow/Red wire between the starter switch and starter relay.
• Open circuit in Green wire between the starter relay and ground.
• Faulty ignition switch (page 18-12)
• Faulty starter switch (page 18-13)
6. Starter Relay Continuity Inspection
Check the starter relay for continuity (page 5-10)
Is there continuity?
YES – Intermittent failure.
NO – Faulty starter relay.
5-4
Starter motor turns engine slowly
• Low battery voltage.
• Poorly connected battery terminal cable.
• Poorly connected starter motor cable.
• Faulty starter motor.
• Poorly connected battery ground cable.
Starter motor turns, but engine does not turn
• Starter motor is running backwards.
– Case assembled improperly.
– Terminals connected improperly.
• Faulty starter clutch.
Starter relay “CLICK”, but engine does not turn
• Crankshaft does not turn due to engine problems.
• Faulty starter clutch.
STARTER MOTOR
REMOVAL
– Right side body cover (page 2-9)
– Right lower side cover (page 2-6)
Disconnect the starter motor 2P connector [1] and
[2]
release the starter motor cable from the wire band [2].
Remove the bolts [3] and starter motor.
[1] [3]
Remove the O-ring [1].

[1]
5-5
Pull off the dust cover [1].
[4]/[5]
Remove the screw [2] and starter motor cable [3].
Remove the screw [4] and ground cable [5].
INSTALLATION
Install the ground cable [3] and tighten the screw [2] to
the specified torque.
Install the starter motor cable [4] and tighten the screw
[5] to the specified torque.
TORQUE: 2.0 N·m (0.20 kgf·m) [1]
Put the dust cover [1] back in the appropriate position.

[2]/[3]
Coat a new O-ring [1] with engine oil and install it into
the starter motor groove. [1]
Install the starter motor and tighten bolts [1]. [2]

Connect the starter motor 2P connector [2] and secure
the starter motor cable with the wire band [3].
[2] [1]
Install the following:

– Right side body cover (page 2-9)
– Right lower side cover (page 2-6)
5-6
DISASSEMBLY
Remove the screws [1] and starter motor case [2].
– Armature [3]
– Bracket [4]
– Springs [5]
– Gasket [6] [1] [2]
[3]
[4]
[6]
[5]
ASSEMBLY
Install the springs [1] in the brush holders [2].
[2]
[1]
Install the armature [1] into the bracket while holding the
brushes [2]. [1]
[2]
5-7
Install a new gasket [1] onto the bracket [2]. [4]
[2]
The coil may be Install the bracket and armature [3] to the motor case
damaged if the [4] while holding the bracket side armature shaft tightly.
magnet pulls the
armature against
the case.
[3]
[1]
Install the motor case screws [1] and tighten them to the
[1]
specified torque.
INSPECTION
BRUSH
Inspect the brushes for damage and measure the brush
length.
SERVICE LIMIT: 3.5 mm
ARMATURE
Do not use emery Inspect the commutator bars [1] of the armature for
or sand paper on discoloration. [1]
the commutator.
Bars discolored in pairs indicate shorted coils.
5-8
Check for continuity between each pair of commutator
CONTINUITY:
bars.
There should be continuity.
Check for continuity between each commutator bar and

the armature shaft. NO CONTINUITY:
There should be no continuity.
STARTER RELAY
Pull the dust cover up.
[1]
Remove the starter relay [1] from the stay.
Disconnect the starter relay 5P connector [2].
[2]
OPERATION INSPECTION
Remove the battery cover (page 17-5)
Push the starter switch.
The system is normal if the starter relay [1] clicks. [1]
If you don’t hear the relay “CLICK”, inspect the

following:
– Starter relay coil circuit (page 5-10)
– Battery testing (page 17-5)
If you hear the relay “CLICK”, but starter does not turn,
inspect the starter relay continuity (page 5-10)
5-9
STARTER RELAY COIL CIRCUIT
INSPECTION
Remove the battery cover(page 17-5)
Remove the starter relay from the stay. IGNITION
Disconnect the starter relay 5P connector. MAIN FUSE SWITCH
10 A
Turn the ignition switch “ON”. R R
Measure the voltage between the starter relay 5P G
connector of the wire harness side while pressing and

holding the starter switch.
SUB FUSE
CONNECTION: Yellow/Red (+) – Green (–) 7.5 A
G Y/R Bl R/Bl
If the battery voltage appears only when the ignition
switch is “ON” and starter switch is pressed, the circuit
is normal. STARTER
STARTER RELAY
5P CONNECTOR SWITCH
STARTER RELAY CONTINUITY

INSPECTION
Remove the starter relay
Connect a fully charged 12 V battery positive wire to the
relay switch terminal A and negative wire to the terminal
B.
Check for continuity at the terminal C and terminal D.
There should be continuity between the C and D
terminals while the battery is connected, and no
continuity when the battery is disconnected.
A C
B D
A B C D
5-10
dummytext
6. FUEL SYSTEM
COMPONENT LOCATION ····························6-2 AIR SCREW ADJUSTMENT······················· 6-11
SERVICE INFORMATION ·····························6-3 FUEL TANK ················································ 6-12
TROUBLESHOOTING···································6-4 FUEL FILTER ·············································· 6-13
AIR CLEANER HOUSING·····························6-5 FUEL STRAINER SCREEN ························ 6-13
CARBURETOR REMOVAL···························6-5 SECONDARY AIR SUPPLY SYSTEM ······· 6-14
CARBURETOR INSTALLATION ··················6-7 SEPARATE AIR FILTER ···························· 6-16
CARBURETOR DISASSEMBLY/ AIR SUPPLY PIPE ······································ 6-16

ASSEMBLY ···················································6-9
INLET PIPE ················································· 6-17
6-1
FUEL SYSTEM
COMPONENT LOCATION
FUEL SYSTEM
12 N·m (1.2 kgf·m)
6-2
FUEL SYSTEM
SERVICE INFORMATION
GENERAL
• Bending or twisting the throttle cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of
vehicle control.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
• If the vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause clogged
jets, resulting in hard starting or poor drive ability.
• Before disassembling the carburetor, place an approved fuel container under the carburetor, loosen the drain screw and drain
the carburetor.
• When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with a piece of tape to prevent any
foreign material from dropping into the engine. Be sure to remove the cover when reinstalling the carburetor.
SPECIFICATIONS
ITEM SPECIFICATIONS
Carburetor identification number PB7UL
Main jet #90
Slow jet #35
Float level 11.7 mm
Air screw initial opening See page 6-11
PAIR control valve specified vacuum 60 kPa
TORQUE VALUE
Inlet pipe band screw – See page 6-17
Fuel valve screw 0.88 N·m (0.090 kgf·m)
Air cut-off valve screw 2.1 N·m (0.21 kgf·m)
Slow jet 1.5 N·m (0.15 kgf·m)
Main jet 1.5 N·m (0.15 kgf·m)
Needle jet holder 2.5 N·m (0.25 kgf·m)
Float chamber screw 2.1 N·m (0.21 kgf·m)
Float chamber drain screw 1.5 N·m (0.15 kgf·m)
Fuel strainer cup 5.9 N·m (0.60 kgf·m)
Throttle cable holder screw 3.4 N·m (0.35 kgf·m)
Fuel valve lever screw 2.1 N·m (0.21 kgf·m) Apply locking agent to the threads
Inlet pipe mounting bolt 12 N·m (1.2 kgf·m)
PAIR control valve mounting bolt 10 N·m (1.0 kgf·m)
PAIR check valve cover screw 2.1 N·m (0.21 kgf·m)
6-3
FUEL SYSTEM
TROUBLESHOOTING
Engine won’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 strainer clogged
– Fuel tank cap breather hole clogged
– Fuel line clogged/bent
– No fuel in tank
Lean mixture
• Fuel jets clogged
• Float valve faulty
• Float level too low
• Fuel line restricted
• Carburetor air vent hose clogged
• Intake air leak
• Throttle valve faulty
Rich mixture
• Carburetor choke stuck
• Float valve faulty
• Float level too high
• Air jets clogged
• Air cleaner element contaminated
• Flooded carburetor
Engine stall, hard to start, rough idling
• Fuel line restricted
• Ignition system malfunction
• Fuel mixture too lean/rich
• Fuel contaminated/deteriorated
• Intake air leak
• Idle speed misadjusted
• Air screw misadjusted
• Slow circuit clogged
• Improper choke operation
• Low cylinder compression
• Air cleaner clogged
After burn when engine braking is used
• Lean mixture in slow circuit
• Faulty pulse secondary air injection (PAIR) system
– Faulty PAIR control valve
– Clogged hose of the PAIR system
• Faulty air cut-off valve
Backfiring or misfiring during acceleration
• Fuel mixture too lean
Poor performance (drive ability) and poor fuel economy
• Fuel system clogged
• Air cleaner clogged
6-4
FUEL SYSTEM
AIR CLEANER HOUSING
– Main pipe cover (page 2-7). [1]
– Air cleaner element (page 3-5)
Disconnect the crankcase breather hose [1].
Loosen the connecting hose band screw [2].
[2]
Disconnect the air supply hose [1] and air vent hose [2]. [2]
Remove the bolts [3] and air cleaner rear housing [1] [4]
assembly [4].
[3]

• Tighten the connecting hose band screw so that the
gap between the band ends is 5 mm.
5 mm
CARBURETOR REMOVAL
THROTTLE VALVE
– Lower side covers (page 2-6).
– Main pipe cover (page 2-7).
Remove the carburetor top [1] and throttle valve from
the carburetor.
6-5
FUEL SYSTEM
Remove the throttle cable [1] from the throttle valve [2]
while compressing the throttle valve spring [3].
[1]
[3]
[2]
Remove the retainer [1], spring [2] and jet needle [3] [5] [4]
while pushing the retainer with a screwdriver [4] slightly
and turning it counterclockwise.
Check the throttle valve [5] and jet needle for scratches,
wear or damage.
Replace them if necessary.
[3]
[2]
[1]
CARBURETOR BODY
Turn the fuel valve “OFF”.
Place a suitable container under the carburetor drain
hose and drain fuel from the carburetor by loosening
the drain screw [1].
Tighten the float chamber drain screw.
[1]
Pinch the fuel hose with the hose clamp [1].

[4]
Disconnect the following: [1]
– Fuel hose [2]
– Drain hose [3]
– Air vent hose [4]
[3] [2]
6-6
FUEL SYSTEM
Loosen the air cleaner connecting hose band screw [1].
Remove the carburetor mounting bolts [2], insulator [3], [5]
O-rings [4] and carburetor [5] from the inlet pipe. [2]
[1]
[3]/[4]
Release the choke cable [1] from the cable holder [2] [1] [2]
and disconnect the choke cable.
CARBURETOR INSTALLATION
CARBURETOR BODY
Connect the choke cable [1] to the carburetor and install [1] [2]
it to the cable holder [2].
Install the carburetor body [1] to the air cleaner [1]

connecting hose.
[4]
Install the insulator Install new O-rings [2] into the insulator [3] and
with the boss [4] carburetor body grooves.
facing up.
[2] [3]
6-7
FUEL SYSTEM
Install the carburetor body [1] and insulator [2] to the
inlet pipe and tighten the bolts [3].
Tighten the connecting hose band screw [4] so that the [1]
gap between the band ends is 5 mm.
5 mm
[4]
[3] [2]
Connect the following:

[1]
– Air vent hose [1] [4]
– Drain hose [2]
– Fuel hose [3]
Remove the hose clamp [4].
Turn the fuel valve “ON”.
[2] [3]
THROTTLE VALVE
Install the jet needle [1] into the throttle valve [2]. [2] [5]
Secure the jet needle with retainer [3] and spring [4]
while pushing the retainer with a screwdriver [5] slightly
and turning it clockwise.
[1]
[4]
[3]
Install the throttle valve spring [1] onto the throttle cable
[2].
Connect the throttle cable to the throttle valve [3] while
compressing the throttle valve spring.
[2]
[1]
[3]
6-8
FUEL SYSTEM
Install the throttle valve [1] into the carburetor body by [1]
aligning its cut-out [2] with the throttle stop screw [3].
[2]
[3]
Tighten the carburetor top [1]. [1]

After installing the carburetor, check for the following:
– Throttle grip free play (page 3-4)
– Engine idle speed (page 3-10)
– Air screw adjustment (page 6-11)
– Main pipe cover (page 2-7).
CARBURETOR DISASSEMBLY/
ASSEMBLY
• The air cut-off valve cover is under spring pressure.
Be careful during removal.
• Install the air cut-off valve O-ring with its flat side
facing the carburetor body.
• Handle all jets with care. They can easily be scored
or scratched.
• Turn the air screw in and record the number of turns
until it seats lightly. Make a note of the number to
use as a reference when reinstalling the air screw.
• Damage to the air screw seat will occur if the air
screw is tightened against the seat.
– Screw [1]/fuel valve [2]/O-ring [3].
– Screw [4]/fuel valve lever [5]
– Screws [6]/air cut-off valve cover [7]/spring [8]/
diaphragm [9]/O-ring [10]
– Screws [11]/float chamber [12]/O-ring [13]/float pin
[14]/float [15]/float valve [16]
– Fuel stainer cup [17]/fuel stainer screen [18]/O-rings
[19]
– Main jet [20]/needle jet holder [21]/needle jet [22]/
slow jet [23]
– Throttle stop screw [24]/spring [25]/air screw [26]/
spring [27]/washer [28]/O-rings [29]
– Float chamber drain screw [30]/O-ring [31]
6-9
FUEL SYSTEM
[9]
[14]
[29]
[1] [16] [28]
0.88 N·m (0.090 kgf·m) [26]
[15]
[27]
[5]
[3] [29]
[25]
[24]
[10]
[13]
[8]
[4] [23] [6]

2.1 N·m 1.5 N·m 2.1 N·m
(0.21 kgf·m) (0.15 kgf·m) (0.21 kgf·m)
[2] [7]
[22]
[11]
2.1 N·m (0.21 [21]
kgf·m) [31] 2.5 N·m (0.25 kgf·m)
[12]
[20]
[19] 1.5 N·m (0.15 kgf·m)
[18]
[30]
[17] 1.5 N·m (0.15 kgf·m)
5.9 N·m (0.60 kgf·m)
INSPECTION
AIR CUT-OFF VALVE
Check the following:
[2] [4]
– Diaphragm [1] for pin holes, deterioration or damage
– Spring [2] for deterioration
– Needle [3] of diaphragm for wear
– Air passages [4] for clogging
[3]
[1]
6-10
FUEL SYSTEM
FLOAT VALVE/VALVE SEAT
Inspect the float valve seat [1] for scratches, clogging
Float valve tip check:
and damage.
[2]
Check the tip of the float valve [2] where it contacts the
valve seat for stepped wear or contamination.
Check the float valve operation by pushing its end pin [1]
[3].
The pin should return smoothly.
Replace the valve if the tip is worn or contaminated.
Float valve operation check:
[3]
FLOAT LEVEL INSPECTION

With the float valve seated and the float arm just
touching the valve, measure the float level with the float [1]
level gauge [1] as shown.
FLOAT LEVEL: 11.7 mm
TOOL:
Float Level Gauge 07401-0010000
The float level cannot be adjusted.
Replace the float assembly if the float level is out of
specification.
AIR SCREW ADJUSTMENT

IDLE DROP PROCEDURE
• The air screw is factory pre-set and no adjustment is
necessary unless the carburetor is overhauled or the
air screw is replaced.
• Use a tachometer with graduations of 50 min-1 or
smaller that will accurately indicate a 50 min-1
change.
Damage to the air Remove the right lower side cover (page 2-6).
screw seat will
1. Turn the air screw [1] clockwise until it seats lightly, [1]
occur if the air
then back it out to specification given. [2]
screw is tightened
This is an initial setting prior to the final air screw
against the seat.
adjustment.
INITIAL OPENING: 2 1/8 turns out
2. Warm up the engine to operating temperature. Stop
and go riding for 10 minutes is sufficient.
3. Stop the engine and connect the tachometer
according to its manufacturer’s instructions.
4. Disconnect the vacuum hose [2] of PAIR control
valve, then connect it to the vacuum pump [3] and
plug the vacuum port.
[4]
6-11
FUEL SYSTEM
5. Apply the specified vacuum to the PAIR control
[3]
valve vacuum hose more than 60 kPa.
[2]
6. Start the engine and adjust the idle speed with the
throttle stop screw [4].
7. Turn the air screw in or out slowly to obtain the PLUG
highest engine speed.
8. Lightly open the throttle 2 or 3 times, then adjust the
idle speed with the throttle stop screw.
9. Turn the air screw out until the engine speed drops
by 50 min-1 .
10.Turn the air screw clockwise to the final opening
from the position obtained step 9.
FINAL OPENING:1/4 turns in
11.Disconnect the plug from the vacuum port, then
remove the vacuum pump and connect the vacuum
hose of PAIR control valve.
12.Readjust the idle speed with the throttle stop screw.
Install the right lower side cover (page 2-6).
FUEL TANK
Remove the body covers (page 2-9).
Disconnect the fuel level sensor 3P (Black) connector
[1].
Release the wire from the clamp [2].
[2]
[1]
Remove the mounting bolts [1].
[1]
6-12
FUEL SYSTEM
Clamp [1] the fuel hose.
[1]
Disconnect the fuel hose and remove the fuel tank.
FUEL FILTER
[2] [1]
Clamp [1] the fuel hose of the fuel tank side.
Disconnect the fuel hoses and remove the fuel filter [2].
Wipe off spilled out Place an approved fuel container and drain the fuel.
fuel.
Check the fuel filter [3] for damage or contamination.

Replace the fuel filter if necessary. TO THE FUEL TANK SIDE
TO THE FUEL VALVE SIDE
[3] DIRECTION MARK
FUEL STRAINER SCREEN

Remove the right lower side cover (page 2-6).
[2]/[3]
Turn the fuel valve “OFF”.
Remove the fuel strainer cup [1], strainer screen [2] and
O-rings [3].
Clean the strainer screen and strainer cup in non-
flammable or high flash point solvent.
Replace the strainer screen if necessary.
[1]
6-13
FUEL SYSTEM
Install new O-rings [3], strainer screen [2] and strainer
cup [1]. [3]
Tighten the strainer cup to the specified torque.
Turn the fuel valve “ON” and make sure that there are
no fuel leakage.
Install the right lower side cover (page 2-6).
[2] [1]
SECONDARY AIR SUPPLY SYSTEM

PAIR (PULSE SECONDARY AIR
INJECTION) CHECK VALVE
INSPECTION
Remove the screws [1] and check valve cover [2] from [1] [3]
the PAIR control valve body [3].
[2]
Remove the check valve [1] from the PAIR control valve
body.
[1]
Check the reed [1] for damage or fatigue, replace if

necessary.
Replace the PAIR check valve if the rubber seat [2] is
cracked, deteriorated or damaged, or if there is
clearance between the reed and seat
Installation is in the reverse order of removal. [1]
TORQUE:
PAIR check valve 2.1 N·m (0.21 kgf·m)
cover screw
[2]
6-14
FUEL SYSTEM
PAIR CONTROL VALVE REMOVAL/
INSTALLATION
[3] [4]
Disconnect the vacuum hose [1] and air supply hoses
[2] from the PAIR control valve [3].
Remove the bolts [4] and PAIR control valve body.
[2]
[1]
SYSTEM INSPECTION
– Center cover (page 2-6).
VACUUM HOSE
Start the engine and warm it up to normal operating
temperature and stop the engine.
Disconnect the air supply hose from the separate air
AIR SUPPLY HOSE
filter (page 6-16).
VACUUM PUMP
Remove the PAIR check valve (page 6-14) and check
the inside of PAIR control valve is clean and free of
carbon deposits.
Check the PAIR check valve if the inside of PAIR
control valve is carbon fouled. PLUG
Disconnect the PAIR control valve vacuum hose from
the inlet pipe and plug the hose joint.
Connect the vacuum pump to the PAIR control valve
vacuum hose.
Start the engine and open the throttle slightly to be
certain that air is sucked in through the air supply hose.
If the air is not drawn in, check the air supply hose for
clogging.
With the engine running, gradually apply vacuum to the
PAIR control valve vacuum hose.
Check that the air supply hose stops drawing air, and
that the vacuum does not bleed.
SPECIFIED VACUUM: 60 kPa
If the air is drawn in or if the specified vacuum is not
maintained, install a new PAIR control valve.
If after burn occurs on deceleration, even when the
secondary air supply system is normal, check the air
cut-off valve.
removal.
6-15
FUEL SYSTEM
SEPARATE AIR FILTER
Remove the main pipe cover (page 2-7). [3] [2]
Release the air supply hoses [1] from the guide [2] and [4]
air cleaner housing [3].
Disconnect the air supply hoses from the separate air
filter [4] and remove the separate air filter.
Check the separate air filter and replace it if necessary.
• Install the separate air filter with its direction mark [5] [1]
facing the PAIR control valve side.
[4]
[5]
TO THE PAIR
CONTROL VALVE
AIR SUPPLY PIPE

[1]
Remove the bolts [1].
Disconnect the air supply hose [2] and air supply pipe
[3].
Remove the gasket [4].
• Before installation, clean the gasket mating surfaces
of the air supply pipe and cylinder head. [2]
• Replace the gasket with a new one.
[3]
[4]
INSPECTION
Check the air supply pipe [1] for crack or damage.
[1]
6-16
FUEL SYSTEM
INLET PIPE
REMOVAL
Remove the lower side covers (page 2-6).
[2] [4]
Disconnect the vacuum hose[1].
– Bolts [2]
– Insulator [3]
– O-rings [4]
– Inlet pipe [5]
[3]
[5]
[1]
INSTALLATION
Install a new gasket [1] to the cylinder head.
[1]
Install the inlet pipe [1] and bolts [2] to the cylinder
head. [1]
Tighten the bolts to the specified torque.
[2]
Install the insulator Install new O-rings [1] into the insulator [3] and
with the boss [2] carburetor body grooves. [2]
facing up.
[3]
[1]
6-17
FUEL SYSTEM
Install the insulator [1] and bolts [2] to the carburetor [2]
body and tighten the bolts.
Connect the vacuum hose [3] to the inlet pipe.
Install the lower side covers (page 2-6).
[1]
[3]
6-18
dummytext
7. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM ············7-2 TROUBLESHOOTING ·································· 7-3 7
SERVICE INFORMATION ·····························7-3 OIL PUMP ····················································· 7-4
7-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM
CAMSHAFT
PISTON
OIL PUMP
CRANKSHAFT
MAINSHAFT
OIL CENTRIFUGAL
FILTER
COUNTERSHAFT
OIL STRAINER SCREEN
7-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
• This section covers service of the oil pump.

• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks.
SPECIFICATIONS
Unit: mm
Engine oil capacity At draining 0.75 liter –
At disassembly 1.0 liter –
Recommended engine oil Honda “4-stroke motorcycle oil” or an
equivalent motor oil
API classification: SG or higher –
Oil pump rotor Tip clearance – 0.15
Body clearance 0.15 – 0.21 0.26
Side clearance 0.03 – 0.09 0.15
TORQUE VALUE
Oil pump cover screw 5 N·m (0.51 kgf·m)
TROUBLESHOOTING
Engine oil level too low
• Oil consumption
• External oil leak
• Worn piston rings (page 9-5)
• Improperly installed piston rings (page 9-8)
• Worn valve guide or stem seal (page 8-12)
• Worn cylinder (page 9-5)
Oil contamination
• Worn piston rings (page 9-6)
• Improperly installed piston rings (page 9-8)
• Worn valve guide or stem seal (page 8-12)
• Oil not changed frequently enough
• Clogged oil strainer screen (page 3-8)
7-3
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
Drain the engine oil (page 3-8).
[2]
– Right crankcase cover (page 11-5)
– Three bolts [1]
– Oil pump [2]
[1]
Remove the gasket [1] from the oil pump [2].

[1]
[2]
OIL PUMP BODY
OIL PUMP SHAFT
SCREWS
5 N·m (0.51 kgf·m)
OUTER ROTOR
INNER ROTOR
OIL PUMP COVER
7-4
LUBRICATION SYSTEM
Apply engine oil to the inner rotor [1] and outer rotor [2]
sliding surfaces. [1]
Install the inner and outer rotors to the oil pump body.
Install the oil pump shaft [3] aligning the flat surfaces of
the oil pump shaft and the inner rotor.
[3]
Align [2]
Install the oil pump cover [1].
Install and tighten the three screws [2] to the specified [2]
torque.
Install the oil pump (page 7-6).
[1]
INSPECTION
If any clearance of oil pump exceeds the specified

service limits,replace the oil pump as an assembly.
If any portion of the Disassemble the oil pump (page 7-4).
oil pump is worn TIP CLEARANCE:
Temporarily install the outer and inner rotors into the oil
beyond the service
pump body.
limit, replace the oil
Install the oil pump shaft.
pump as an
assembly. Measure the tip clearance between the inner and outer
rotors.
Measure the pump body clearance between the outer

rotor and the oil pump body. BODY CLEARANCE:
7-5
LUBRICATION SYSTEM
Measure the side clearance using a straight edge and a
SIDE CLEARANCE:
feeler gauge.

Assemble the oil pump (page 7-4).
INSTALLATION
Install the new gasket [1] to the oil pump [2].
Align [1]
Install the oil pump to the crankcase aligning the oil
pump shaft groove with the cam chain guide sprocket
spindle.
[2]
Install and tighten the three bolts [1].

Clean the oil strainer screen (page 3-8).
Install the right crankcase cover (page 11-8)
After installation, fill the crankcase with recommended
engine oil (page 3-8).
Start the engine and check that there are no oil leaks.
[1]
7-6
dummytext
8. CYLINDER HEAD/VALVES
COMPONENT LOCATION ····························8-2 CAMSHAFT··················································· 8-7

8
SERVICE INFORMATION ·····························8-3 CYLINDER HEAD ······································· 8-10
TROUBLESHOOTING···································8-4 CAM CHAIN TENSIONER ·························· 8-20
CYLINDER COMPRESSION TEST···············8-5 OIL STOPPER PLATE ································ 8-22
CYLINDER HEAD COVER····························8-5
8-1
COMPONENT LOCATION
27 N·m (2.8 kgf·m)

10 N·m (1.0 kgf·m)
13 N·m (1.3 kgf·m)
16 N·m (1.6 kgf·m)

22 N·m (2.2 kgf·m)
8-2
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves, camshaft and cam chain tensioner.
• The cylinder head, valves, camshaft and cam chain tensioner services can be done with the engine installed in the frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder
head.
• Be careful not to damage the mating surfaces when removing the cylinder head.
SPECIFICATIONS
Unit: mm
Cylinder compression 824 kPa (120 psi)
–
at 400 min-1
Cylinder head warpage – 0.05
Valve, Valve clearance IN/EX 0.10 ± 0.02 –
valve guide Valve stem O.D. IN 4.975 – 4.990 4.965
EX 4.955 – 4.970 4.945
Valve guide I.D. IN/EX 5.000 – 5.012 5.03
Stem-to-guide clearance IN 0.010 – 0.037 0.065
EX 0.030 – 0.057 0.085
Valve guide projection IN/EX 9.1 – 9.3 –
Valve seat width IN/EX 0.90 – 1.10 1.6
Valve spring free length IN/EX 30.67 29.70
Rocker arm/ Rocker arm I.D. IN/EX 10.000 – 10.015 10.10
shaft Rocker arm shaft O.D. IN/EX 9.972 – 9.987 9.91
Rocker arm-to-shaft
IN/EX 0.013 – 0.043 0.044
clearance
Camshaft Cam lobe height IN 32.194 – 32.434 32.16
EX 31.990 – 32.230 31.96
Cam chain Push rod O.D. 11.985 – 12.000 11.94
tensioner Spring free length 111.3 109
TORQUE VALUES
Cylinder head cover special bolt 10 N·m (1.0 kgf·m)
Cylinder head nut 13 N·m (1.3 kgf·m) Apply oil to the threads and seating surface.
Cam sprocket bolt 27 N·m (2.8 kgf·m) Apply oil to the threads and seating surface.
Cam chain tensioner sealing bolt 22 N·m (2.2 kgf·m)
Cam chain tensioner arm pivot bolt 16 N·m (1.6 kgf·m)
8-3
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a
compression test or by tracing engine noises to the top-end with a sounding rod stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose
is smoky, check for a seized piston ring (page 9-6).
Compression too low, hard starting or poor performance at low speed
• Valves:
– Incorrect valve clearance
– Burned or bent valves
– Incorrect valve timing
– Broken valve spring
– Valve stuck open
• Cylinder head:
– Uneven valve seating
– Leaking or damaged cylinder head gasket
– Warped or cracked cylinder head
• Worn cylinder, piston or piston rings (page 9-6)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston head or combustion chamber
• Decompressor malfunction
Excessive smoke
• Cylinder head:
– Worn valve stem or valve guide
– Damaged stem seal
Excessive noise
• Cylinder head:
– Incorrect valve clearance
– Sticking valve or broken valve spring
– Damaged or worn camshaft
– Loose or worn cam chain
– Worn or damaged cam chain guide roller/sprocket
– Worn or damaged cam chain tensioner
– Worn cam sprocket teeth
– Worn rocker arm and/or shaft
Rough idle
• Low cylinder compression
• Faulty fuel system (page 6-3)
8-4
CYLINDER COMPRESSION TEST
Warm up the engine to normal operating temperature.
Stop the engine and disconnect the spark plug cap.
Remove the spark plug (page 3-6).
Install the compression gauge [1] in the spark plug hole.
Turn the ignition switch ON.
Shift the transmission into neutral.
To avoid Open the throttle all the way and crank the engine with
discharging the the starter until the gauge reading stops rising.
battery, do not The maximum reading is usually reached within 4 – 7
operate the starter seconds.
motor for more than [1]
7 seconds.
STANDARD:
824 kPa (120 psi) at 400 min-1
If compression is high, it indicates that carbon deposits
have accumulated on the combustion chamber and/or
the piston head.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of
engine oil into the cylinder through the spark plug hole
and recheck the compression.
If the compression increases from the previous value,
check the cylinder, piston and piston rings for the
following:
– Leaking cylinder head gasket
– Worn piston ring
– Worn cylinder and piston
If the compression is the same as the previous value,
check the valves for leakage.
CYLINDER HEAD COVER

REMOVAL
Remove the special bolts [1], mounting rubbers [2] and
cylinder head cover [3].
[1]/[2]
[3]
8-5
Remove the rubber seal [1] and dowel pin [2] from the
[2]
cylinder head cover [3].
[1]
[3]
INSTALLATION
Blow open the oil passage in the cylinder head cover [1]
with the compressed air.
[1]
Make sure the rubber seal is in good condition and

[3]
replace it if necessary.
[1]
Install the rubber seal [1] into the groove on the cylinder
head cover [2].
Install the dowel pin [3].
[2]
Apply liquid sealant (Three Bond 1215 or 5211C,

Shinetsu-Silicone KE45 or equivalent) to the
semicircular area [1] of rubber seal as shown. [1]
8-6
Install the mounting rubbers [1] to the special bolts [2]
with their “UP” mark [3] facing up.
[2]
Set the cylinder head cover [4] onto the cylinder head.
Install the special bolts and tighten them to the specified
torque. [3]
[1]
[4]
CAMSHAFT
REMOVAL
– Left crankcase cover (page 9-5)
Remove the cam chain tensioner sealing bolt and
washer [1].
[1]
Turn the crankshaft counterclockwise until the index

[4] [5]
lines [1] on the cam sprocket [2] is aligned with the top
surface of the cylinder head. [2]
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
This position can be obtained by confirming that there is
slack in the rocker arms. If there is no slack, turn the
crankshaft again until the correct position is obtained.
Hold the cam sprocket by using the special tool.
TOOLS:
[3] Universal holder 07725-0030000
Remove the washer bolt [4], cam sprocket from the
camshaft and cam chain [5] off the cam sprocket. [3] [1]
Attach a piece of wire to the cam chain to prevent it
from falling into the crankcase.
Remove the bolt/washer [1] from the cylinder head.
[1]
8-7
Remove the camshaft [1] from the cylinder head while
[2] [1]
holding the rocker arms [2] to ease removal.
DECOMPRESSOR WEIGHT
INSPECTION
Remove the camshaft (page 8-7).
[2] [1]
Turn the decompressor [1] with your finger.
Make sure the decompressor operates smoothly and
returns to the original position by the spring [2].
If the decompressor is faulty, replace the camshaft as
an assembly.
INSTALLATION
Apply engine oil to the bearing rotating surface [1] and
cam lobe surface [2]. [3] [2]
Apply molybdenum oil solution to the decompressor
cam [3] sliding surface.
[1]
Install the camshaft [1] into the cylinder head with its
[3] [1]
groove [2] facing forward while holding the rocker arms
[3] to ease installation.
[2]
8-8
Install and tighten the bolt/washer [1].
[1]
Rotate the crankshaft counterclockwise until the index

line [1] on the flywheel is aligned with the index notch [2]
[2] on the left crankcase.
[1]
Apply engine oil to the cam chain [1] and cam sprocket
teeth. [1]
Install the cam chain on the cam sprocket [2] by
aligning its tab with the groove of the camshaft, making
sure that the index lines [3] on the cam sprocket are Align
flush with the top surface of the cylinder head as shown
(TDC on the compression stroke).
Install the cam sprocket to the camshaft.
[3]
[2]
Hold the cam sprocket [1] by using the special tool.

[3]
[1]
TOOL:
[2] Universal Holder 07725-0030000
Apply engine oil to the cam sprocket washer bolt [3]
threads and seating surface.
Install and tighten the cam sprocket washer bolt to
specified torque.
[2]
8-9
Pour 4.0 cc minimum of engine oil into the push rod.
Install a new sealing washer [1] and bolt [2], then [1]/[2]
tighten it.
– Left crankcase cover (page 9-5)
CYLINDER HEAD
REMOVAL
[2]/[3]
– Cam sprocket (page 8-7)
– Exhaust pipe/muffler (page 2-16)
– Inlet pipe mounting bolts/gasket (page 6-17)
Remove the cylinder head bolts [1].
Loosen the cylinder head nuts [2] in a crisscross pattern
in two or three steps.
Remove the four nuts and washers [3].
[1]
Remove the cylinder head [1]. [1]
Remove the gasket [1] and dowel pins [2].

[2]
[1]
8-10
DISASSEMBLY
ROCKER ARM/SHAFT
Remove the rocker arm shaft stopper bolt [1].
[1]
Screw the 5 mm bolt [1] into the threaded hole in the [3]
rocker arm shaft [2] and pull it out of the cylinder head.
Remove the rocker arms [3]. [1]
[2]
CAMSHAFT
Remove the bolt/washer [1] and camshaft [2].
[1]
[2]
VALVE
To prevent loss of Remove the valve cotters using the special tools.
tension, do not
[1]
compress the valve TOOLS:
springs more than [1] Valve spring compressor 07757-0010000
necessary to [2] Valve spring compressor 07959-KM30101
remove the cotters. attachment
[2]
8-11
Mark all parts Remove the valve spring compressor and remove the
during disassembly following: [4]
so they can be
– Valve spring retainers [1]
placed back in their
– Valve springs [2] [5]
original locations.
– Valve spring seats [3]
– Valves [4]
– Valve stem seals [5]
[3]
[2]
[1]
Avoid damaging the Remove the carbon deposits form the combustion [1]
mating surface and chamber [1] and clean off the cylinder head gasket
valve seat surfaces. surface.
INSPECTION
CYLINDER HEAD
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with a straight
edge and a feeler gauge.
ROCKER ARM/SHAFT
Disassemble the cylinder head (page 8-11).
Check the rocker arm shafts and rocker arms for wear [1]
or damage.
Turn the rocker arm rollers [1] with your finger.
The rollers should turn smoothly and quietly.
Measure the I.D. of each rocker arm.
SERVICE LIMIT: IN/EX: 10.10 mm
Measure the O.D. of each rocker arm shaft.
Calculate the rocker arm-to-shaft clearance.
8-12
VALVE SPRING
Measure the free length of the valve springs.
Replace the springs if they are shorter than the service
limit.
VALVE/VALVE GUIDE
Check that the valve moves smoothly in the guide.
Check each valve for bend, burn, scratch or abnormal
wear.
Measure each valve stem O.D. and record it.
SERVICE LIMIT: IN: 4.965 mm
EX: 4.945 mm
Always rotate the Ream the valve guide to remove any carbon build up
[1]
reamer clockwise, before measuring the guide.
never Insert the reamer from the combustion chamber side of
counterclockwise the cylinder head and always rotate the reamer
when inserting, clockwise.
removing and
reaming. TOOL:
[1] Valve guide reamer, 5.0 mm 07984-MA60001
Inspect and reface Measure each valve guide I.D. and record it.
the valve seats
whenever the valve SERVICE LIMIT: IN/EX: 5.03 mm
guides are replaced
Subtract each valve stem O.D. from the corresponding
(page 8-18).
guide I.D. to obtain the stem-to-guide clearance.
SERVICE LIMIT: IN: 0.065 mm
EX: 0.085 mm
If the stem-to-guide clearance exceeds the service limit,
determine if a new guide with standard dimensions
would bring the clearance within tolerance.
If so, replace any guides as necessary and ream to fit
(page 8-17).
If the stem-to-guide clearance exceeds the service limit
with new guide, also replace the valve.
8-13
ASSEMBLY
VALVE COTTER
SPRING RETAINER
EXHAUST ROCKER ARM

VALVE SPRING
INTAKE ROCKER ARM
EXHAUST ROCKER VALVE STEM SEAL

ARM SHAFT
SPRING SEAT
VALVE GUIDE
Align the stopper
bolt holes. CLIP
INTAKE ROCKER
ARM SHAFT
ROCKER ARM SHAFT

STOPPER BOLTS
Align the stopper

bolt holes.
BOLT/WASHER
CAMSHAFT
: Cam lobes/bearings
EXHAUST VALVE
: Decompressor cam sliding area INTAKE VALVE
VALVE
Blow through the oil passage in the cylinder head with
compressed air.
Install the valve spring seats [1] and new valve stem [3]
seals [2].
Coat the valve stem [3] sliding surface with engine oil. [1]
Insert the valves into the valve guides while turning
them slowly to avoid damage to the valve stem seals.
[2]
8-14
Install the valve springs with the tightly wound coils
facing the combustion chamber.
To combustion
chamber
Install the valve spring retainer.

[1]
To prevent loss of Install the valve cotters using the special tools.
tension, do not
compress the valve
TOOLS:
spring more than [1] Valve spring compressor 07757-0010000
necessary to install [2] Valve spring compressor 07959-KM30101
the cotters. attachment
[2]
Support the cylinder Place a suitable tool [1] onto the valve stem [2].
head above the [1]
Tap the tool gently to seat the cotters [3] firmly using a
work bench surface
hammer.
to prevent valve
damage.
[3]
[2]
CAMSHAFT
Apply oil to the cam lobes and camshaft bearings.
Apply molybdenum oil solution to the decompressor
cam and arm sliding area.
Install the camshaft with its groove [1] facing up.
[1]
8-15
Install and tighten the bolt/washer [1].
[1]
ROCKER ARM
Apply engine oil to the rocker arm [1] hole inner surface
and roller rolling area. [1]
Apply engine oil to the sliding surface of the rocker arm
shaft [2].
[2]
Install the rocker arms [1] to the cylinder head. [1]

Insert the rocker arm shaft [2] into the cylinder head
using a screwdriver [3] while aligning the bolt holes of
the shaft and cylinder head. [3]
[2]
Install and tighten the rocker arm shaft stopper bolt [1].
[1]
8-16
INSTALLATION
Clean the cylinder and cylinder head mating surface.
Install the dowel pins and a new gasket onto the
cylinder.
Route the cam chain [1] through the cylinder head [2] [2] [1]
and install the cylinder head onto the cylinder.
Apply engine oil to the seating surface and threads of

the cylinder head nuts [1]. Install the four washers [2] [1]/[2]
and tighten the cylinder head nuts in a crisscross
pattern to the specified torque.

Install and tighten the cylinder head mounting bolts [3].
– Cam sprocket (page 8-8)
– Gasket/insulator mounting bolts (page 6-17)
[3]
VALVE GUIDE REPLACEMENT

[2]
Chill new valve guides in a freezer for about 1 hour.
• Be sure to wear heavy gloves to avoid burns when

handling the heated cylinder head. [1]
• Using a torch to heat the cylinder head may cause
warpage.
• Drive new guides from the camshaft side while the
cylinder head is still heated.
Heat the cylinder head to 130 – 140°C with a hot plate
or oven. Do not heat the cylinder head beyond 150°C .
Use temperature indicator sticks, available from welding
supply stores, to be sure the cylinder head is heated to
the proper temperature.
Support the cylinder head and drive the valve guides [1]
out of the cylinder head from the combustion chamber
side.
TOOL:
[2] Valve guide driver, 5.0 mm 07942-MA60000
8-17
Take out new valve guides [1] from the freezer.
[3]
Drive new clips [2] and valve guides into the cylinder
head to the specified height from the cylinder head. [2]
TOOL:
[3] Valve guide driver, 5.0 mm 07942-MA60000
VALVE GUIDE PROJECTION:

IN/EX: 9.1 – 9.3 mm
Let the cylinder head cool to room temperature.
[1]
9.1 – 9.3 mm
Ream new valve guides after installation.
• Take care not to tilt or lean the reamer in the guide [1]
while reaming.
• Use cutting oil on the reamer during this operation.
Insert the reamer from the combustion chamber side of
the cylinder head and always rotate the reamer
clockwise.
TOOL:
[1] Valve guide reamer, 5.0 mm 07984-MA60001
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve seat
(page 8-18).
VALVE SEAT INSPECTION/REFACING
Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coat of Prussian Blue to the valve seats.
Tap the valve against the valve seat several times using
a hand-lapping tool, without rotating the valve to make a
clear pattern.
The valves cannot Remove the valve and inspect the valve seat face.
be ground. If the
The valve seat contact should be within the specified
valve face is
width and even all around the circumference.
burned, badly worn
or if it contacts the STANDARD: 0.90 – 1.10 mm
seat unevenly, SERVICE LIMIT: 1.6 mm
replace the valve.
If the valve seat width is not within specification, go to
following step.
SEAT WIDTH
8-18
Reface the seat Use a 45° seat cutter, remove any roughness or
with a 45° cutter irregularities from the seat.
whenever a valve
guide is replaced.
TOOLS:
Seat cutter, 27.5 mm (45° IN) 07780-0010200 45°
Seat cutter, 24 mm (45° EX) 07780-0010600
Cutter holder, 5.0 mm 07781-0010400
60°
Use a 32° flat cutter, remove the top 1/4 of the existing
valve seat material. 32°
TOOLS:
Flat cutter, 27 mm (32° IN) 07780-0013300
Flat cutter, 22 mm (32° EX) 07780-0012601
Use a 60° interior cutter, remove the bottom 1/4 of the
existing valve seat material.
TOOLS:
Interior cutter, 26 mm (60° IN) 07780-0014500
Interior cutter, 22 mm (60° EX) 07780-0014202
Using a 45° seat cutter, cut the seat to the proper width.
VALVE SEAT WIDTH: 0.90 – 1.10 mm
Make sure that all pitting and irregularities are removed.
• Excessive lapping pressure may deform or damage

the seat.
• Change the angle of lapping tool frequently to
prevent uneven seat wear.
• Do not allow lapping compound to enter the guides.
After cutting the seat, apply lapping compound to the
valve face, and lap the valve using light pressure.
After lapping, wash any residual compound off the
cylinder head and valve and recheck the seat contact.
Assemble the cylinder head (page 8-14).
8-19
CAM CHAIN TENSIONER
REMOVAL
Remove the flywheel (page 10-6).
[3] [4]
Remove the cam chain tensioner sealing washer [1]
bolt [2], tensioner spring [3] and the push rod [4].
[1]/[2]
Remove the pivot bolt [1], washer [2], tensioner arm [3]
[5] [1]/[2]
collar [4] and the tensioner roller [5].
[3]/[4]
INSPECTION
Measure the tensioner spring free length.
SERVICE LIMIT: 109 mm
Check the push rod for wear or damage.

Measure the push rod O.D.
8-20
Inspect the check valve [1] in the push rod for wear or
damage.
[1]
INSTALLATION
Install the cam chain tensioner roller [1], collar [2],
tensioner arm [3] and the pivot bolt [4] washer [5], then [1] [2]
tighten it to the specified torque.
[3] [4]/[5]
Install the push rod [1].

Tapered side [1]
Install the tensioner spring [2] with its tapered side
facing down.
Install and tighten the sealing bolt [3] with a new sealing
washer [4] to the specified torque.
[2] [3]/[[4]
Remove the cam chain tensioner sealing bolt [1] and

4.0 – 5.0 cc
washer [2].
Pour 4.0 – 5.0 cc of engine oil into the push rod.
Install and tighten the sealing bolt with a new sealing
washer.
Install the flywheel (page 10-11).
[1]/[2]
8-21
OIL STOPPER PLATE
Remove the flywheel (page 10-6).
Coating width: 6.5 ± 1.0 mm from tip
Remove the bolt [1] and oil stopper plate [2].
Apply locking agent to the bolt threads as specified.
Install the oil stopper plate and tighten the bolt.
Install the flywheel (page 10-11).
[1] [2]
8-22
dummytext
9. CYLINDER/PISTON
COMPONENT LOCATION ····························9-2 TROUBLESHOOTING ·································· 9-3
SERVICE INFORMATION ·····························9-3 CYLINDER/PISTON ······································ 9-4

9
9-1
dummyhead
CYLINDER/PISTON
COMPONENT LOCATION
CYLINDER/PISTON
10 N·m (1.0 kgf·m)
9-2
dummyhead
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder and piston. These services can be performed with the engine installed in the frame.
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces when removing the cylinder. Do not tap the cylinder too hard during removal.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
SPECIFICATIONS
Unit: mm
Cylinder I.D. 50.005 – 50.015 50.05
Out-of-round – 0.10
Taper – 0.10
Warpage – 0.05
Piston, piston Piston mark direction “IN” mark facing toward the intake side –
rings Piston O.D. 49.980 – 49.995 49.91
Piston O.D. measurement point 10 mm from bottom of skirt –
Piston pin bore I.D. 13.002 – 13.008 13.03
Piston pin O.D. 12.994 – 13.000 12.98
Piston-to-piston pin clearance 0.002 – 0.014 0.075
groove clearance
Second 0.015 – 0.050 0.09
(Riken)
groove clearance
Second 0.015 – 0.045 0.09
(Teikoku)
(Riken) Second 0.10 – 0.25 0.5
Oil (side rail) 0.20 – 0.70 1.1
(Teikoku) Second 0.10 – 0.25 0.5
Oil (side rail) 0.20 – 0.70 1.1
Cylinder-to-piston clearance 0.010 – 0.035 0.10
Connecting rod small end I.D. 13.016 – 13.034 13.05
Connecting rod-to-piston pin clearance 0.016 – 0.040 0.07
TORQUE VALUES
Cam chain guide roller pin bolt 10 N·m (1.0 kgf·m)
Cylinder stud bolt – See page 9-7
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
• Bent connecting rod
• Cylinder head/valve problem (page 8-4)
Compression too high, overheating or knocking
• Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
• Cylinder head/valve problem (page 8-4)
Abnormal noise
• Worn piston pin or piston pin hole
• Worn cylinder, piston or piston rings
• Worn connecting rod small end
9-3
dummyhead
CYLINDER/PISTON
CYLINDER/PISTON
CYLINDER REMOVAL
• Cylinder and piston can be serviced with the engine

installed on the frame.
[1]
– Cylinder head (page 8-10)
– Two bolts [1]
– Lower side cover stay [2]
[2]
Be careful not to – Cam chain guide roller pin bolt [1]/sealing washer [2]
drop the guide roller – Guide roller [3] [3]
into the crankcase.
[1]/[2]
Be careful not to – Cylinder [1]

damage the mating
surface.
[1]
– Gasket [1]
– Dowel pins [2] [1]
[2]
9-4
dummyhead
CYLINDER/PISTON
PISTON REMOVAL
Place a clean shop Remove the piston pin clip [1] with pliers.
[1]
towel over the
Push the piston pin out [2] of the piston [3]and
crankcase to
connecting rod, and remove the piston.
prevent the clip
from falling into the
crankcase.
[3] [2]
Do not damage the Spread each piston ring and remove it by lifting it up at
piston ring by a point just opposite the gap.
spreading the ends
too far.
Never use a wire Clean carbon deposits from the piston ring grooves [1] [2]
brush; it will with a used piston ring [2] that will be discarded.
damage the groove.
Blow the oil passage with compressed air, if necessary.
[1]
INSPECTION
CYLINDER
Inspect the cylinder wall for scratches and wear.
Measure and record the cylinder I.D. at three levels in
both the X and Y axis. Take the maximum reading to
determine the cylinder wear.
Calculate the cylinder-to-piston clearance.
For measurement of the piston O.D. (page 9-6).
9-5
dummyhead
CYLINDER/PISTON
Calculate the cylinder for taper and out-of-round at
three levels in an X and Y axis. Take the maximum
reading to determine the taper and out-of-round. Y
SERVICE LIMITS: TOP X

Taper: 0.10 mm
Out-of-round: 0.10 mm
The cylinder must be rebored and an oversize piston MIDDLE
fitted if the service limits are exceeded.
BOTTOM
Check the cylinder for warpage by placing a straight

edge and a feeler gauge across the stud holes as
shown.
PISTON/PISTON RING
Always replace the Inspect the piston rings for smooth movement by
piston rings as a rotating them. The rings should be able to move in their
set. grooves without catching.
Push the ring until the outer surface of the piston ring is
nearly flush with the piston and measure the clearance
using a feeler gauge.
SERVICE LIMITS:
Top: 0.09 mm
Second: 0.09 mm
Insert the piston ring [1] into the bottom of the cylinder
[1]
squarely using the piston crown.
Measure the ring end gap.
SERVICE LIMITS:
Top: 0.5 mm
Second: 0.5 mm
Oil (side rail): 1.1 mm
9-6
dummyhead
CYLINDER/PISTON
Measure the piston O.D. at a point 10 mm from the
bottom and 90° to the piston pin hole.

90°
For measurement of the cylinder I.D. (page 9-6). 10 mm
Calculate the cylinder-to-piston clearance.
Measure piston pin bore I.D. in an X and Y axis.

Take the maximum reading to determine I.D.
Measure the piston pin O.D. at three points.
Calculate the piston-to-piston pin clearance.
CONNECTING ROD
Measure the connecting rod small end I.D.
Calculate the connecting rod-to-piston pin clearance.
CYLINDER STUD BOLT

REPLACEMENT
If replacing the cylinder stud bolts, be sure to install
them as shown.
Thread two nuts onto the stud bolt, and tighten them
together, then use a wrench on them to turn the stud
bolt out.
Install and tighten new stud bolts to the specified
torque.
176.0 ± 1.0 mm
After tightening the stud bolts, check that the length
from the bolt head to the crankcase surface is within
specification.
9-7
dummyhead
CYLINDER/PISTON
PISTON INSTALLATION
Clean the piston heads, ring grooves and skirts.
Carefully install the piston rings onto the piston with SECOND RING MARKING TOP RING MARKING
their markings facing up. (“RN” or “A”) (“R” or “T”)
• Be careful not to damage the piston and piston rings

during installation.
• Do not confuse the top and second rings.
• When installing the oil ring, install the spacer first
and then the side rails. TOP RING
Stagger the piston ring end gaps 120 degrees apart 120°
Do not align the SECOND
gaps of the oil ring from each other as shown.
120° RING
side rails. Stagger the side rails gaps as shown. 120°
After installation, the piston rings should be free to
rotate in the groove.
SPACER SIDE RAILS
20 mm OR MORE
Place a clean shop towel over the crankcase to prevent

the dirt, dust or piston pin clips from entering the
crankcase.
Be careful not to Clean the gasket mating surfaces of the crankcase and
damage the gasket cylinder thoroughly.
mating surfaces.
Apply engine oil to the connecting rod small end inner
surface.
Apply engine oil to the piston pin [1] hole inner surface
[1]
and piston pin outer surface. “IN” MARK
Install the piston [2] with the “IN” mark facing the intake
side.
Instal the piston pin.
[2]
9-8
dummyhead
CYLINDER/PISTON
Install the new piston pin clips [2].
• Make sure the piston pin clips are seated securely.

• Do not align the piston pin clip end gap with the
piston cutout.
[2]
CYLINDER INSTALLATION
Do not reuse the Install the dowel pins [1] and a new gasket [2]. [2]
gasket, replace with
a new one.
[1]
Apply engine oil to the cylinder bore, piston outer

surface, piston ring grooves and piston rings.
Route the cam chain [1] through the cylinder.
Be careful not to Install the cylinder over the piston while compressing
damage the piston the piston rings with your fingers.
rings and cylinder
bore.
[1]
Be careful not to Install the cam chain guide roller [1], new sealing
drop the guide roller washer [2] and the cam chain guide roller pin bolt [3]. [1] [3]
into the crankcase. Tighten the roller pin bolt to the specified torque.
[2]
9-9
dummyhead
CYLINDER/PISTON
Install the lower side cover stay [1] while aligning its tab
with the bolt boss on the cylinder, then install and Align [2]
tighten the bolts [2].
Install the cylinder head (page 8-17).
[1]
9-10
dummytext
10. ALTERNATOR/STARTER CLUTCH
COMPONENT LOCATION ··························10-2 STATOR ······················································ 10-5
SERVICE INFORMATION ···························10-3 FLYWHEEL/STARTER CLUTCH ··············· 10-6
LEFT CRANKCASE COVER ······················10-4

10
10-1
dummyhead
COMPONENT LOCATION
40 N·m (4.1 kgf·m)
10-2
dummyhead
SERVICE INFORMATION
GENERAL
• This section covers service of the and starter clutch.
• These services can be done with the engine installed in the frame.
• For alternator inspection (page 17-7).
• For ignition pulse generator inspection (page 4-7).
SPECIFICATIONS
Unit: mm
Starter driven gear boss O.D. 45.660 – 45.673 45.2
TORQUE VALUE
Flywheel nut 40 N·m (4.1 kgf·m) Apply oil to the threads and seating surface
Starter clutch mounting torx bolt 16 N·m (1.6 kgf·m) Apply locking agent to the threads and seating
surface: See page 10-10
10-3
dummyhead
LEFT CRANKCASE COVER
REMOVAL
[1]
– Left crankcase rear cover (page 2-15)
– Left body cover (page 2-9)
When removing the Remove the bolt [1] and gearshift pedal [2].
gearshift pedal,
mark the pedal
position to ensure
the original position.
[2]
Release the air supply hoses from the guides [1].

Disconnect the following: [3]
– Alternator wire (Yellow) connector [1] [1]/[2]
– Ignition pulse generator wire (Blue/yellow) connector
[2]
Remove the wire band boss [3].
Disconnect the alternator 2P connector [4].
[4]
Loosen the bolts [1] in a crisscross pattern in several

[3]
steps and remove them and guide [2].
The left crankcase Remove the left crankcase cover [3].
cover (stator) is
magnetically
attached to the
flywheel, be careful
during removal.
[2] [1]

[1]
INSTALLATION
Be careful not to Clean any gasket material from the left crankcase cover
damage the mating mating surface.
surface.
Install the dowel pins [1] and a new gasket [2].
[2]
10-4
dummyhead
The left crankcase Apply engine oil to the starter reduction gear journal [1]
[2]
cover is of the left crankcase cover [2].
magnetically Install the left crankcase cover.
attached to the Install the bolts [3] and guide [4], then tighten the bolts
flywheel, be careful in a crisscross pattern in several steps.
during installation.
[1]
[3]/[4] [3]
Connect the alternator 2P connector [1].

Connect the following: [4]
– Alternator wire (Yellow) connector [2] [2]/[3]
[3]
Install the wire band boss [4].
[1]
Install the gearshift pedal [1] in its original position as

marked during removal. [1]
Install and tighten the bolt [2].
– Left body cover (page 2-9)
Fill the engine with the recommended engine oil
(page 3-8).
[2]
STATOR
Remove the left crankcase cover (page 10-4).
[2]
Remove the ignition pulse generator mounting bolts [1]
and release the wire grommet [2] from the left
crankcase cover.
[1]
10-5
dummyhead
Remove the stator mounting bolts [1], then remove the [2]
stator [2] from the left crankcase cover.
• Apply liquid sealant (THREE BOND 1215 or
equivalent) to the wire grommet seating surface and
install the grommet into the cover groove.
[1]
FLYWHEEL/STARTER CLUTCH
REMOVAL
Remove the left crankcase cover (page 10-4). [2]
Remove the shaft [1] and starter reduction gear [2].
[1]
Remove the flywheel nut [1] and washer [2] using the
[1]/[2]
special tool.
TOOL:
[3] Flywheel holder 07725-0040001
[3]
Remove the flywheel/starter clutch [1] using the special

tool. [1]
TOOL:
[2] Flywheel puller, 28 mm 07933-KG20000
[2]
10-6
dummyhead
Remove the needle bearing [1]. [1]
When woodruff key Remove the woodruff key [1]. [1]

removal, be careful
not to damage the
key groove and
crankshaft.
Do not lose the
woodruff key.
STARTER CLUTCH DISASSEMBLY

Remove the flywheel/starter clutch (page 10-6).
[1]
Check the operation of the one way clutch by turning
the driven gear.
You should be able to turn the driven gear [1]
counterclockwise smoothly, but the gear should not turn
clockwise.
Remove the starter driven gear from the flywheel/starter
clutch while turning the driven gear counterclockwise.
Hold the flywheel using the special tool and remove the
starter clutch outer mounting torx bolts [1]. [1]
TOOL:
[2]
10-7
dummyhead
Remove the starter clutch assembly [3].
[3]
INSPECTION
Check the starter reduction gear [1] for wear or
damage.
[1]
Check the starter driven gear [1] for wear or damage.

Measure the driven gear boss O.D.
[1]
Remove the plate [1], rollers [2] and springs [3] from the
[4]
starter clutch outer [4].
[3]
[2]
[1]
10-8
dummyhead
Starter clutch Check the rollers [1], springs [2], starter clutch outer [3]
should be replaced for wear or damage. [3]
as an assembly if
any parts are
damaged or worn.
[2] [1]
Install the plate [1], springs [2] and rollers [3] to the
starter clutch outer as shown.
[2]
[3]
[1]
STARTER CLUTCH ASSEMBLY
STARTER DRIVEN GEAR
STARTER CLUTCH OUTER
PLATE
FLYWHEEL
SPRING
ROLLER
TORX BOLT
16 N·m (1.6 kgf·m)
10-9
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Install the starter clutch assembly [1] onto the flywheel
[2]. [1]
[2]
Apply a locking agent to the starter clutch mounting torx Coating width: 6.5 ± 1.0 mm
bolt [1] threads as specified.
from tip
Hold the flywheel using the special tool and tighten the
bolts to the specified torque.
TOOL:

[1]
[2]
Apply engine oil to the starter clutch rolling surface of

[1]
the driven gear [1].
Install the starter driven gear [1] to the flywheel/starter

clutch while turning it counterclockwise. [1]
Make sure that the starter driven gear turns

counterclockwise smoothly and does not turn
clockwise.
Install the flywheel/starter clutch (page 10-11).
10-10
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INSTALLATION
During woodruff key Install the woodruff key in the crankshaft key groove [1]. [1]
installation, be
careful not to
damage the key
groove or
crankshaft.
Apply engine oil to the needle bearing [1].

[1]
Install the needle bearing.
Wipe any oil off the mating surface of the crankshaft [3]
and flywheel. [1]
Install the flywheel/starter clutch [1] to the crankshaft,

aligning the key way [2] with the woodruff key [3].
[2]
Install the washer [1].

Apply engine oil to the flywheel nut [2] threads and [2]
seating surface, then install it.
Hold the flywheel using the special tool and tighten the
flywheel nut to the specified torque.
TOOL:
[3] Flywheel holder 07725-0040001 [1]
[3]
10-11
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Apply engine oil to the starter reduction gear journals [1]
[4] [1]
(left crankcase and cover) and gear teeth.
Install the starter reduction gear [2] with aligning the
starter drive gear [3] and starter driven gear [4].
[3]
[2]
Apply engine oil to the starter reduction gear shaft [1].

[1]
Install the shaft into the reduction gear.
Install the left crankcase cover (page 10-4).
10-12
dummytext
11. CLUTCH/GEARSHIFT LINKAGE
COMPONENT LOCATION ··························11-2 RIGHT CRANKCASE COVER ···················· 11-5
SERVICE INFORMATION ···························11-3 CLUTCH ······················································ 11-9
TROUBLESHOOTING·································11-4 GEARSHIFT LINKAGE ····························· 11-27
11
11-1
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COMPONENT LOCATION
17 N·m (1.7 kgf·m)
10 N·m (1.0 kgf·m)
54 N·m (5.5 kgf·m)
54 N·m (5.5 kgf·m)
5 N·m (0.51 kgf·m)
11-2
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SERVICE INFORMATION
GENERAL
• This section covers service of the clutch (centrifugal clutch and manual clutch) and gearshift linkage. These service can be done
with the engine installed in the frame.
• Engine oil viscosity, oil level and the use of oil additives have an effect on clutch operation. Oil additives of any kind are
specifically not recommended. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect
the engine oil and oil level before servicing the clutch system.
SPECIFICATIONS
Unit: mm
Manual clutch Disc thickness 2.00 – 2.20 1.82
Plate warpage – 0.20
Clutch spring free height 5.01 4.63
Clutch outer I.D. 16.991 – 17.009 17.049
guide O.D. 22.959 – 22.980 22.940
Primary driven gear I.D. 23.000 – 23.021 23.07
Mainshaft O.D. at clutch outer
16.966 – 16.984 16.87
guide
Centrifugal clutch Clutch drum I.D. 104.0 – 104.2 104.3
Clutch weight lining thickness 1.5 1.0
One-way clutch drum I.D. 42.000 – 42.020 42.04
One-way clutch roller O.D. 4.990 – 5.000 4.97
Primary drive gear I.D. 19.030 – 19.058 19.11
Crankshaft O.D. at primary drive
18.967 – 18.980 18.92
gear
TORQUE VALUES
Oil centrifugal filter cover bolt 5 N·m (0.51 kgf·m) Apply locking agent to the threads; See page 3-9
Shift drum stopper arm bolt 10 N·m (1.0 kgf·m) Apply locking agent to the threads; See page 11-30
Shift return spring pin 30 N·m (3.1 kgf·m)
Gearshift cam plate bolt 17 N·m (1.7 kgf·m) Apply locking agent to the threads; See page 11-29
Centrifugal clutch lock nut 54 N·m (5.5 kgf·m) Apply engine oil to the threads and seating surface
Clutch center lock nut 54 N·m (5.5 kgf·m) Apply engine oil to the threads and seating surface
Clutch lifter plate bolt 12 N·m (1.2 kgf·m)
11-3
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TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the clutch system.
Clutch slips when accelerating
• Incorrect clutch adjustment
• Worn clutch disc
• Weak clutch spring
• Faulty clutch weight
• Molybdenum or graphite additive
Motorcycle creeps with clutch disengaged (when idling)
• Faulty clutch weight springs
• Faulty clutch weights
• Idle speed too high (page 3-10)
Hard to shift
• Damaged gearshift spindle
• Damaged stopper plate and pin
• Loose stopper plate bolt
• Incorrect clutch adjustment
• Loose gearshift cam plate bolt
Transmission jumps out of gear
• Damaged stopper arm
• Damaged gearshift cam plate
• Loose gearshift cam plate bolt
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Bent gearshift spindle
11-4
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RIGHT CRANKCASE COVER

REMOVAL
[1]
When removing the Remove the following:
kickstarter pedal,
– Footpeg bar (page 2-15)
mark the pedal
– Bolt [1]
position to ensure
– Kickstarter pedal [2]
[2]
Loosen the bolts [1] in a crisscross pattern in several [1]/[2]

steps and remove them and guide [2].
Be careful not to Remove the right crankcase cover [3].
damage the mating
surface.
[3] [1]

[2]
[1]
DISASSEMBLY
[1]/[2]/[3] [4]
– Clutch adjuster lock nut [1]
– Washer [2]
– O-ring [3]
– Clutch adjuster/lifter boss [4]
11-5
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Remove the clutch adjuster bolt [1].
[1]

– Snap ring [1]
– Clutch lifter boss [2]
– Spring [3]
[1] [3]
KICKSTARTER SPINDLE OIL SEAL

Check that the kickstarter spindle oil seal [1] is in good
condition, replace it if necessary.
If replacing the oil seal, install it until it is fully seated.
[1]
OIL PASSAGES
Blow open the oil passage of the right crankcase cover
with compressed air.
Check the oil passage for clog.
11-6
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ASSEMBLY
Make sure that the Install the following: [2]
snap ring is firmly
– Spring [1]
seated in the
– Clutch lifter boss [2]
groove.
– Snap ring [3]
[1] [3]
Install the clutch adjuster bolt [1].
[1]
Install the clutch adjuster/lifter boss [1] into the right
Align
crankcase cover aligning its boss with the hole in the
crankcase cover.
Apply engine oil to a new O-ring [2].
Install the O-ring onto the clutch adjuster/lifter boss.
[1] [2]
Install the washer [1] and clutch adjuster lock nut [2].
[2]
Adjust the clutch system (page 3-16) after installing the
right crankcase cover.
[1]
11-7
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INSTALLATION
Apply grease to the kickstarter spindle oil seal lips [1].
[1]
Be careful not to Clean the gasket mating surface of the crankcase and
drop any foreign right crankcase cover, being careful not to damage [1]
materials into the them.
engine.
Install the dowel pins [1] and a new gasket [2] onto the
crankcase.
Apply engine oil to the gearshift spindle journal area.
[2]
Be careful not to Install the right crankcase cover [1].

damage the Install the right crankcase cover bolts [2] and guide [3] [2]/[3]
kickstarter oil seal then tighten the bolts in a crisscross pattern in several
lips. steps.
[1] [2]
Install the kickstarter pedal [1] to its original position as

[2]
marked during removal.
Install the footpeg bar (page 2-15).
Fill the engine with recommended engine oil (page 3-8).
Make sure there are no oil leaks.
Check the clutch system adjustment (page 3-16).
[1]
11-8
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CLUTCH
REMOVAL
• Clutch system can be serviced with the engine

installed on the frame.
[2]
– Engine oil centrifugal filter cover (page 3-9)
Remove the clutch lever [1] and the clutch lifter cam
plate [2].
[1]
Bend up the tab [1] of the lock washer to clear the lock
nut [2] groove. [1] [2]
Install the clutch center holder using proper bolts or [1]

[2]
screws.
Remove the centrifugal clutch lock nut [1] using the
special tools.
TOOLS:
[2] Lock nut wrench, 20 x 24 mm 07716-0020100
[3] Extension bar 07716-0020500
[4] Clutch center holder 07HMB-HB70100
[4]
[3]
Remove the washer [1] and lock washer [2].

[2] [1]
11-9
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Remove the clutch weight assembly [1].
[1]
Remove the clutch lifter bearing [1].

[1]
Hold the clutch lifter plate [1] and remove the clutch
[2] [1]
center lock nut [2] using the special tool.
[4]
TOOLS:
[5] Extension bar 07716-0020500
[3] [5]
Remove the washer [1].

[2]
Loosen the clutch lifter plate bolts [2].
[1]
11-10
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Remove the two oil separator plate mounting bolts [1].
[1]
Remove the centrifugal clutch outer [1], manual clutch
[2]
[2] and the oil separator plate [3] as an assembly. [1]
[3]
Remove the collar [1] from the crankshaft.

[3] [1]
Remove the clutch outer guide [2] and collar [3] from
the mainshaft.
[2]
CENTRIFUGAL CLUTCH
DISASSEMBLY/INSPECTION
ONE-WAY CLUTCH
Temporarily install the centrifugal clutch outer to the
crankshaft.
Hold the crankshaft and turn the centrifugal clutch outer
by hand.
Make sure that the centrifugal clutch outer only turns
counterclockwise as shown and does not turn
clockwise.
Remove the centrifugal clutch outer from the
crankshaft.
11-11
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Remove the snap ring [1] and retainer [2].
[1]
[2]
Be careful not to Remove the following:
[2] [1]
lose the clutch
– Rollers [1]
rollers and clutch
– Springs [2]
springs.
– One-way clutch inner [3]
– Washer [4]
[3] [4]
Replace the clutch Check the rollers [1] for excessive wear or damage.
rollers as a set.
Measure the one-way clutch roller O.D.
SERVICE LIMIT: 4.97mm [1]
Replace the clutch Check the springs [2] for fatigue or damage.
springs as a set.
[2]
Check the one-way clutch inner [1] for wear or damage.
[1]
11-12
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CLUTCH OUTER/SUB-GEAR
Be careful not to Remove the spring retainer [1] and spring [2].
[3] [1]/[2]
lose the pin [3].
Remove the pin[1], snap ring [2] and sub-gear [3].

[1] [2]
Check the sub-gear for wear or damage.
[3]
Check the sliding surfaces of the centrifugal clutch

outer for excessive wear or damage.
Measure the one-way clutch drum I.D.
Check the inside of the centrifugal clutch drum for
scratches or excessive wear.
Measure the centrifugal clutch drum I.D.
CLUTCH WEIGHT
Check the clutch weight assembly for damage.
Measure the clutch weight lining thickness.
11-13
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Remove the E-clips [1].
[1]
Remove the side plate [1], friction spring [2] and spring
[3]
seat [3].
[2]
[1]
Alternately lift the clutch weights [1], then remove the

[1]
clutch weights and springs [2].
[2]
Remove the damper rubbers [1] from the drive plate [2].
[1]
[2]
11-14
dummyhead
Check the drive plate bosses [1] for wear or damage.
Check each clutch weight [2] for wear or damage. [1]
[2]
PRIMARY DRIVE GEAR

Measure the primary drive gear [1] I.D.
[1]
CRANKSHAFT
Measure the crankshaft [1] O.D.
[1]
11-15
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CENTRIFUGAL CLUTCH ASSEMBLY
SPRING SEAT
CLUTCH WEIGHT E-CLIP
DAMPER RUBBER SPRING
DRIVE PLATE
SIDE PLATE
SPRING RETAINER
FRICTION SPRING
SPRING WASHER
SPRING
RETAINER
SNAP RING
PIN
SUB-GEAR
SNAP RING ROLLER CLUTCH INNER CENTRIFUGAL CLUTCH OUTER
CLUTCH WEIGHT
Install the damper rubbers [1] to the drive plate [2].
[1]
[2]
Hook the springs [1] to the clutch weights [2] so that
their open ends facing the drive plate side. [2]
Install the clutch weights and springs onto the drive

plate as shown.
[1]
11-16
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Install the spring seat [1], friction spring [2] and side [4]
plate [3] to the clutch weight assembly [4] as shown.
[3]
[3]
[1]
[2]
Align the open end Install the new E-clips [1] while compressing the side [3]
of the E-clips and plate [2]. [1]
bosses [3] of the
side plate.
[2]
CLUTCH OUTER/SUB-GEAR
Install the sub-gear [1] by aligning its hole and primary
drive gear cut-out. [3]
Check that the snap Install the snap ring [2].

ring is seated in the
groove.
Be careful not to Install the pin [3].
lose the pin [3]. Align
[2] [1]
Insert the bent end of the spring [1] into the hole on the
spring retainer [2]. [2] [1]
Coil the spring into the spring retainer, making sure that
the spring is set between the retainer and tab [3].
Insert
(BENT END
and HOLE)
[3]
11-17
dummyhead
Install the spring retainer/spring [1] to the clutch outer [1]
while aligning the straight end of spring with the hole on Align
the sub-gear [2] and aligning the retainer groove with (GROOVE and PIN)
the pin.
Align (STRAIGHT
[2] END and HOLE)
Check the sub-gear [1] operation by moving it and

make sure that it returns without binding.
[1]
ONE-WAY CLUTCH
Install the washer [1] and one-way clutch inner [2] into [2]
the centrifugal clutch outer.
[1]
Install the springs [1] and rollers [2] as shown. [2]

[1]
11-18
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Install the retainer [1].
[2]
Check that the snap Install the snap ring [2] into the groove of the one-way
ring is seated in the clutch outer securely.
groove.
[1]
Temporarily install the centrifugal clutch outer to the
crankshaft.
Hold the crankshaft and turn the centrifugal clutch outer
by hand.
Make sure that the centrifugal clutch outer only turns
counterclockwise as shown and does not turn
clockwise.
Remove the centrifugal clutch outer from the
crankshaft.
MANUAL CLUTCH DISASSEMBLY

Remove the clutch lifter plate [1] assembly and washer [1]
[2] from the clutch outer [3]. [2]
[3]

[2]
– Bolts [1] [3]
– Clutch lifter plate [2]
– Spring [3]
– Clutch center [4]
– Clutch discs [5]
– Clutch plates [6]
[1] [4]/[5]/[6]
11-19
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Turn the clutch spring seat [1] until its tabs [2] are
aligned with the slots [3] on the clutch lifter plate [4], [2] [3]
then remove it.
[1] [4]
MANUAL CLUTCH INSPECTION
CLUTCH LIFTER BEARING
Temporarily install the clutch lifter bearing [1] to the
clutch lifter plate [2]. [1]
Turn the inner race of the clutch lifter bearing with your
finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race of the bearing fits
tightly in the clutch lifter plate.
Replace the bearing if the inner race does not turn
smoothly, quietly, or if the outer race fits loosely in the
clutch lifter plate.
[2]
CLUTCH SPRING
Check the grooves and tabs of clutch spring [1] for
damage.
Check the spring for fatigue or other damage.
Measure the clutch spring free height.
[1]
CLUTCH CENTER
Check the grooves [1] of the clutch center [2] for
[2]
damage or wear caused by the clutch plates.
Replace if necessary.
[1]
11-20
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CLUTCH DISC
Replace the clutch Replace the clutch discs if they show signs of scoring or
discs and plates as discoloration.
a set.
Measure the thickness of each clutch disc.
CLUTCH PLATE
Replace the clutch Check each clutch plate for warpage on a surface plate
discs and plates as using a feeler gauge.
a set.
CLUTCH OUTER/CLUTCH OUTER GUIDE

Check the primary driven gear teeth for wear or
damage.
Check the slots of the clutch outer for damage or wear
caused by the clutch discs.
Measure the primary driven gear I.D.
Measure the clutch outer guide I.D. and O.D.
SERVICE LIMITS:
I.D.: 17.049 mm
O.D.: 22.940 mm
MAINSHAFT
Measure the mainshaft O.D. at clutch outer guide.
11-21
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MANUAL CLUTCH ASSEMBLY
CLUTCH SPRING CLUTCH CENTER
SPRING SEAT
PRESSURE PLATE
LIFTER PLATE
WASHER
CLUTCH OUTER
CLUTCH PLATES
BOLTS
12 N·m (1.2 kgf·m)
CLUTCH DISC B
(ID MARK: BLUE PAINT)
CLUTCH DISC A
Coat the clutch discs with oil.

CLUTCH SPRING
Replace the clutch Install the items in the following sequence:
discs and plates as CLUTCH
– Clutch spring CENTER
a set.
– Clutch center
Do not confuse the
– Clutch disc A
disc A with disc B.
– Clutch plate
– Clutch disc B (ID mark: Blue paint on a tab)
– Clutch plate
– Clutch disc A DISC A
– Pressure plate
CLUTCH
PLATES
DISC A
DISC B
(ID MARK: BLUE PAINT) PRESSURE PLATE
11-22
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Set the spring seat [1] with its chamfered edge [2]
facing the clutch lifter plate [3] as shown while aligning Align
its tab with the slot on the plate.
Turn the clutch spring seat about 45°.
[1] [3]
[1]
Turn 45°
[2] [3]
Install the clutch lifter plate [1].

[1] [2]
Temporarily install the bolts [2].
Align the tabs of the clutch discs.
Align
Install the washer [1] onto the clutch outer [2].

Install the clutch center assembly [3] into the clutch [3]
outer.
[1] [2]
11-23
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INSTALLATION
Install the collar [1] onto the mainshaft.
[1] [3]
Apply engine oil to the clutch outer guide [2] outer
surface.
Install the clutch outer guide.
Install the collar [3] onto the crankshaft.
[2]
Apply molybdenum disulfide oil to the primary drive

gear inner surface.
Apply engine oil to the primary drive gear teeth.
Align the cut-outs of the primary drive gear and sub- [1] Align
gear as shown, then engage the primary drive/driven
gears.
Install the manual clutch [1], centrifugal clutch outer [2]
and oil separator plate [3] as assembly.
[2]
[3]
Install and tighten the two oil separator plate mounting
bolts [1].
[1]
11-24
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Install the washer [1] onto the mainshaft.
[2]
Tighten the clutch lifter plate bolts [2] to the specified
torque.
[1]
Apply engine oil to the clutch center lock nut [1] threads
and seating surface. [2] [3]
Install the clutch center lock nut.
Hold the clutch lifter plate and tighten the clutch center
lock nut to the specified torque using the special tools.
TOOLS: [4]
[4] Extension bar 07716-0020500
[1]
Apply engine oil to the clutch lifter bearing [1] and install
it into the clutch lifter plate. [1]
Install the clutch weight assembly [1] into the clutch

outer while aligning the splines of the clutch weight Align
assembly and crankshaft.
[1]
11-25
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Install a new lock washer [1] onto the crankshaft
aligning its inner tab with the groove of the clutch weight [1] Align
assembly.
Install the washer [1] with its “OUT SIDE” mark [2]
facing out. [2]
[1]
Apply engine oil to the centrifugal clutch lock nut [1]

[4]
threads and seating surface. [1]
Install the special tool using proper bolts or screws.
TOOLS:
[2] Clutch center holder 07HMB-HB70100
Tighten the centrifugal clutch lock nut to the specified
torque using the special tools.
TOOLS:
[4] Extension bar 07716-0020500
[3]
[2]
If any of the centrifugal clutch lock nut [1] groove is not

aligned with the lock washer tab [2], further tighten the [2] [1]
centrifugal clutch lock nut and align the centrifugal
clutch lock nut groove with the lock washer tab.
Bend the lock washer tab against the centrifugal clutch
lock nut groove.
11-26
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Install the clutch lever [1] onto the gearshift spindle
while aligning its punch mark with the index line on the [2]
spindle.
Install the clutch lifter cam plate [2] onto the clutch lifter
bearing.
– Engine oil centrifugal filter cover (page 3-9)
[1] Align
GEARSHIFT LINKAGE
REMOVAL
Remove the clutch (page 11-9).
When removing the Remove the bolt [1] and the gearshift pedal [2].
gearshift pedal,
mark the pedal
position to ensure
[1] [2]
Clean the gearshift spindle [1] thoroughly to prevent the

dirt or dust from entering the engine.
[1]

[1]
– Shift drum stopper arm/bolt [1]
– Return spring [2]
[2]
11-27
dummyhead
Remove the gearshift spindle [1] by holding down the
gearshift arm [2] as shown.
[1]
[2]
Remove the bolt [1] and the gearshift cam plate [2].
[1]
[2]
Remove the gearshift drum pins [1] and stopper plate

pins [2] from the gearshift drum [3]. [1]
[2]
[3]
INSPECTION
Check the gearshift spindle [1] for bend, wear or
damage. [4]
Check the gearshift arm spring [2] and return spring [3] [1]
for damage or fatigue.
Check the gearshift arm [4] for wear or damage.
[2]
[3]
11-28
dummyhead
Inspect the gearshift spindle oil seal [1] for deterioration
or damage, replace if necessary.
If replacing the oil seal, install it until it is fully seated.
[1]
INSTALLATION
Apply grease to the gearshift spindle oil seal lips [1].
[1]
Install the five gearshift drum pins [1] and two stopper
plate pins [2] to the holes on the gearshift drum. Align [1]
Install the gearshift cam plate [3] while aligning the
holes on the plate with the stopper plate pins.
[2]
[3]
Apply locking agent to the gearshift cam plate bolt [1] as Coating width: 6.5 ± 1.0 mm
specified, then install and tighten it to the specified
from tip
torque.
[1]
11-29
dummyhead
Install the gearshift spindle [1] so that the shift return
[4]
spring pin [2] is located between both ends [3] of the [1]
return spring as shown.
Insert the gearshift spindle completely while holding
down the gearshift arm [4] as shown.
[2] [3]
Apply locking agent to the shift drum stopper arm bolt Coating width: 6.5 ± 1.0 mm
[1] as specified.
from tip
Set the return spring end [2] along the crankcase wall
as shown.
Install the stopper arm/bolt, then tighten it to the [1]
specified torque.
[2]
Install the gearshift pedal [1] to its original position as

marked during removal.
Install the clutch (page 11-24).
[2] [1]
11-30
dummytext
12. CRANKSHAFT/TRANSMISSION/KICKSTARTER
COMPONENT LOCATION ··························12-2 TRANSMISSION ········································· 12-8
SERVICE INFORMATION ···························12-3 CAM CHAIN GUIDE SPROCKET ············· 12-16
TROUBLESHOOTING·································12-4 CRANKCASE ASSEMBLY ······················· 12-17
CRANKCASE SEPARATION······················12-5 KICKSTARTER ········································· 12-18
CRANKSHAFT ············································12-6 12
12-1
dummyhead
COMPONENT LOCATION
10 N·m (1.0 kgf·m)
12-2
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SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the crankshaft, transmission, kickstarter and cam chain guide sprocket.
• The following parts must be removed before separating the crankcase.
– Engine (page 13-4)
– Stator (page 10-5)
– Flywheel (page 10-6)
– Clutch (page 11-9)
– Gearshift linkage (page 11-27)
– Cam chain tensioner (page 8-20)
– Cylinder/piston (page 9-4)
– Oil pump (page 7-4)
– Starter motor (page 5-5)
– Gear position switch (page 18-17)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Prior to assembling the crankcase halves, apply sealant to the mating surface. Wipe off excess sealant thoroughly.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
SPECIFICATIONS
Unit: mm
Crankshaft Connecting rod side clearance 0.10 – 0.35 0.60
Connecting rod radial clearance 0 – 0.008 0.05
Runout – 0.10
Transmission Gear I.D. M2, M3 17.000 – 17.018 17.04
C1 18.000 – 18.018 18.04
C4 20.000 – 20.021 20.04
Bushing O.D. C1 17.966 – 17.984 17.94
Bushing I.D. C1 15.000 – 15.018 15.04
Gear-to-bushing
C1 0.016 – 0.052 0.10
clearance
Mainshaft O.D. M3 16.966 – 16.984 16.95
Countershaft O.D. C1 14.966 – 14.984 14.95
Gear-to-shaft clearance M3 0.016 – 0.052 0.09
Bushing-to-shaft
C1 0.016 – 0.052 0.09
clearance
Shift fork/ Shift fork I.D. 34.075 – 34.100 34.14
Shift drum Shift fork claw thickness 4.85 – 4.95 4.60
Shift drum O.D. Right 33.950 – 33.975 33.93
Left 23.940 – 23.980 23.92
Kickstarter Pinion I.D. 20.000 – 20.021 20.08
Spindle O.D. 19.959 – 19.980 19.94
TORQUE VALUE
Cam chain guide sprocket spindle 10 N·m (1.0 kgf·m)
12-3
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TROUBLESHOOTING
Hard to shift
• Incorrect clutch adjustment (page 3-16)
• Bent shift forks
• Bent gearshift spindle (page 11-29)
• Damaged shift drum cam grooves
• Incorrect engine oil viscosity
Transmission jumps out of gear
• Worn gear dogs and dog holes
• Broken shift drum stopper arm
• Broken drum stopper arm spring (page 11-29)
• Broken gearshift spindle return spring (page 11-29)
• Worn or bent shift forks
• Worn gear shifter groove
Excessive noise
• Worn connecting rod big end bearing
• Worn crankshaft bearing
• Worn transmission bearing
• Worn or damaged transmission gears
12-4
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CRANKCASE SEPARATION
Refer to Service Information (page 11-3) for removal of
necessary parts before separating the crankcase. [1]
Remove the cam chain [1] from the timing sprocket.
Loosen and remove the crankcase bolts [1] in a

[1]
crisscross pattern in several steps.
Place the left crankcase up. [1]

Carefully separate the left crankcase [1] from the right
crankcase [2] while tapping them at several locations
with a soft hammer.
[2]
Remove the dowel pins [1].
Be careful not to Clean off the sealant from the left and right crankcase
damage the mating mating surfaces.
surfaces.
[1]
12-5
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CRANKSHAFT
REMOVAL
Remove the transmission (page 11-11).
[2] [1]
Be careful not to Remove the crankshaft [1] from the right crankcase [2]
drop the crankshaft. using a hydraulic press.
If the crankshaft bearing [1] remains on the crankshaft, [1]

remove it using a special tool as shown.
TOOL:
[2] Universal bearing puller 07631-0010000 or
equivalent
commercially
available
[2]
If the bearing remains in the crankcase, drive it out from

RIGHT CRANKCASE:
the outside.
Do not reuse the Discard the crankshaft bearing [1].
crankshaft bearing.
[1]
INSPECTION
SIDE CLEARANCE
Measure the side clearance by inserting the feeler
[1]
gauge [1] between the crankshaft and connecting rod
big end.
12-6
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RADIAL CLEARANCE
Set the crankshaft on V-blocks and measure the
connecting rod big end radial clearance.
CRANKSHAFT
Check the timing sprocket [1] for wear or damage.
[2]
If replacing the timing sprocket, align the center of the
sprocket teeth with the center of the woodruff key
groove [2] as shown.
[1]
Place the crankshaft on a stand or V-blocks and

measure the runout using a dial gauge.
The measuring locations are shown in the illustration.
30 mm
46 mm 120 mm
Turn the outer race of the left crankshaft bearing with

your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing inner race fits tightly on the
crankshaft.
Replace the bearing if the outer race does not turn
smoothly, quietly, or if inner race fits loosely on the
crankshaft.
12-7
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CRANKSHAFT BEARING
REPLACEMENT
Apply oil to a new right crankshaft bearing [1] rolling
[2]
surface.
Be careful not to Drive in the right crankshaft bearing with its marked
damage the side facing up until it is fully seated, using the special
crankcase. tools.
TOOLS:
[2] Driver 07749-0010000
[3] Attachment, 52 x 55 mm 07746-0010400
[4] Pilot, 22 mm 07746-0041000
For transmission bearing replacement (page 11-22).
[3]/[4]
[1]
INSTALLATION
Apply 1.0 – 2.0 cm3 of oil to the connecting rod [1] big
end. [2]
[1]
Be sure that the Draw the crankshaft [2] into the right crankcase [3]
connecting rod is bearing inner race using the special tool.
located in the
crankcase opening.
TOOLS:
[4] Assembly set, 14 mm 07JMF-KW70100
Install the transmission (page 11-24).
Assemble the crankcase (page 12-5).
[4] [3]
TRANSMISSION
REMOVAL
Separate the crankcase halves (page 11-5).
[2]
Remove the mainshaft [1], countershaft [2] and shift
drum [3] as an assembly.
[3] [1]
12-8
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Remove the countershaft oil seal [1] from the left
crankcase.
[1]
DISASSEMBLY
Do not expand the Disassemble the mainshaft [1], countershaft [2] and
[3]
snap ring more than shift drum [3].
necessary for
Clean all disassembled parts in solvent thoroughly.
removal.
Keep track of the disassembled parts (gears, bushings,

drum lock plate, friction spring, washers and snap rings)
by sliding them onto a tool or slipping them onto a piece
of wire.
[1] [2]
Remove the following from shift drum [1]:

[4]
– Guide pin clips [2] [3]
– Guide pins [3]
– Shift forks [4]
[2] [1]
INSPECTION
SHIFT FORK
Check the shift fork for deformation or abnormal wear.
Measure each shift fork claw thickness.
Measure each shift fork I.D.
12-9
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SHIFT DRUM
Check the shift drum grooves [1] for wear or damage.
Measure the shift drum O.D. at each end.
SERVICE LIMITS: LEFT SIDE
Left side: 23.92 mm
Right side: 33.93 mm
[1]
Inspect the shift drum journal [1] for abnormal wear or

LEFT CRANKCASE: RIGHT CRANKCASE:
damage.
[1]
GEAR/BUSHING/SHAFT
Check the gear shifter groove [1] for abnormal wear or
[2]
damage.
Check the gear dogs [2] and teeth for abnormal wear or
lack of lubrication.
[1]
Check the dog holes [1] for abnormal wear or lack of

lubrication.
Measure the I.D. of each gear.
SERVICE LIMITS:
M2, M3: 17.04 mm
C1: 18.04 mm
C4: 20.04 mm
Check the C1 gear bushing for wear or damage.
Measure the gear bushing O.D. and I.D.
SERVICE LIMITS:
O.D.: 17.94 mm
[1]
I.D.: 15.04 mm
Calculate the gear to bushing clearance.
SERVICE LIMIT:
C1: 0.10 mm
12-10
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Check the mainshaft [1] and countershaft [2] for
abnormal wear or damage. [2]
Measure the O.D. of the mainshaft and countershaft.
C1 BUSHING
SERVICE LIMITS:
At M3: 16.95 mm
At C1: 14.95 mm
Calculate the gear to shaft clearance.
SERVICE LIMIT:
M3: 0.09 mm
Calculate the bushing to shaft clearance. M3
SERVICE LIMIT:
[1]
C1: 0.09 mm
TRANSMISSION BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that each bearing outer race fits tightly in the
crankcase.
Replace the bearing if the inner race does not turn
smoothly, quietly, or if the outer race fits loosely in the
crankcase.
OIL PASSAGES
Blow open the oil passages of the right crankcase with
compressed air.
Check the oil passages for clog, wear or damage.
ASSEMBLY
Clean all parts in solvent and dry them thoroughly.
Apply molybdenum disulfide oil to the each rotating
gear inner surface and C1 bushing whole surface to
ensure initial lubrication.
Assemble all parts into their original positions.
12-11
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• Check the gears for freedom of movement or

rotation on the shaft.
• Install the washers and snap rings with the
chamfered edges facing the thrust load side.
• Do not reuse a worn snap ring which could easily
spin in the groove.
• Check that the snap rings are seated in the grooves
and align their end gaps with the grooves of the
spline.
• Check the special washers are seated in the shaft
grooves.
MAINSHAFT:
SNAP RINGS
M2/M3: inner surface
M4: shift fork groove
SPLINE WASHER
SPECIAL WASHER
M3 GEAR (22T)
M2 GEAR (18T)
MAINSHAFT M1 GEAR (13T)

SPLINE WASHER
M4 GEAR (24T)
Washer and snap ring direction:
12-12
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COUNTERSHAFT:
Install the friction spring into the C2 gear groove.
C1/C4: inner surface
Insert the spring end into the hole on the drum lock plate.
C3: shift fork groove
THRUST WASHER
C2 GEAR (28T)
COUNTERSHAFT
LOCK WASHER
DRUM LOCK COLLAR

PLATE SPLINE WASHER
FRICTION SPRING
THRUST WASHER
C3 GEAR (25T)
C1 BUSHING Insert the lock washer

tabs into the slots of the
C4 GEAR (22T) spline washer.
SPLINE
WASHER
SNAP RING
THRUST WASHER
SPECIAL WASHER
C1 GEAR (34T)
SHIFT DRUM:
GUIDE PIN CLIPS
SHIFT FORKS
SHIFT DRUM
GUIDE PINS
12-13
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TRANSMISSION BEARING
REPLACEMENT
Remove the crankshaft (page 11-5).
RIGHT CRANKCASE: [3]
Remove the bolts [1] and mainshaft bearing set plates
[2].
Drive out the mainshaft bearing [3] and countershaft
bearing [4] from the right crankcase.
[1]/[2]
[4]
Drive out the countershaft bearing [1] from the left

LEFT CRANKCASE:
crankcase.
[1]
Remove the mainshaft bearing [1] from the left [1]

LEFT CRANKCASE:
crankcase using the special tools.
TOOLS: [3]
[2] Bearing remover set, 12 mm 07936-1660101
– Bearing remover shaft, 12 mm 07936-1660120
– Bearing remover head, 12 mm 07936-1660110
[3] Remover weight 07741-0010201
[2]
Drive new bearings into the crankcase with their

[2]
marked side facing up until they are fully seated, using
the special tools.
TOOLS:
Right crankcase mainshaft bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 17 mm 07746-0040400
Right crankcase countershaft bearing:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
[1] Left crankcase mainshaft bearing: [1] [3]/[4]
[2] Driver 07749-0010000
[3] Attachment, 28 x 30 mm 07946-1870100
[4] Pilot, 12 mm 07746-0040200
Left crankcase countershaft bearing:
12-14
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Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 17 mm 07746-0040400
Apply locking agent to the mainshaft bearing set plate Coating width: 6.5 ± 1.0 mm
bolt [1] threads as specified.
from tip
Install the mainshaft bearing set plates [2] and bolts to
the right crankcase and tighten the bolts.
Install the crankshaft (page 11-9).
[1]/[2]
TRANSMISSION INSTALLATION
Apply grease to a new countershaft oil seal [1] lips.
LEFT CRANKCASE:
Install the oil seal until it is fully seated.
[1]
Apply engine oil to the transmission gears and shift

[1]
drum [1] whole surface.
Engage the mainshaft [2], countershaft [3] gears and
shift drum assembly.
[2] [3]
Install the mainshaft [1], countershaft [2] and shift drum

[2]
[3] into the right crankcase.
[3] [1]
12-15
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Rotate the shift drum to check the transmission [1]
operation.
Align the tip of the lock plate [1] and shift drum groove
[2].
[2]
CAM CHAIN GUIDE SPROCKET

REMOVAL
Separate the crankcase (page 11-5).
Hold the cam chain guide sprocket [1], turn the cam
chain guide sprocket spindle [2] counterclockwise and
remove them from the left crankcase.
[1]
[2]
INSPECTION
Inspect the following:
[1]
– Cam chain guide sprocket [1] for wear or damage
– Cam chain guide sprocket spindle [2] for wear or
damage
[2]
– Spindle journal [1] for abnormal wear or damage
[1]
12-16
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INSTALLATION
Apply engine oil to the cam chain guide sprocket
spindle [1] sliding surface.
Install the spindle to the left crankcase, hold the
sprocket [2] and tighten the spindle to the specified
torque.
[2]
[1]
CRANKCASE ASSEMBLY
Clean off the sealant from the left and right crankcase
mating surfaces.
Install the dowel pins [1] onto the right crankcase.
[1]
Apply light but through coating of sealant
(THREEBOND 1215 or 1207B or LOCTITE 5020 or
equivalent) to the left crankcase mating surface except
the oil passage area as shown.
Install the left crankcase [1] onto the right crankcase [2].
[1]
[2]
12-17
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Install and tighten the crankcase bolts [1] in a crisscross
[1]
pattern in several steps.
Apply oil to the cam chain [1] whole surface.

[1] [2]
Install the cam chain over the timing sprocket [2].
Install the removed parts (page 11-3) in the reverse
order of removal.
KICKSTARTER
REMOVAL
Remove the gearshift linkage (page 10-5).
[1]
Remove the snap ring [1] and retainer [2] from the
kickstarter spindle.
[2]
Separate the crankcase (page 11-5).

Remove the kickstarter spindle [1] from the right
crankcase.
[1]
12-18
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[2]
– Special washer [1]
– Collar [2]
– Return spring [3]
[1]
– Snap ring [1]
– Starter ratchet [2] [2]
[3]
– Ratchet spring [3]
[1]
– Snap ring [1]

– Washer [2] [3] [1]
– Starter pinion gear [3]
[2]
INSPECTION
Check the kickstarter spindle [1] for bend, wear or
damage. [1]
Measure the kickstarter spindle O.D.

Check the starter pinion gear [2] for abnormal wear or
damage.
Measure the starter pinion gear I.D.
[2]
12-19
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Check the kickstarter spindle journals [1] of the left and
LEFT CRANKCASE: RIGHT CRANKCASE:
right crankcase for excessive wear or damage.
[1]
ASSEMBLY
Clean all parts in solvent and dry them thoroughly.
• Install the washers and snap rings with the

chamfered edges facing the thrust load side.
• Do not reuse a worn snap ring which could easily
spin in the groove.
• Check that the snap rings are seated in the grooves
and align their end gaps with the grooves of the
spline.
12-20
dummyhead
• Check that the special washer is seated in the groove.
KICKSTARTER SPINDLE RETURN SPRING
COLLAR
SPECIAL WASHER
SNAP RINGS
WASHER
View from inner side:
Install the ratchet spring and
friction spring as shown.
STARTER
RATCHET
STARTER PINION GEAR
RATCHET SPRING
Apply molybdenum oil solution to the starter pinion gear

[1] inner surface. [1] [3]
Make sure that the Install the starter pinion gear, washer [2] and snap ring
snap ring is firmly [3].
seated in the
groove.
[2]
12-21
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Install the ratchet spring [1] to the starter ratchet [2].
[2] [1]
Make sure that the Install the starter ratchet and snap ring [3] to the
snap ring is firmly kickstarter spindle.
seated in the
groove.
[3]
Install the return spring [1] to the kickstarter spindle

while aligning the spring end with the hole on the Align
spindle.
[1]
Install the collar [1] to the kickstarter spindle while

aligning its groove with the return spring end. Align
[1]
Install the special washer [1] to the kickstarter spindle.

[1]
12-22
dummyhead
INSTALLATION
Apply engine oil to the kickstarter gear teeth.
[1]
Install the kickstarter spindle [1] while aligning its
ratchet spring with the groove of the right crankcase as
shown.
Insert the return spring end into the hole on the right
crankcase as shown.
Align Insert
Set the retainer [1] to the kickstarter spindle.

[3]
Temporarily install the kickstarter pedal [2] and bolt [3].
Turn the kickstarter pedal and completely install the
retainer while aligning its wide tooth with the wide spline
on the spindle.
Release the kickstarter pedal.
Remove the bolt and kickstarter pedal.
[2]
Align [1]
Make sure that the Install the snap ring [1] to the kickstarter spindle groove.
snap ring is firmly [1]
Install the gearshift linkage (page 10-7).
seated in the
groove.
12-23
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MEMO
dummytext
13. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION ··························13-2 ENGINE REMOVAL ···································· 13-4
SERVICE INFORMATION ···························13-3 ENGINE INSTALLATION···························· 13-6
13
13-1
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COMPONENT LOCATION
59 N·m (6.0 kgf·m)

59 N·m (6.0 kgf·m)
12 N·m (1.2 kgf·m
12 N·m (1.2 kgf·m)
13-2
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SERVICE INFORMATION
GENERAL
• During engine removal and installation, support the motorcycle with its centerstand.
• Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal.
• The following components can be serviced with the engine installed in the frame.
– Alternator (page 10-5)
– Manual clutch (page 11-9)
– Centrifugal clutch (page 11-9)
– Gearshift linkage (page 11-27)
– Cylinder/piston (page 9-4)
– Oil pump (page 7-4)
– Starter motor (page 5-5)
• The following components require engine removal for service.
– Crankshaft/transmission/kickstarter (page 12-5)
– Shift forks/shift drum (page 12-8)
– Cam chain guide sprocket (page 12-16)
SPECIFICATIONS
ITEM SPECIFICATIONS
Engine dry weight 22.6 kg
Engine oil capacity At draining 0.8 liter
At disassembly 1.0 liter
Recommended engine oil Honda “4-stroke motorcycle oil” or an equivalent motor oil
TORQUE VALUES
Engine hanger nut 59 N·m (6.0 kgf·m)
Drive sprocket fixing plate bolt 12 N·m (1.2 kgf·m)
Inlet pipe mounting bolt 12 N·m (1.2 kgf·m)
Swingarm pivot nuts 59 N·m (6.0 kgf·m) U-nut
13-3
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ENGINE REMOVAL
[2]
– Body covers (page 2-9)
– PAIR control valve (page 6-15)
Disconnect the spark plug cap [1] and release the spark
plug wire from the guide [2].
[1]
Disconnect the following:

– Starter motor 2P connector [1]
[1]
Disconnect the following: [1]/[2] [4]

– Alternator wire (Yellow) connector [1]
[2]
– Alternator 2P connector [3]
– Gear position switch 6P (Black) connector [4] [3]
– Crankcase breather hose [5]
[5]
Release the carburetor drain hose [1] from the guide

[2].
[2]
[1]
13-4
dummyhead
Remove the inlet pipe mounting bolts [1] and gasket [2].
[1]
[2]
Loosen the lock nuts [1], drive chain adjusters [2] and
axle nut [3]. [1]
Push the rear wheel forward.
[2]
[3]
Remove the drive sprocket fixing plate bolts [1].

[1] [2]
Turn and remove the fixing plate [2].
Remove the drive sprocket [3] from the countershaft [4] [5]
and drive chain [5].
[4]
[3]

[1]/[2]
– Pivot nut [1]/washer [2]
– Bolt [3]
– Plate [4]
[4]
[3]
13-5
dummyhead
Remove the collar [1] from the pivot bolt.
[1]
Support the engine using a jack or other adjustable

support.
Remove the front engine hanger nut [1].
Remove the rear upper engine hanger nut and rear
lower engine hanger nut.
Remove the engine hanger bolts [2] and engine from
the frame.
• Wrap the inlet pipe port with a shop towel or cover it
with a piece of tape to prevent any foreign material
from dropping into the engine.
[1]/[2]
ENGINE INSTALLATION
• Note the direction of the hanger bolts.
• Use a floor jack or other adjustable support, carefully
place the engine into the frame and maneuver it into
place.
• Route the wires and hoses properly (page 1-15).
During engine Place the engine into the frame and support the engine
installation, hold the using a jack or other adjustable support.
engine securely
Install the engine hanger bolts [1] and nuts [2].
and be careful not
to damage the Tighten the rear upper engine hanger nut to the
frame and engine. specified torque.
Tighten the rear lower engine hanger nut to the
specified torque.
Tighten the front engine hanger nut to the specified [1]/[2]
torque.
13-6
dummyhead
Install the collar [1] to pivot bolt.
[1]

[2]/[3]
– Plate [1]
– Bolt [4]
[1]
Retract the centerstand carefully and support the
motorcycle securely, then tighten the swingarm pivot
nut to the specified torque while holding the pivot bolt.
Tighten the bolt.
[4]
Support the motorcycle with its centerstand. [3]

Install the drive chain [1] onto the drive sprocket [2]. [1]
Install the drive sprocket onto the countershaft.
Install the fixing plate [3] to the countershaft while
aligning their teeth.
Rotate the fixing plate and align their bolt holes.
Install and tighten the drive sprocket fixing plate bolts
[4] alternately to the specified torque.
[2] [4]
Install a new gasket [1] to the cylinder head.

Install and tighten the mounting bolts [2] to the specified [2]
torque.
[1]
13-7
dummyhead
Route the carburetor drain hose [1] through the guide
[2].
[2]
[1]
Connect the following: [4]/[5] [3]

– Crankcase breather hose [1]
– Alternator 2P connector [2]
– Gear position switch 6P (Black) connector [3]
– Alternator wire (Yellow) connector [4]
– Ignition pulse generator wire (Blue/yellow) connector [2]
[5]
[1]
Connect the following:

– Starter motor 2P connector [1]
[1]
Connect the spark plug cap [1] and spark plug wire to [2]
the guide [2].
– PAIR control valve (page 6-15)
– Body covers (page 2-9)
Fill the recommended engine oil up to the proper level
(page 3-8).
[1]
13-8
dummytext
14. FRONT WHEEL/BRAKE/SUSPENSION/STEERING
COMPONENT LOCATION ··························14-2 FORK··························································· 14-8
SERVICE INFORMATION ···························14-3 HANDLEBAR ············································ 14-17
TROUBLESHOOTING·································14-4 STEERING STEM ····································· 14-19
FRONT WHEEL···········································14-5
14
14-1
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COMPONENT LOCATION
9 N·m (0.92 kgf·m)
59 N·m (6.0 kgf·m)
64 N·m (6.5 kgf·m)
59 N·m (6.0 kgf·m)
14-2
dummyhead
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad and shoe 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.
• This section covers the front wheel, fork, handlebar and steering stem.
• When servicing the front wheel, fork or steering stem, support the motorcycle using a jack or other support.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• After the front wheel installation, check the brake operation by applying the brake lever.
• For brake system service, refer to (page 15-2).
SPECIFICATIONS
Unit: mm
Wheel hub-to-rim distance See page 14-7
Axial – 2.0
Fork Spring free length 294.3
Spring direction With the tightly wound coil side facing
–
down
Pipe runout – 0.20
Recommended fork fluid Fork fluid –
Fluid level (full bottom) 78 –
Fluid capacity 62 ± 1 cm3 –
TORQUE VALUES
Handlebar weight screw 9 N·m (0.92 kgf·m) SL thread screw
Steering stem lock nut – For tightening sequence (page 14-22)
Steering stem top thread – For tightening sequence (page 14-22)
Bottom bridge pinch bolt 64 N·m (6.5 kgf·m)
Handlebar post mounting nut 59 N·m (6.0 kgf·m) U-nut
Front axle nut 59 N·m (6.0 kgf·m) U-nut
Front brake disc socket bolt 42 N·m (4.3 kgf·m) ALOC bolt; replace with new ones
Front spoke 3.2 N·m (0.33 kgf·m)
Fork socket bolt 20 N·m (2.0 kgf·m) Apply locking agent to the threads
Brake hose clamp bolt 12 N·m (1.2 kgf·m) ALOC bolt; replace with new ones
14-3
dummyhead
TROUBLESHOOTING
Hard steering
• Insufficient tire pressure
• Faulty tire
• Steering stem top threads too tight
• Faulty steering head bearing
• Faulty steering head bearing race
• Bent steering stem
Steers to one side or does not track straight
• Bent front axle
• Wheel installed incorrectly
• Worn or damaged front wheel bearings
• Bent fork
• Bent frame
• Faulty steering head bearing
• Worn or damaged swingarm bushings
Front wheel wobbles
• Loose front axle fasteners
• Bent rim
• Worn or damaged front wheel bearings
• Faulty tire
Front wheel turns hard
• Front brake drag
• Bent front axle
• Faulty front wheel bearings
Soft suspension
• Low tire pressure
• Deteriorated fork fluid
• Incorrect fork fluid weight
• Insufficient fluid in fork
• Weak fork spring
Hard suspension
• High tire pressure
• Too much fluid in fork
• Incorrect fork fluid weight
• Bent fork pipes
• Fork slider binds
• Clogged fork fluid passage
Suspension noisy
• Bent fork slider
• Insufficient fluid in fork
• Loose fork fasteners
14-4
dummyhead
FRONT WHEEL
Remove/install the following:
– Speedometer cable [1]
– O-ring [2]
– Axle nut cap [3]
– Axle nut [4]
– Front axle [5]
– Front wheel [6]
– Side collar [7]
– Speedometer gearbox [8]
TORQUE:
AXLE NUT 59 N·m (6.0 kgf·m)
• Replace the speedometer cable O-ring with a new one.
• Apply grease to the front axle, speedometer gear and speedometer
cable O-ring.
• Check the brake operation after installation.
* : 3 g to gear teeth
: 0.5 – 1.0 g to gear inner surface
[5]
[6]
[7] 59 N·m (6.0 kgf·m)

[4]
[3]
Align the speedometer

*
gearbox groove with the
boss on the fork leg.
Align the speedometer gear tabs with

[1]
the wheel hub grooves.
Release the tab while
pushing it and disconnect the
[2] speedometer cable.
[8]
14-5
dummyhead
– Dust seals [1]
– Socket bolts [2]
– Brake disc [3]
– Wheel bearings [4]
– Distance collar [5]
• Replace the socket bolts, bearings and dust seals
with new ones.
• Apply grease to the dust seal lips, bearing cavities
and distance collar.
TORQUE:
BRAKE DISC 42 N·m (4.3 kgf·m)
SOCKET BOLT
For wheel bearing replacement (page 14-7).
Tighten the bolts in a criss-

[2]
cross pattern in 2 or 3 steps.
42 N·m (4.3 kgf·m)
[1]
[5]
[3]
DUST SEAL
[4]
6201U)
[4]
6201U)
Install the right dust seal until it is flush with

the wheel end surface.
Install the left dust seal until it is fully
seated.
LEFT DUST SEAL
RIGHT DUST SEAL
14-6
dummyhead
WHEEL CENTER ADJUSTMENT
Place the rim on the work bench.
Place the wheel hub in the center of the rim and begin
lacing with new spokes.
13 ± 1.0 mm
Adjust the wheel hub position so that the distance from
the wheel hub left end surface to the side of rim is 13 ±
1.0 mm as shown.
TOOL:
Spoke wrench, 4.5 x 5.1 mm 07701-0020200

Check the rim runout (page 14-8).
BEARING REPLACEMENT
Install the bearing remover head into the bearing [1].
From the opposite side, install the bearing remover [2] [3]
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
[2] Bearing remover head, 12 mm07746-0050300
[3] Bearing remover shaft 07746-0050100
[1] [2]
[1]
[3] [2]
Pack all bearing cavities with grease.

[3] [2]
Never install the old Drive in a new right bearing [1] squarely with its sealed
bearings. Once the side facing up until it is fully seated.
bearings have been
removed, the
TOOLS:
bearings must be [2] Driver 07749-0010000
replaced with new [3] Attachment, 32 x 35 mm 07746-0010100
ones. [4] Pilot, 12 mm 07746-0040200
[1] [4]
14-7
dummyhead
Apply thin coat of grease to the distance collar [1] and
install it.
Drive in a new left bearing [2] squarely with its sealed [2]
side facing up. [1]
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
INSPECTION
AXLE
Place the axle on V-blocks and measure the runout with
a dial indicator.
Actual runout is 1/2 of the total indicator reading.
WHEEL 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
hub.
Replace the Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly, quietly, or if they fit loosely in the hub.
WHEEL RIM
Check the wheel rim runout by placing the wheel on a
turning stand.
Spin the wheel by hand and read the runout using a dial
indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT:
Axial: 2.0 mm
Radial: 2.0 mm
FORK
REMOVAL
Remove the front fender B (page 2-5).
[1]
Support the front Remove the brake caliper mounting bolts and brake
brake caliper with a caliper from the right fork leg (page 15-14).
piece of wire so that
Remove the bottom bridge upper pinch bolts [1].
it does not hang
Loosen the bottom bridge lower pinch bolts [2] and
from the front brake
remove the fork legs.
hose.
Do not twist the
brake hose.
[2]
14-8
dummyhead
DISASSEMBLY
Hold the fork slider [1] in a vice with soft jaws or a shop
towel. [1] [2]
Loosen the fork socket bolt [2] but do not remove yet.
Put the suitable tool [1] on the spring seat [2].

[1]
To prevent loss of Press the spring seat into the fork pipe using a suitable
tension, do not tool and hydraulic press, then remove the stopper ring [2]
compress the fork [3] using a small screwdriver.
spring more than
Remove the spring seat, O-ring [4] and spring [5] from
necessary. The
the fork pipe.
spring seat is under
spring pressure.
Use care when
removing the fork
assembly from the
[3]
hydraulic press.
[5] [4]
Pour out the fork fluid by pumping the fork pipe several
times.
Remove the dust seal [1].
[1]
14-9
dummyhead
Remove the oil seal stopper ring [2].
[2]
Remove the socket bolt [1] and sealing washer [2].

[2]
[1]
Remove the fork piston [1] and rebound spring [2] from
the fork pipe. [1]
[2]
Pull the fork pipe [1] out from the fork slider [2].
[2]
[1]
14-10
dummyhead
Remove the oil seal [1] using the special tool.
[2]
TOOL:
[2] Oil seal remover 07748-0010001
or equivalent commercially
available.
[1]
Remove the back-up ring [1] from the fork slider [2].
[1]
[2]
INSPECTION
FORK SPRING
Measure the fork spring [1] free length.
SERVICE LIMIT: 300.2 mm [1]
FORK PIPE/SLIDER/PISTON
Check the fork pipe [1], fork slider [2] and fork piston [3]
for score mark, and excessive or abnormal wear. [2]
Check the fork piston ring [4] for wear or damage.

Check the rebound spring [5] for fatigue or damage.
Replace the components if necessary. [1]
Place the fork pipe on V-block and measure the runout.
[5]
[3]
[4]
14-11
dummyhead
FORK PIPE BUSHING
Visually inspect the guide bushing [1] in the fork slider.
Replace the fork slider as an assembly if there is
excessive scoring or scratching, or if the teflon is worn [1]
so that the copper surface appears on more than 3/4 of [2]
the entire surface.
Check the back-up ring [2]; replace it if there is any
distortion at the points [3] indicated by arrows on the
figure.
[3]
ASSEMBLY
FORK PIPE FORK PISTON RING

FORK PISTON
DUST SEAL
STOPPER RING
STOPPER RING
OIL SEAL
SPRING
BACK-UP RING
SEAT
FORK SLIDER
O-RING
SOCKET BOLT
20 N·m
(2.0 kgf·m)
FORK SPRING
SEALING WASHER REBOUND SPRING
14-12
dummyhead
Before assembly, wash all parts with high flash point or
non-flammable solvent and wipe them dry. [2]
Install the fork pipe [1] into the fork slider [2].
[1]
Install the fork If removing the fork piston ring [1] from the fork piston
piston ring with its [2], install a new fork piston ring to the fork piston [1]
cut-out side facing groove.
down.
[2]
Make sure that the Install the rebound spring [1] and fork piston [2] into the
fork piston ring is fork pipe. [2]
seated in the
groove.
[1]
Clean the socket bolt [1] threads and apply locking

agent to the bolt threads.
[2]
Install and tighten the socket bolt with a new sealing [2]
washer to the fork piston.
[1]
14-13
dummyhead
Install the back-up ring [1] into the fork slider [2].
[1]
[2]
Apply fork fluid to the lip of a new oil seal.

[2]
Install the oil seal Drive the oil seal [1] into the fork slider using the special
with its marked side tools until it is fully seated.
facing up.
TOOLS:
[2] Fork seal driver body 07747-0010100
[3] Fork seal driver attachment, 07747-0010300
27.2 mm
[3] [1]
Install the oil seal stopper ring [1] into the stopper ring
groove on the fork slider. [1]
Apply fork fluid to a new dust seal lip.

Do not tap the dust Install the dust seal [1] until it is fully seated.
seal lip too hard.
[1]
14-14
dummyhead
Pour the specified amount of recommended fork fluid
into the fork pipe.
FORK FLUID CAPACITY:
62 ± 1 cm3
Pump the fork pipe several times to remove trapped air
from the lower portion of the fork pipe.
Be sure the oil level Compress the fork leg fully and measure the fluid level
is same in the both from the top of the fork pipe.
forks.
FORK FLUID LEVEL: 78 mm
78 mm
Pull the fork pipe [1] up and install the fork spring [2]
with its tapered side [3] facing down. [2]
[1]
[3]
Coat a new O-ring [1] with fork fluid and install it into the
groove in the spring seat [2]. [4]
Set the fork assembly, spring seat and stopper ring [3]
onto the hydraulic press.
Put the suitable tool [4] on the spring seat.
[3]
To prevent loss of Press the spring seat into the fork pipe until the stopper
tension, do not ring groove is visible.
compress the fork
[1]
spring more than
necessary.
[2]
14-15
dummyhead
Install the stopper ring [1] into the stopper ring groove
on the fork pipe.
[1]
Hold the fork slider [1] in a vise with soft jaws or a shop
towel. [1]
Tighten the fork socket bolt [2] to the specified torque.

[2]
INSTALLATION
Install the fork pipe into the steering stem [1].
[2]
Align the upper pinch bolt hole [2] with the groove [3] of
the fork pipe [4] as shown.
[3]
[4] [1]
Install the bottom bridge upper pinch bolts [1].

Tighten the bottom bridge upper/lower pinch bolts [2] to [1]
the specified torque.
– Front fender B (page 2-5)
– Brake caliper (page 15-14)
[2]
14-16
dummyhead
HANDLEBAR
[5]
– Handlebar rear cover (page 2-14)
– Main pipe cover (page 2-7)
[4]
Release the following from the handlebar clamps [1]:
– Front brake hose [2]
– Throttle cable [3] [2]
– Speedometer cable [4]
– Choke cable [5]
– Master cylinder [6]/holder [7]/bolts [8]
– Screws [9]/handlebar weights [10]
– Throttle pipe [11]
– Left handlebar grip [12]
– Nut [13]/collars [14]/bolt [15]/handlebar post [16]
[1]
TORQUE:
HANDLEBAR 9 N·m (0.92 kgf·m)
WEIGHT SCREW
[3]
HANDLEBAR POST 59 N·m (6.0 kgf·m)
MOUNTING NUT
• For handlebar post/handlebar grip installation
(page 14-17).
• Route the wires/cables properly (page 1-15).
[9] Align the end of master Tighten the upper bolt first,
9 N·m (0.92 kgf·m) cylinder with the punch then the lower bolt.
mark on handlebar.
[10]
[11]
[7]
[8]
Set the holder with its
“UP” mark facing up.
[16]
[12]
[6]
[13]
[15] 59 N·m (6.0 kgf·m)
[14]
[14]
14-17
dummyhead
HANDLEBAR POST INSTALLATION
Install the handlebar post onto the steering stem while
aligning the bolt holes.
[3] [2]
Rear collar is taller Install the front [1]/rear [2] collars, bolt [3] and nut [4].
than the front collar.
Tighten the nut to the specified torque.
[1] [4]
HANDLEBAR GRIP INSTALLATION

If the handlebar grips [1] were removed, apply Honda
Bond A or equivalent to the inside of the grip and to the [1]
clean surfaces of the left handlebar [2].
Wait 3 – 5 minutes and install the grip.
Allow the adhesive Rotate the grip for even application of the adhesive.
to dry for 1 hour
before using.
[2]
HANDLEBAR INNER WEIGHT REPLACEMENT

Push the retainer tab [1] through the handlebar hole [2] [1] RETAINER
with a screwdriver or punch.
RUBBER CUSHION
Apply lubricant Temporarily install the grip end and screw, then remove
spray through the the inner weight [3] assembly by turning the grip end.
handlebar hole to
the rubber for easy
removal.
[3]
[2]
Remove the screw [1], grip end [2] and rubber cushions
[3] from the inner weight [4]. [4]
Discard the retainer [5].
Check that the condition of the rubber cushions, replace [5]
them if necessary.
Install the rubber cushions and a new retainer onto the
inner weight.
Install the grip end onto the inner weight aligning its [1]
boss with groove each other.
Install the grip end screw.
[3]
[2]
14-18
dummyhead
Insert the inner weight assembly [1] into the handlebar. [2]
Turn the inner weight and hook the retainer tab [2] with [1]
[3]
the hole [3] in the handlebar.
Remove the grip end screw [4] and grip end [5].
[5] [4]
STEERING STEM
REMOVAL
– Fork (page 14-8)
– Handlebar (page 14-17)
Loosen the steering stem lock nut [1] using the socket
wrench. [1]
TOOL:
[2] Socket wrench 07916-KM10000
[3] Adjustable pin spanner 07702-0020001
Remove the steering stem lock nut and lock washer.
[3] [2]
Be careful not to Hold the steering stem and remove the top thread [1]
drop the steering using the special tool.
stem.
TOOL: [2]
[2] Steering stem socket 07916-3710101
[1]
Be careful not to Remove the upper bearing inner race [1] and the upper
drop the steering steel balls [2] while holding the steering stem [3]. [1]
stem and the upper
• Upper bearing: 23 balls
steel balls. [2]
[3]
14-19
dummyhead
Be careful not to Remove the steering stem [1] and lower steel balls [2].
drop the steering [1]
• Lower bearing: 29 balls
stem and the lower
steel balls.
[2]
STEERING STEM BEARINGS

REPLACEMENT
• Always replace the steel balls and races as a set.
Remove the steering stem (page 14-19). [1]
Remove the upper bearing outer race [1] using the
following tool.
TOOL:
[2] Ball race remover shaft 07GMD-KS40100
[2]
Remove the lower bearing outer race [1] using the

following tools. [3]
TOOLS:
[2] Ball race remover, 34.5 mm 07948-4630100
[3] Ball race remover shaft 07GMD-KS40100
[2]
[1]
Remove the dust seal [1] from the steering stem lower
bearing inner race [2]. [2]
Remove the lower bearing inner race with a chisel or [3]

equivalent tool being careful not to damage the stem
[3].
[1]
14-20
dummyhead
Install a new lower bearing inner race [1] using the
[1]
following tool and hydraulic press.
TOOL:
[2] Fork seal driver attachment, 07947-KA20200
35.2 mm
[2]
Apply 3g of grease with extreme pressure agent

(recommended: EXCELIGHT EP2 manufactured by
KYODO YUSHI, japan or Shell ALVANIA EP2 or
equivalent) to a new dust seal [1] lip then install it to the
lower bearing inner race.
[1]
Drive a new upper bearing outer race [1] into the head
pipe using the following tools. [2]
[3]
TOOLS:
[2] Driver 07749-0010000
[3] Bearing driver attachment 07946-3710701
[1]
Drive a new lower bearing outer race [1] into the head [1]
pipe using the following tools.
TOOL:
[2] Oil seal driver 53.5 mm 07947-SB00200
Install the steering stem (page 14-22).
[2]
14-21
dummyhead
INSTALLATION
For steering stem bearing replacement (page 14-20).
: grease with extreme pressure agent

LOCK NUT
(recommended: EXCELIGHT EP2
manufactured by KYODO YUSHI, japan or
Shell ALVANIA EP2 or equivalent)
: Apply 3g minimum each to lower/upper TOP THREAD
races and dust seal lip
UPPER INNER RACE
UPPER BEARING (23)
UPPER OUTER RACE
STEERING STEM
LOWER OUTER RACE
LOWER BEARING (29)
LOWER INNER RACE
DUST SEAL
(recommended: EXCELIGHT EP2 manufactured by [1]
equivalent) to the lower bearing races.
Replace the bearing Install the lower bearing balls [1] to the steering stem
races and balls as a [2].
set.
• Lower bearing: 29 balls
Be careful not to Insert the steering stem into the steering head pipe,
drop the steering being careful not to drop the steel balls.
stem and the lower
steel balls. [2]

[2]
(recommended: EXCELIGHT EP2 manufactured by
equivalent) to the upper bearing races.
Replace the bearing Install the upper bearing balls [1] onto the upper bearing
races and balls as a outer race.
set.
• Upper bearing: 23 balls [1]
Be careful not to Install the upper bearing inner race [2] onto the stem.
drop the steering
stem and the upper
steel balls.
14-22
dummyhead
Install the top thread [1].
Hold the steering stem and tighten the stem top thread [2]
to the initial torque using the special tool.
TOOL:
[1]
Turn the steering stem lock-to-lock several times to

seat the bearing.
Completely loosen the top thread [1].
[1]
Hold the steering stem and tighten the stem top thread
[1] to the specified torque using the special tool. [2]
TOOL:
TORQUE: 2.5 N·m (0.25 kgf·m) [1]
14-23
dummyhead
Turn the top thread [1] counterclockwise about 45°
degrees.
[1]
45°
Hold the top thread using the pin spanner and tighten
the steering stem lock nut [1] to the specified torque. [1]
Tighten the steering stem lock nut to the specified

torque.
TOOL:
[2] Socket wrench 07916-KM10000
[3] Adjustable pin spanner 07702-0020001

Turn the steering stem lock-to-lock several times.
Make sure the steering stem moves smoothly without
play or binding. [2]
[3]
– Fork (page 14-16)
– Handlebar (page 14-17)
14-24
dummytext
15. REAR WHEEL/BRAKE/SUSPENSION
COMPONENT LOCATION ··························15-2 REAR BRAKE ··········································· 15-11
SERVICE INFORMATION ···························15-3 SWINGARM ·············································· 15-12
TROUBLESHOOTING·································15-4 SHOCK ABSORBER ································ 15-17
REAR WHEEL ·············································15-5 BRAKE PEDAL ········································· 15-17
15
15-1
dummyhead
COMPONENT LOCATION
24 N·m (2.4 kgf·m)
59 N·m (6.0 kgf·m)
24 N·m (2.4 kgf·m)
59 N·m (6.0 kgf·m)
22 N·m (2.2 kgf·m)
24 N·m (2.4 kgf·m)
15-2
dummyhead
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• This section covers service of the rear wheel, rear brake, swingarm, shock absorber and brake pedal.
• A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with
a high quality brake degreasing agent.
• When servicing the rear wheel and suspension, support the motorcycle with its centerstand.
• Use only genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
SPECIFICATION
Unit: mm
Axial – 2.0
Wheel hub-to-rim distance See page 15-9 –
Drive chain Size – link RK 420SL – 102RJ –
DID 420DX – 102RB –
KMC 420JB – 102 –
Slack 30 – 40 –
Brake Brake drum I.D. 110.0 – 110.2 111.0
Brake pedal freeplay 20 – 30 –
TORQUE VALUES
Rear axle nut 59 N·m (6.0 kgf·m) U-nut
Rear spoke 3.7 N·m (0.38 kgf·m)
Driven sprocket nut 32 N·m (3.3 kgf·m,) U-nut
Driven flange stud bolt – See page 15-10
Rear brake stopper arm nut 22 N·m (2.2 kgf·m)
Rear brake arm nut 10 N·m (1.0 kgf·m, U-nut
Shock absorber upper mounting bolt 24 N·m (2.4 kgf·m)
Shock absorber lower mounting cap nut/nut 24 N·m (2.4 kgf·m)
Swingarm pivot nut 59 N·m (6.0 kgf·m,) U-nut
15-3
dummyhead
TROUBLESHOOTING
Rear wheel wobbles
• Bent rim
• Worn wheel bearings
• Faulty tire
• Improperly tightened axle fasteners
• Faulty swingarm pivot bushings
• Insufficient tire pressure
Soft suspension
• Weak shock absorber springs
• Oil leakage from damper unit
• Low tire pressure
Stiff suspension
• Bent shock absorber damper rod
• Damaged swingarm pivot bushings
• Bent swingarm pivot
• High tire pressure
• Damaged shock absorber bushings
Steers to one side or does not track straight
• Bent rear axle
• Bent frame
• Damaged swingarm pivot bushing
• Axle alignment/chain adjustment not equal on both sides
Poor brake performance
• Improper brake adjustment
• Worn brake linings
• Contaminated brake linings
• Worn brake cam
• Worn brake drum
• Brake arm serrations improperly engaged
• Worn brake shoes at cam contact faces
15-4
dummyhead
REAR WHEEL
REMOVAL
[3]
Remove the chain case (page 2-16).
Remove the exhaust pipe muffler (page 2-16).
Remove the brake adjusting nut [1], spring [2] and joint
pin [3].
[1] [2]

[2] [1]
– Cotter pin [1] [3]
– Nut [2]
– Washer [3]
– Rubber washer [4]
Remove the bolt [5] and release the stopper arm [6]
from the brake panel.
[4]
[5] [6]
Loosen the axle nut [1].

[6] [5]
Loosen both drive chain adjuster lock nuts [2] and
[1]/[4]
adjusters [3].
Push the rear wheel forward and release the drive
chain.
– Axle nut
– Rear axle[4] [2]
– Adjuster plates [5]
– Rear wheel
– Right side collar [6]
[3]
Remove the brake panel assembly [1] from the right
wheel hub. [1]
15-5
dummyhead
Remove the side collar [1] from the left side.
[1]
INSPECTION
AXLE
Set the rear axle in V-blocks.
Turn the rear axle and measure the runout using a dial
indicator.
WHEEL BEARING AND DRIVEN FLANGE BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
wheel hub or driven flange.
Replace the Replace the bearings if the inner race does not turn
bearings in pairs. smoothly and quietly, or if the outer race fit loosely in
the wheel hub or driven flange.
WHEEL RIM
Check the rim runout by placing the wheel in a turing
stand.
Spin the wheel slowly, and read the runout using a dial
indicator.
SERVICE LIMITS:
Radial: 2.0 mm
Axial: 2.0 mm
• Four nut [1]
• Driven sprocket [2]
• Dust seal [3]
• Driven flange [4]
• Driven flange collar [5]
• Damper rubbers [6]
• O-ring [7]
For replace the wheel bearings [8] and remove the
distance collar [9] (page 14-8).
For replace the driven flange bearing [10] (page 14-11).
15-6
dummyhead
[8] (6301U)
[7]
[6]
[9] [3]
[4]
[2]
[5]
[8] (6201U)
[1]
[10] (6203U) 32 N·m (3.3 kgf·m)
WHEEL BEARING REPLACEMENT

Replace the wheel Install the bearing remover head into the wheel bearing
bearings in pairs. [1]. [2] [3]
Do not reuse the From opposite side install the bearing remover shaft
old bearings. and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
[2] Bearing remover head, 12 mm07746-0050300
[3] Bearing remover shaft 07746-0050100
[2]
[1]
[1]
[3] [2]
15-7
dummyhead
[3] [2]
Drive in a new right bearing [1] squarely with its sealed
side facing up until it is fully seated.
TOOLS:
[2] Driver 07749-0010000
[3] Attachment, 37 x 40 mm 07746-0010200
[4] Pilot, 12 mm 07746-0040200
[1] [4]
Apply thin coat of grease to the distance collar [1]and

install it.
Drive in a new left bearing [2] squarely with its sealed
side facing up.
[2] [1]
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
DRIVEN FLANGE BEARING REPLACEMENT

Remove the driven flange collar [1].
[1]
Drive out the driven flange bearing [2].
[2]
15-8
dummyhead
[2]
Install the new driven flange bearing [1] squarely with its
sealed side facing up.
TOOLS:
[2] Driver 07749-0010000
[3] Attachment, 37 x 40 mm 07746-0010200
[4] Pilot, 12 mm 07746-0040200
[1] [3]/[4]
Install the driven flange collar [1] into the driven flange
bearing [2].
[2]
[1]
WHEEL CENTER ADJUSTMENT

Place the wheel rim on the work bench.
Place the wheel hub in the center of the rim and begin
lacing with new spokes.
Adjust the wheel hub position so that the distance from
the wheel hub right end surface to the side of rim is 6 ±
1.0 mm as shown.
TOOL:
Spoke wrench, 4.5 x 5.1 mm 07701-0020200

Check the rim runout (page 14-8).
6 ± 1.0 mm
DRIVEN FLANGE STUD BOLT

Apply locking agent to the driven flange stud bolt [1]
threads if the stud bolts are removed. 12.7 ± 0.5 mm
Install and tighten the driven flange stud bolt.
After installing the stud bolts, check that the height from
the bolt head to the driven flange surface is within
specification.
[1]
15-9
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INSTALLATION
Install the side collar [1] into the driven flange [2].
[1]
[2]
Do not get grease Install the brake panel assembly [1] into the wheel hub. [1]
on the brake drum
or stopping power
will be reduced.
Place the rear wheel between the swingarm.

[4] [5]
Install the drive chain [1] over the driven sprocket. [2]/[3]
Apply grease to the rear axle surface.
– Left adjuster plate
– Rear axle [2]
– Axle nut [3]
– Right side collar [4]
– Right adjuster plate [5]
[1]
Install the stopper arm [1] to the brake panel with bolt
[5] [6]
[2], rubber washer [3], washer [4] and nut [5].
[3]
Install a new cotter pin [6].
[4]
[2] [1]
15-10
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Install the joint pin [1] into the brake arm, then install the
[3] [2]
spring [2], brake rod [3] and adjusting nut [4].
Adjust the brake pedal freeplay (page 3-14).
Install the chain case (page 2-16).
Install the exhaust pipe muffler (page 2-16).
[4] [1]
REAR BRAKE
• Always replace the brake shoes as a set.
• When the brake shoes are reused, mark all parts
before disassembly so they can be installed in their
original locations.
Remove the rear drum brake panel assembly
(page 14-5).
Expand the brake shoes [1] and remove them from the
brake panel [2].
Remove the brake shoe springs [3] from the brake
shoes.
– Nut [4]/bolt [5]/brake arm [6]/indicator plate [7]
– Brake cam [8]/felt seal [9]
• Apply grease to the brake cam and anchor pin [10].
• Apply gear oil to the felt seal.
Adjust the rear brake pedal freeplay (page 3-14).
[5]
[7]
[6] [9]
Apply gear oil
Align the wide tooth on the indicator plate with

the wide groove on the brake cam.
[8]
[4]
10 N·m (1.0 kgf·m) Sliding surface: 0.06 - 0.08 g
Shoe contact area: 0.03 - 0.05 g
[3]
[10]
0.02 - 0.04 g
[2]
[1]
Align the punch marks on the
brake arm and brake cam.
15-11
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INSPECTION
Measure the rear brake drum I.D.

Install the rear wheel (page 14-9)
SWINGARM
REMOVAL
[2]
– Rear wheel (page 14-6)
Unhook the brake light switch spring [1] from the brake
pedal [2].
[1]
Unhook the brake pedal return spring [1] from the

swingarm.
[1]

[3]
– Pivot nut/washer [1]
– Bolt [2]
– Plate [3]
[2]
15-12
dummyhead
[3]
– Collar [1]
– Pivot bolt [2]
– Swingarm [3]
[1]
[2]
Remove the rear shock absorber lower mounting cap
[3]
nuts [1] and washers [2].
Release both shock absorber lower mounts [3] from the
swingarm studs.
[1]/[2]
Check the drive chain slider for wear or damage. [5] [4]
Release the drive chain slider front side slots [1] from
the hooks [2] on the swingarm.
Remove the drive chain slider [3] by releasing its slots [1]/[2]
[4] from the chain case guides [5] and rear side slot [6] (FRONT SIDE)
from the hook [7]on the swingarm.
[6]/[7]
(REAR SIDE) [3]

[6]
– Cotter pin [1]
– Nut [2]
– Washer [3]
– Spring washer [4]
– Bolt [5]
– Stopper arm [6]
[1]
[2]/[3]/[4]/[5]
15-13
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Check the pivot bushings [1] for wear or damage.
Check the swingarm for cracks or damage.
[1]
ASSEMBLY
[1]
– Stopper arm [1]
– Bolt [2]
– Spring washer [3]
– Washer [4]
– Nut [5]
– Cotter pin [6]
Install a new cotter pin [6].
[6]
[2]/[3]/[4]/[5]
Install the drive chain slider [1] by aligning rear side slot
[1]
to the hook on the swingarm and slots to the chain case
Align
guides.
Install the front side slots to the hooks on swingarm. Align
INSTALLATION
Route the drive chain and install the swingarm into the
[1]
frame.
Insert the pivot bolt [1] from the left side.
15-14
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Install the collar [1] to pivot bolt.
[1]

[1] [2]/[3]
– Plate [1]
– Bolt [4]
[4]
Hook the rear shock absorber lower mounts [1] onto the
pivots, then install the washers and lower mounting cap [1]
nuts [2].
Temporarily tighten the rear shock absorber lower
mounting nuts.
[2]
Install the rear wheel (page 14-9)

Retract the centerstand carefully and support the
motorcycle securely, then tighten the swingarm pivot
nut [1] to the specified torque.
[1]
15-15
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Hook the brake pedal return spring [1] to the swingarm.
[1]
BRAKE ROD
HOLE SIDE
SWINGARM
SLOT SIDE
Hook the brake light switch spring [1] to the brake pedal [2]
[2].
[1]
Tighten the rear shock absorber lower mounting cap

[1]
nuts [1] to the specified torque.

Install the exhaust pipe/muffler (page 2-16).
15-16
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SHOCK ABSORBER
.
– Body cover (page 2-9)

Remove the shock absorber upper mounting bolts [1].
Remove the shock absorber lower mounting cap nuts
[2] and washers [3], then remove the shock absorbers
[4].
TORQUE: Shock absorber upper mounting bolt:

24 N·m (2.4 kgf·m) [2]/[3]
Shock absorber lower mounting cap nut:
24 N·m (2.4 kgf·m)
INSPECTION
Do not disassemble Visually inspect the shock absorber for wear or
the shock absorber. damage. [1]
Replace the shock
absorbers as a set.
– Deformation or oil leakage
– Bushings [1] for wear or damage
– Damper rod [2] for bend or damage
Check the smooth damper operation.
[2]
BRAKE PEDAL
REMOVAL
Remove the exhaust pipe/muffler (page 2-16). [2]
Support the motorcycle using a safety stand or hoist.
Remove the brake pedal adjusting nut [1], brake rod [2],
spring [3] and joint pin [4] from the brake arm.
[3]
[1] [4]
15-17
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Unhook the brake pedal return spring [1].
[1]
Remove the following: [1]/[2]

[4]
– Bolt [3]
– Plate [4]
[3]

– Collar [1]
– Pivot bolt [2]
– Swingarm [3]
[1] [2]
Unhook the brake light switch spring [1] and
[2]
centerstand spring [2].
[1]
15-18
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Remove the cotter pin [1], then remove the centerstand [2] [1]
pivot [2].
Remove the centerstand [3] and brake pedal.
[3]
Remove the centerstand spring plate [1].
[1]
Remove the cotter pin [1], washer [2], and separate the
brake rod [3] from the brake pedal [4]. [1] [3]
[2]
• Replace the cotter pins with new ones.
• Apply grease to the brake pedal/centerstand pivot
sliding surface.
• Insert the centerstand pivot while aligning its groove
with the stopper of the frame.
[4]
15-19
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MEMO
dummytext
16. HYDRAULIC BRAKE
COMPONENT LOCATION ··························16-2 BRAKE PAD/DISC ······································ 16-7
SERVICE INFORMATION ···························16-3 MASTER CYLINDER ·································· 16-9
TROUBLESHOOTING·································16-4 BRAKE CALIPER ····································· 16-11
BRAKE FLUID REPLACEMENT/

AIR BLEEDING ···········································16-5
16
16-1
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HYDRAULIC BRAKE
COMPONENT LOCATION
HYDRAULIC BRAKE
34 N·m (3.5 kgf·m)
30 N·m (3.1 kgf·m)
34 N·m (3.5 kgf·m)
16-2
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HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Never use an air hose or brush to clean brake assemblies.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• Check the brake system by applying the brake lever after the air bleeding.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid, they may not be compatible.
• Always check the brake operation before riding the motorcycle.
SPECIFICATIONS
Unit: mm
Recommended brake fluid DOT 3 or DOT 4 –
Brake pad wear indicator – To the groove
Brake disc thickness 3.3 – 3.7 3.0
Brake disc runout – 0.30
Master cylinder I.D. 11.000 – 11.043 11.055
Master piston O.D. 10.957 – 10.984 10.945
Caliper cylinder I.D. 33.96 – 34.01 34.02
Caliper piston O.D. 33.878 – 33.928 33.87
TORQUE VALUES
Caliper bleed valve 5.4 N·m (0.55 kgf·m)
Pad pin 17 N·m (1.7 kgf·m)
Caliper bracket pin bolt 17 N·m (1.7 kgf·m)
Caliper mounting bolt 30 N·m (3.1 kgf·m) ALOC bolt; replace with new ones
Brake hose oil bolt 34 N·m (3.5 kgf·m)
Master cylinder reservoir cap screw 1.5 N·m (0.15 kgf·m)
Front brake light switch screw 1.2 N·m (0.12 kgf·m)
Brake lever pivot bolt 1.0 N·m (0.10 kgf·m)
Brake lever pivot nut 5.9 N·m (0.60 kgf·m)
Brake hose clamp bolt 12 N·m (1.2 kgf·m) ALOC bolt; replace with new ones
16-3
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HYDRAULIC BRAKE
TROUBLESHOOTING
Brake lever soft or spongy
• Air in the hydraulic system
• Leaking hydraulic system
• Worn caliper piston seal
• Worn brake pad/disc
• Caliper not sliding properly
• Worn master cylinder piston cups
• Low brake fluid level
• Clogged brake fluid passage
• Contaminated brake pad/disc
• Contaminated caliper
• Contaminated master cylinder
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master piston
• Bent brake lever
Brake lever hard
• Sticking/worn caliper piston
• Clogged/restricted brake fluid passage
• Bent brake lever
Brake drag
• Contaminated brake disc/pad
• Warped/deformed brake disc
• Sticking caliper piston
• Clogged/restricted brake hose joint
16-4
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HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
Spilled fluid can damage painted, plastic, or rubber

parts. Place a rag over these parts whenever the
system is serviced.
• Do not allow foreign material to enter the system
when filling the reservoir.
• When using a commercially available brake bleeder,
follow the manufacturer’s operating instructions.
BRAKE FLUID DRAINING
Remove the handlebar top cover (page 2-12).
[1]
Turn the handlebar to the left until the reservoir is level
before removing the reservoir cap.
Remove the screws [1], reservoir cap [2], setting plate
[3] and diaphragm [4].
[2]
[3]
[4]
Connect a bleed hose [1] to the bleed valve [2].

[2]
Loosen the bleed valve and pump the brake lever until
no more fluid flows out of the bleed valve.
Tighten the bleed valve.
[1]
BRAKE FLUID FILLING/AIR BLEEDING
Do not mix different Fill the reservoir to the casting ledge [1] with DOT 3 or [1]
types of fluid. They DOT 4 brake fluid from a sealed container.
are not compatible.
16-5
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HYDRAULIC BRAKE
Connect a commercially available brake bleeder [1] to [2]
the bleed valve [2].
[1]
Operate the brake bleeder and loosen the bleed valve.
• Check the fluid level often when bleeding to prevent
air from being pumped into the system.
• When using a brake bleeding tool, follow the
manufacturer’s operating instruction.
• If air is entering the bleeder from around the bleed
valve threads, seal the threads with teflon tape.
After bleeding the air completely, tighten the bleed
valve to the specified torque.
If a brake bleeder is not available, use the following

procedure:
Do not mix different Fill the reservoir to the casting ledge with DOT 3 or
types of fluid. They DOT 4 brake fluid from the sealed container.
are not compatible.
Pump up the system pressure with the brake lever until
lever resistance is felt.
Connect a bleed hose [1] to the bleed valve [2] and

bleed the system as follows: [2]
Do not release the 1. Squeeze the brake lever. Open the bleed valve 1/2
brake lever until the turn and close it.
bleed valve has
been closed.
2. Release the brake lever slowly and wait several

seconds after it reaches the end of its travel.
Repeat steps 1 and 2 until air bubbles do not appear in
the bleed hose.
After bleeding the air completely, tighten the bleed
valve to the specified torque. [1]

Fill the reservoir to the casting ledge [1] with DOT 3 or [1]
DOT 4 brake fluid from a sealed container.
16-6
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HYDRAULIC BRAKE
Install the diaphragm [1], setting plate [2] and reservoir
cap [3]. [4]
Tighten the screws [4] to the specified torque.
Install the handlebar top cover (page 2-12).
[3]
[2]
[1]
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Check the brake Push the caliper pistons all the way in to allow
fluid level in the installation of new brake pads.
reservoir as this
operation causes
the level to rise.
Remove the pad pin, O-ring [1] and brake pads [2].
[1] [2]
Always replace the Install new brake pads [1] into the brake caliper so their
[1]
brake pads in pairs ends seat against the retainer [2] and bracket pin bolt A
to ensure even disc [3].
pressure.
[2] [3]
16-7
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HYDRAULIC BRAKE
Apply silicon grease to the new O-ring [1] and install it
to the pad pin [2]. [2]
Install the pad pin while pushing the pads against pad
spring.
[1]
Tighten the pad pin [1] to the specified torque.

Operate the brake lever to seat the caliper pistons
against the pads.
[1]
BRAKE DISC INSPECTION

Visually inspect the brake disc for damage or cracks.
Measure the brake disc thickness at several points.
Measure the brake disc runout with a dial indicator.

Check the wheel bearings for excessive play, if the
runout exceeds the service limit.
Replace the brake disc if the bearings are normal.
For brake disc replacement (page 16-8).
16-8
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HYDRAULIC BRAKE
MASTER CYLINDER
Drain the brake fluid (page 15-6).
Remove the handlebar rear cover (page 2-14).
When removing the Remove the oil bolt [1], brake hose [2] and sealing
oil bolt, cover the washers [3].
end of the hose to
Remove the bolts [4], holder [5] and master cylinder [6].
prevent
contamination. Install the removed parts in the reverse order of
removal.
• Replace the sealing washer with new ones.
TORQUE:
OIL BOLT 34 N·m (3.5 kgf·m)
Fill and air bleed the hydraulic system (page 15-6).
Align the end of master

cylinder with the punch
mark on handlebar.
[4] [5] Tighten the upper

bolt first, then the
lower bolt.
Set the holder with

its “UP” mark facing
up.
[3]
Set the brake hose

[2] eyelet against the
stopper.
[6] [1]
34 N·m (3.5 kgf·m)
16-9
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HYDRAULIC BRAKE
– Brake lever pivot nut [1], bolt [2] and brake lever [3] [7]
– Screw [4] and brake light switch [5]
– Boot [6]
Remove/install the snap ring [7] using the special tool.
TOOL:
[8] Snap ring pliers 07914-SA50001
[8]
Remove/install the washer [9], master piston [10] and
spring [11].
• Keep the piston, cups [12], spring, snap ring and
boot as a set; do not substitute individual parts.
• When installing the cups, do not allow the lips to turn
inside out.
• Be sure that snap ring is firmly seated in the groove.
• Apply brake fluid to the spring, piston cups and
master piston.
• Apply silicone grease to the pivot bolt sliding surface
and brake lever contact area with piston.
Fill the brake fluid and bleed the hydraulic system
(page 15-6).
TORQUE:
PIVOT BOLT 1.0 N·m (0.10 kgf·m)
PIVOT NUT 5.9 N·m (0.60 kgf·m)
BRAKE LIGHT 1.2 N·m (0.12 kgf·m)
SWITCH SCREW
[2] *
1.0 N·m (0.10 kgf·m)
[11] [5]
[9] [12]
[4]
1.2 N·m (0.12 kgf·m)
[6]
[10]
[7]
*: Apply 0.1 g of
silicone grease
[3] [1] Align the switch boss with the hole.

5.9 N·m (0.60 kgf·m)
16-10
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HYDRAULIC BRAKE
INSPECTION
Check the piston cups [1] for wear, deterioration or
[3]
damage.
Check the spring [2] for fatigue or damage.
Check the master cylinder [3] inner surface and piston
[4] outer surface for scratches or damage.
[1]
[2]
[4]
Measure the master cylinder I.D.

Measure the master piston O.D.
BRAKE CALIPER
Avoid spilling fluid Drain the brake fluid (page 15-6).
on painted, plastic,
or rubber parts.
Place a shop towel – Oil bolt [1]/brake hose [2]/sealing washers [3] [5]
over these parts – Mounting bolts [4]
whenever the – Brake caliper [5] [4]
system is serviced. [2]
TORQUE:
BRAKE CALIPER 30 N·m (3.1 kgf·m)
MOUNTING BOLT
OIL BOLT 34 N·m (3.5 kgf·m)
• Replace the brake caliper mounting bolts and
sealing washers with new ones.
Fill the brake fluid and bleed the hydraulic system [1] [3]
(page 15-6).
16-11
dummyhead
HYDRAULIC BRAKE
CALIPER PISTON
– Brake pads (page 15-11)
– Caliper bracket [1]
– Bracket pin boots [2]
– Pad spring [3]
– Bleed valve [4]
Place a shop towel over the piston [5].
Do not use high Position the caliper body [6] with the piston facing down
pressure air or bring and apply small squirts of air pressure to the fluid inlet
the nozzle too close to remove the piston.
to the inlet.
Remove the dust seal [7]/piston seal [8].
removal.
• Apply brake fluid to the caliper piston and piston
seal.
• Apply silicone grease to the bracket pin sliding
surface and dust seal.
• Replace the piston seal and dust seal with new ones as a set.
[4] [2] * *: Apply 0.4 g minimum of

5.4 N·m (0.55 kgf·m) silicone grease
[7]
[8]
[1]
[5]
[2]
Install the caliper piston with
its opened end facing the
[6] brake pads.
[3]
INSPECTION
Check the caliper cylinders for scoring, scratches or
damage.
Measure the caliper cylinder I.D.
Check the pistons for scoring, scratches or damage.
Measure the caliper piston O.D.
16-12
dummytext
17. BATTERY/CHARGING SYSTEM
SYSTEM LOCATION···································17-2 BATTERY ···················································· 17-5
SYSTEM DIAGRAM ····································17-2 CHARGING SYSTEM INSPECTION ·········· 17-6
SERVICE INFORMATION ···························17-3 ALTERNATOR INSPECTION ····················· 17-7
TROUBLESHOOTING·································17-4 REGULATOR/RECTIFIER ·························· 17-7
17
17-1
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BATTERY/CHARGING SYSTEM
SYSTEM LOCATION
REGULATOR/RECTIFIER
MAIN FUSE 10 A
SUB FUSE 7.5 A
ALTERNATOR
BATTERY
SYSTEM DIAGRAM
Y To LIGHTING SWITCH
W
G
MAIN FUSE
10A
W
W
G
G
R
R
Y
Y : Yellow
G
G : Green
BATTERY REGULATOR/ R : Red
RECTIFIER W : White
ALTERNATOR
17-2
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SERVICE INFORMATION
GENERAL
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
– If electrolyte gets on your skin, flush with water.
– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician
immediately.
• Always turn OFF the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON position and current is present.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every two weeks.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• The maintenance free (MF) battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions
contribute to shortening the “life span” of the battery. Even under normal use, the performance of the battery deteriorates after 2
– 3 years.
• Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and eventually die
out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage
does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level
goes down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the turn signal and brake lights on for long periods of time without riding the
motorcycle.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
• When checking the charging system, always follow the steps in the troubleshooting (page 16-5).
• For alternator service (page 16-11).
BATTERY CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instruction of the Operation Manual for the recommended battery tester for details about battery testing. The
recommended battery tester puts a “load” on the battery so that the actual battery condition during load can be measured.
Recommended battery tester: BM-210 or BATTERY MATE or equivalent
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Battery brand GTZ4V/YTZ4V
Capacity 12 V – 3.0 Ah
Current leakage 20 mA max.
Voltage (20°C) Fully charged 13.0 – 13.2 V
Needs charging Below 12.4 V
Charging Normal 0.3 A/5 – 10 h
current Quick 3.0 A/0.5 h
Alternator Capacity 0.120 kW/5,000 min-1
Charging coil resistance (20°C) 0.3– 1.0 Ω
17-3
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TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery (page 17-5).
Check the battery condition using the recommended battery tester (page 17-5).
RECOMMENDED BATTERY TESTER:BM-210 or BATTERY MATE or equivalent
Is the battery in good condition?
NO – Faulty battery
2. CURRENT LEAKAGE TEST
Install the battery (page 17-5).
Check the battery current leakage (page 17-6).
Is the current leakage below 20 mA?
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTED
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Is the current leakage below 20 mA?
YES – Faulty regulator/rectifier
NO – • Shorted wire harness
• Faulty ignition switch
4. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil (page 17-7).
Is the alternator charging coil resistance within 0.2 – 1.0 Ω (20°C)?
NO – Faulty charging coil
5. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter (page 17-6).
Start the engine.
Measure the charging voltage (page 17-6).
Compare the measurements to result of the following calculation.
STANDARD:Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 17-5)
• CV = Charging Voltage
Is the measured charging voltage within the standard voltage?
YES – Faulty battery
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier connectors (page 17-8).
Are the results of checked voltage and resistance correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related wire
• Loose or poor contacts of related terminal
• Shorted wire harness
17-4
dummyhead
BATTERY
• Always turn the ignition switch OFF before removing [1]
the battery.
Unlock and open the seat. [3] [2]
Remove the special screw [1] and battery cover [2]

while releasing the battery cover hook [3] from slot [4] in
the luggage box.
[4]
Always disconnect Remove the bolt [1] and disconnect the negative (–)
[1]
the negative cable [2].
terminal first. Pull back the positive terminal cover. [2]
Remove the bolt and disconnect the positive (+) cable
[3]. [3]
Remove the battery [4] out of the luggage box.
• Connect the positive (+) cable to the battery first,
then connect the negative (–) cable.
[4]
VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (20°C):
Fully charged: 13.0 – 13.2 V
Needs charging: Below 12.4 V
(+) (–)
• When measuring the battery voltage after charging,

leave it for least 30 minutes, or the accurate results
cannot be obtained because the battery voltage
fluctuates just after charging.
BATTERY TESTING
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOLS:
Battery tester BM-210,BATTERY MATE or
equivalent
17-5
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CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE TEST
Remove the battery cover (page 17-5). (+)
(–)
Turn the ignition switch OFF and disconnect the
negative (–) cable [1] from the battery.
Connect the ammeter (+) probe to the negative (–)
cable and the ammeter (–) probe to the battery (–)
terminal.
With the ignition switch OFF, check for current leakage.
• When measuring current using a tester, set it to a

high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blow the fuse in the tester.
• While measuring current, do not turn the ignition [1]
switch ON, A sudden surge of current may blow the
fuse in the tester.
SPECIFIED CURRENT 20 mA max.

LEAKAGE:
If current leakage exceeds the specified value, a
shorted circuit is the probable cause.
Locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION
Remove the battery cover (page 17-5).
• Make sure the battery is in good condition before

performing this inspection.
• Do not disconnect the battery or any cable in the
charging system without first switching OFF the
ignition switch. Failure to follow this precaution can (+) (–)
damage the tester or electrical components.
Warm up the engine to normal operating temperature.
To prevent a short, Stop the engine and connect the multimeter as shown.
make absolutely
Connect a tachometer according to its manufacturer’s
certain which are
instructions.
the positive and
negative terminals Restart the engine.
or cables. Measure the voltage on the multimeter when the engine
runs at 5,000 min-1 .
STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 17-5)
• CV = Charging Voltage
17-6
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ALTERNATOR INSPECTION
Disconnect the alternator wire (Yellow) connector [1]
[1]
and alternator 2P connector [2].
[2]
Check the resistance between the following terminals of

ALTERNATOR 2P ALTERNATOR WIRE
the alternator side.
CONNECTOR (Yellow) CONNECTOR
STANDARD:
Charging coil (White – Green):
0.3 – 1.0 Ω (at 20°C)
Lighting coil (Yellow – Green):
0.1 – 0.8 Ω (at 20°C)
Replace the stator if the resistance is out of WG Y WG Y
specification.
For stator removal (page 10-5).
removal.
REGULATOR/RECTIFIER
Remove the center cover (page 2-6). [3]
Turn the ignition switch OFF. [1]/[2]
Remove the bolt [1] and the ground terminal [2].
Remove the regulator/rectifier [3] from the frame.
17-7
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Disconnect the regulator/rectifier 4P connector [1].
[1]
INSTALLATION
Connect the regulator/rectifier 4P connector.
[1]
Position the regulator/rectifier so that its upper left side

is aligned with the stopper on the frame.
[1]/[2]
Route the wire Install the ground terminal [1] and tighten the bolt [2].
harness properly
Install the center cover (page 2-6).
(page 1-15)
Align
SYSTEM INSPECTION
Remove the regulator/rectifier (page 17-7).
Check the regulator/rectifier 4P connector [1] for loose
[1]
contact or corroded terminals.
If the charging voltage reading (page 17-7) is out of the
specification, inspect the regulator/rectifier 4P
connector terminals (wire harness side) as follows:
Item Terminal Specification
Battery charging Red (+) and Battery voltage
line Ground (–) should appear
Charging coil line White and 0.3 – 1.0 Ω
Green (at 20°C)
Ground line Green and Continuity
Ground should exist
If all components of the charging system is normal and

there are no loose connections at the regulator/rectifier
4P connector, replace the regulator/rectifier unit.
17-8
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Disconnect the main wire/combination meter sub
harness 9P connector [1], then check the connector
terminals (wire harness side) as follows:
Item Terminal Specification
Lighting coil line Yellow and 0.1 – 0.8 Ω
ground (at 20°C)
Ground line Green and ground Continuity
should exist
If all components of the system are normal and there

are no loose connections at the regulator/rectifier [1]
connectors, replace the regulator/rectifier unit.
17-9
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MEMO
dummytext
18. LIGHTS/METERS/SWITCHES
SYSTEM LOCATIONS ································18-2 FUEL METER ············································ 18-10
SERVICE INFORMATION ···························18-3 IGNITION SWITCH···································· 18-12
LIGHTING SYSTEM INSPECTION ·············18-4 HANDLEBAR SWITCHES ························ 18-13
HEADLIGHT ················································18-5 BRAKE LIGHT SWITCH ··························· 18-14
TURN SIGNAL LIGHT·································18-5 GEAR POSITION SWITCH ······················· 18-14
BRAKE/TAIL LIGHT····································18-6 HORN ························································ 18-17
COMBINATION METER······························18-7 TURN SIGNAL RELAY ····························· 18-18
18
18-1
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SYSTEM LOCATIONS
FRONT BRAKE LIGHT SWITCH
TURN SIGNAL RELAY LIGHTING SWITCH
COMBINATION METER
STARTER SWITCH
DIMMER SWITCH FUEL LEVEL SENSOR
MAIN FUSE 10 A/
SUB FUSE 7.5 A
HORN SWITCH
TURN SIGNAL
LIGHT SWITCH
HORN
IGNITION SWITCH
REAR BRAKE LIGHT SWITCH
GEAR POSITION SWITCH
18-2
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SERVICE INFORMATION
GENERAL
• Note the following while replacing the halogen headight bulb.

– Wear clean gloves while replacing the bulb. Do not put finger prints on the bulb, as they can create hot spot on the bulb and
cause it to fail.
– If you touch the bulb with your bear hands, clean it with cloth moistened with alcohol to prevent it early failure.
• Be sure to install the dust cover after replacing the bulb.
• Check the battery condition before performing any inspection that requires proper battery voltage.
• Route the wires and cables properly after servicing each component (page 1-15).
• The following color codes are used throughout this section.
Bu = Blue G = Green Lg = Light green R = Red

Bl = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light blue P = Pink Y = Yellow
SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight (High/Low) 12 V – 35/35 W
Position light 12 V – 3.4 W x 2
Brake/tail light 12 V – 18/5 W
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Meter light 12 V – 1.7 W x 2
Turn signal indicator 12 V – 3.4 W x 2
High beam indicator 12 V – 1.7 W
Gear position indicator 12 V – 1.7 W x 4
Neutral indicator 12 V – 1.7 W
Fuse Main 10 A
Sub 7.5 A
TORQUE VALUES
Ignition switch mounting bolt 9 N·m (0.92 kgf·m) ALOC bolt; replace with new one
Key shutter assembly socket bolt 3.9 N·m (0.40 kgf·m) ALOC bolt; replace with new one
18-3
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LIGHTING SYSTEM INSPECTION
HEADLIGHT DOES NOT COME ON OR
IS WEAK
Standard Inspection
[3]
– Burned out bulb or bulb with unspecified wattage
– Loose connector
– Lighting switch
– Dimmer switch
If the above items are normal, check as follows: [1]
[2]
Lighting Circuit Inspection Bu
Bu/R Y
– Handlebar front cover (page 2-12)
Disconnect the alternator wire (Yellow) connector
(page 16-11).
Turn the lighting switch [1] to HL and dimmer switch [2] [4]
to Hi position.
Check the continuity between the Blue terminal of the
headlight 9P connector [3] and Yellow terminal of the
alternator wire connector [4].
If there is continuity, check the following:
Remove the regulator/rectifier (page 16-10).
Check the continuity between the Yellow terminals of
the regulator/rectifier 4P connector [1] and alternator [1]
wire (Yellow) connector [2].
If there is continuity, check the following:
[2]
Ground Inspection
Check the continuity between the Green terminal of the
headlight 9P connector [1] and ground. [1]
If there is continuity, check the lighting coil (page 16-
11).
If the lighting coil is normal, check the regulator/rectifier
(page 16-9).
18-4
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HEADLIGHT
HEADLIGHT BULB REPLACEMENT
• Do not put fingerprints on the headlight bulb, as they

may create hot spots on the bulb and cause it to fail.
Disconnect the connector [1].
Remove the seat rubber [2]. [1] [5]
[3]
Slightly press down the on the pin [3] and turn it counter
clockwise until release.
Remove the headlight bulb [4].
Install a new bulb in the reverse order of the removal.
Install the seat rubber with its “TOP” mark [5] facing up.
[2] [4]
POSITION LIGHT BULB

REPLACEMENT
Remove the handlebar front cover (page 2-12)
Turn the socket [1] counterclockwise and remove it, [2]
then pull out the position light bulb [2] from the socket.
Install a new bulb in the reverse order of removal.
Install the handlebar front cover (page 2-12)
[1]
TURN SIGNAL LIGHT

BULB REPLACEMENT
FRONT TURN SIGNAL LIGHT
Turn the socket [1] counterclockwise and remove it,
then pull out the bulb [2] from the socket. [2]
Install a new bulb in the reverse order of removal.
• Use only the amber bulbs.
• For headlight assembly removal/installation
(page 2-13)
[1]
18-5
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REAR TURN SIGNAL LIGHT
Remove the brake/tail light unit (page 17-7).
Turn the socket [1] counterclockwise and remove it,
then pull out the bulb [2] from the socket.
Install the new bulb in the reverse order of removal.
• Use only the amber bulbs.
[2]
[1]
BRAKE/TAIL LIGHT
BULB REPLACEMENT
Be careful not to Remove the two screws [1], lens covers [2] and brake/
damage the lens. tail light lens [3] by releasing the tab [4].
[4]
[3]
[2]
[1]
While pushing the bulb [1] in, turn it counterclockwise

and remove it.
Install the new bulb in the reverse order of removal.
[1]
18-6
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BRAKE/TAIL LIGHT UNIT REMOVAL/
INSTALLATION
Remove the two bolts [1]and washers [2].
Pull the brake/tail light unit [3] upward and release its
grommets [4] from the bosses [5] on the rear fender and
frame.
[1]/[2]
[4]
Disconnect the brake/tail light 6P connector [6].
[6]
[3]
[5]
Remove the two screws [1] and brake/tail light cover [2]
by releasing its hook [3]. [3]
[2]
[1]
COMBINATION METER
BULB REPLACEMENT
Pull out the bulb socket [1] from the combination meter [2]
assembly.
Remove the bulb [2] from the socket and replace it with
a new one.
[1]
18-7
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Remove the handlebar rear cover (page 2-14)
[2]/[3]/[4]/[5]/[6]
Disconnect the following:
– Dust cover [1] and starter switch 3P (black)
connector [2]
– Lighting switch 4P connector [3]
– Dimmer switch 3P connector [4]
– Turn signal switch 3P (red) connector [5]
– Horn switch 3P (black) connector [6]
[1]
Remove the screws [1] and combination meter

assembly [2]. [2]
[1]
removal.
18-8
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• Be careful not to put fingerprints on the meter panel.
• Be careful not to damage the retainer tabs when
removing the lens.
• Route the combination meter sub harness properly.
– Wire band screw [1]/wire band [2]
– Turn signal relay [3]
– Three terminal screws [4]
– Bulb sockets [5]/combination meter sub harness [6]
– Lens [7]/meter plate [8]
– Two screws [9]/washers [10]
– Lower case [11]
– Combination meter panel [12]
[7]
[11]
[5]
[2]
[1]
[9]/[10]
[6]
[8] [3] [4]
[12]
Bl/Bu, Bl
Br, G
W/Bu, Bl Y/R, Bl
O, G
P, Bl
Lb, G
Bu, G
Lg/R, Bl
Y/W
G Bl
18-9
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FUEL METER
METER CIRCUIT INSPECTION
FUEL METER DOES NOT MOVE
• Before performing the system inspection, make sure
that the following items are normal.
– Fuses
– Meter indicators
Unlock and open the seat using the ignition key.
Disconnect the fuel level sensor 3P (Black) connector
[1].
Do not leave the Short the fuel level sensor connector [2] terminals of the
terminals wire harness side with the jumper wire.
connected with the
jumper wire for a
CONNECTION: Yellow/White – Green
long time, as it Turn the ignition switch “ON” and check the fuel meter.
causes damage to
the fuel meter. If the fuel meter gauge moves to the “F”, it is normal.
[1]
• If the above inspection is normal, check the fuel
level sensor (page 18-10).
If the needle does not move, check the following:
• Yellow/white wire between the fuel level sensor and
fuel meter for open or short circuit
• Black wire between the speedometer 9P connector
[3] and fuel meter for open or short circuit
• Green wire between the fuel meter and ground for
open circuit
If above items are normal, replace the speedometer G
panel with a new one and recheck. From

IGNITION
Bl SWITCH
Y/
G
[2]
INSPECTION
Remove the fuel level sensor (page 18-11).
Measure the resistance between the connector
terminals with the float at upper (full) and lower (empty)
positions. [1]
Float position: FULL EMPTY

Resistance: 6 – 10 Ω 90 – 100 Ω
Replace the fuel level sensor [1] if it is out of
specification. Full
Install the fuel level sensor (page 18-11). Em
p ty
18-10
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FUEL LEVEL SENSOR REMOVAL/
INSTALLATION
Unlock and open the seat using the ignition key.
Disconnect the fuel level sensor 3P (Black) connector [1] [2]
[1] and release the harness from the clamp [2].
Turn the holder plate [1] counterclockwise with a pair of

needle nose pliers and remove the fuel unit holder [3]
plate.
Be careful not to Remove the fuel level sensor [2] and the O-ring [3].
damage the float
arm.
[1] [2]
Install the new O-ring [1] to the fuel level sensor [2].
[1]
Be careful not to Install the fuel level sensor to the fuel tank.
damage the float
arm.
[2]
Set the holder plate [1] as shown.

[2]
Turn the holder plate clockwise until the arrow marks [2]
on the holder plate and the fuel tank are aligned.
[1]
18-11
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Connect the fuel level sensor 3P (Black) connector [1]
to the fuel level sensor. [1] [2]
Secure the harness with the clamp [2].
Close the seat.
IGNITION SWITCH
INSPECTION
Turn the ignition switch “OFF”.
Disconnect the ignition switch 2P connector [1].
Check for continuity between the switch side connector
terminals in each switch position according to the chart
(page 18-2).
[1]
Remove the steering stem (page 14-19).
Disconnect the ignition switch 2P connector [1]. [3] [2]
Remove the two screws [2] and ignition switch [3].
Install and tighten the new screws to the specified
torque.
[1]
18-12
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KEY SHUTTER REMOVAL/
INSTALLATION
Remove the ignition switch (page 18-12).
Remove the socket bolt [1] and key shutter assembly [3]
[2] from the ignition switch [3].
Blow the key shutter cover area with compressed air.
Install the key shutter assembly onto the ignition switch.
Install and tighten the new socket bolt to the specified
torque.
Install the ignition switch (page 18-12).
[2]
[1]
HANDLEBAR SWITCHES
LEFT HANDLEBAR SWITCH
Turn the ignition switch “OFF”. [1] [2]
Disconnect the following connectors.
• Dimmer switch 3P connector [1]
• Horn switch 3P (Black) connector [2]
• Turn signal light switch 3P (Red) connector [3]
Check for continuity between the connector terminals in
each switch position according to the chart (page 18-2).
[3]
RIGHT HANDLEBAR SWITCH

Turn the ignition switch “OFF”. [2]
Disconnect the starter switch 3P (Black) connector [1]
and lighting switch 4p (White) connector [2].
Check for continuity between the connector terminals in
each switch position according to the chart (page 18-2).
[1]
18-13
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BRAKE LIGHT SWITCH
FRONT
Disconnect the front brake light switch wire connectors
[1] and check for continuity between the switch [1]
terminals.
There should be continuity with the brake lever
squeezed and no continuity with the lever released.
REAR
Remove the right side body cover (page 2-9).
[1]
Disconnect the rear brake light switch wire connectors
[1].
Check for continuity between the switch side connector
terminals.
There should be continuity with the brake pedal applied
and no continuity with the pedal released.
GEAR POSITION SWITCH

INSPECTION
Turn the ignition switch ON, and shift the transmission
[1]
into each gear position.
Check the operation of gear position indicators [1] and
neutral indicator [2] lights at each gear position.
If all the indicator bulbs are normal but the gear position
indicator does not light, check as follows:
[2]
18-14
dummyhead
Remove the left side body cover (page 2-9). [1]
Disconnect the gear position switch 6P (Black)
connector [1].
Check for continuity between the terminals at each gear

position.
The gear position switch is normal if the continuity exist
between the color coded wires as shown in the chart.
GEAR GROUND Lg/R Y/R Bl/Bu W/Bu P
N
1
2
3
4
REMOVAL
– Left side body cover (page 2-9)
Disconnect the gear position switch 6P (Black)
connector [1].
Remove the bolt [1] and gear position switch [2].
[1]
[2]
18-15
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Remove the O-ring [1], contact switch cap [2] and
spring [3] from the shift drum. [2]/[3]
[1]
INSTALLATION
Install the spring [1] and contact switch cap [2] into the [1]
shift drum [3].
[2] [3]
Apply engine oil to a new O-ring [1] and install it to the

gear position switch [2]. [1]
Install the gear position switch to the crankcase.
[2]
[1]
18-16
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Route the wire Connect the gear position switch 6P (Black) connector [1]
harness properly [1].
(page 1-15).
– Left side body cover (page 2-9)
HORN
INSPECTION
Disconnect the horn wire connectors.
Connect the 12 V battery to the horn terminals.
The horn is normal if it sounds when the 12 V battery is
connected to the horn terminals.
[2]/[3]/[4]
Disconnect the horn wire connectors [1].
Remove the bolt [2]/collar [3]/damper rubbers [4] and
horn [5].
[1]
[5]
18-17
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TURN SIGNAL RELAY
INSPECTION
– Ignition switch and turn signal switch function
– Loose connectors
– Sub fuse (7.5 A)
If above items are all normal, check the following:
[1]
Disconnect the turn signal relay [1] 2P connector [2].
[2]
Short the Black and Gray terminals of the harness side

connector [1] with the jumper wire. [1]
Turn the ignition switch ON.
Check the turn signal light by moving the turn signal
switch [2] to the right and left. IGNITION
SWITCH
• If the turn signal light does not come on, there is Bl Gr
O
open circuit in wire harness. Lb
• If the lights come on, the circuit is normal. SUB

Replace the turn signal relay. FUSE G
Install the removed parts in the reverse order of 7.5 A

removal.
[2]
[2]
Disconnect the turn signal relay 2P connector [1].
Remove the turn signal relay [2] from the combination
meter.
[1]
18-18
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19. WIRING DIAGRAM
WIRING DIAGRAM······································19-2
19
19-1
WIRING DIAGRAM
STARTER FRONT BRAKE IGNITION IGNITION IGNITION CONTROL REGULATOR/ REAR BRAKE BATTERY
LIGHTING SWITCH SWITCH LIGHT SWITCH SWITCH COIL MODULE (ICM) RECTIFIER LIGHT SWITCH 12V 3.0AH STARTER RELAY
FRAME
19-2
R
R/Bl
GROUND
ST
BAT
TL
HL
C1
C1
BAT1
BAT
SUB MAIN
FUSE FUSE
7.5A 10A
4P 3P 2P 3P 4P 5P
Bl
G
G
R
R
R
Bl
G
G
Y
R
G
R
Y
Y
Bl
R
W
Bl
Br
Y/R
Y/R
Bl/Y
R/Bl
G/Y
R/W
Bu/Y
R/Bl
R/Bl
Bu/R
Bl
G/Y
2P 2P
MINI
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R
RIGHT FRONT
G
Lb
Bl
R/Bl
Bl/Y
G/Y
R
Bl
R/Bl
TURN SIGNAL LIGHT G
12V 10W
WIRING DIAGRAM
L 2PW
TURN SIGNAL Gr
RELAY Br
G
Y/R
WIRING DIAGRAM
Br
METER
G 2P
LIGHT MINI
12V 1.7W x 2 Br
G
G
Y/R
Y/R
1ST Bl
GEAR
POSITION Bl/Bu RIGHT REAR
2ND
INDICATOR Bl TURN SIGNAL LIGHT
12V 1.7W x 4 12V 10W
W/Bu
3RD 9P MINI
Bl Lb
Bl Bl G
P
4TH Y Y 6P MINI
NEUTRAL Bl
Br Br Lb Lb
INDICATOR
Lg/R G G G G G
12V 3.4W x 2 Bl G/Y
Lg/R Lg/R G/Y G/Y
Y/R Y/R Br Br Br
Bu
HIGH BEAM Bl/Bu Bl/Bu O O
G
INDICATOR W/Bu W/Bu BRAKE/TAIL LIGHT
12V 1.7W Lb P P 12V 18W/5W
R G
G
TURN SIGNAL G
L 6P MINI O
INDICATOR O
12V 3.4W x 2 G/Y G/Y LEFT REAR
Lg Lg
Bl O
TURN SIGNAL LIGHT
O
Y/R Y/R
12V 10W
FUEL METER
Y/W Y/W Y/W
G
POSITIN LIGHT Br
12V 3.4W G 9P MINI
Lb Lb
3P Br
Br
Bu Bu Bu
LHEADLIGHT G
G G
12V 35W/35W
P
W
G
G
W W
Y/R
W
Lg/R
Bu/Y
R/W
Bl/Bu
W/Bu
O O
6P
2P MINI 2P
POSITIN LIGHT G
Bl
12V 3.4W Br
G
P
G
W
Y/R
Bu/Y
R/W
Lg/R
Bl/Bu
W/Bu
LEFT FRONT G
TURN SIGNAL LIGHT
O
12V 10W
O
Bl
G
Gr
W
Lb
Lg
Lg
Bu
Y/W
Bu/R
3P 3P
3P
3P MINI
R Bl 32
Bl IGNITION 4
1
PULSE
GENERATOR N
LO
HI
HL
W
WR
WL
BAT
HO
DIMMER TURN SIGNAL HORN
SWITCH LIGHT SWITCH SWITCH HORN FUEL LEVEL
SENSOR
TURN SIGNAL ALTERNATOR GEAR STARTER
IGNITION SWITCH LIGHTING SWITCH DIMMER SWITCH LIGHT SWITCH HORN SWITCH STARTER SWITCH POSITION MOTOR
BAT BAT1 HL C1 TL HL LO HI WR W WL
SWITCH
HO BAT ST BAT
ON LO R FREE FREE
OFF (N) (N) N PUSH PUSH
LOCK TL HI L COLOR Lg Bl COLOR Y/R Bl

Bl BLACK Br BROWN
COLOR R R/Bl (N) COLOR Bu/R W Bu COLOR Lb Gr O Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE
HL G GREEN Lg LIGHT GREEN
R RED P PINK
COLOR L/R Y Br W WHITE Gr GRAY
COLOR COMB : GROUND/MARKING

INDEX
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INDEX
A Few Words About Safety ·············································0-1 ENGINE OIL CENTRIFUGAL FILTER ··························· 3-9
A
AIR CLEANER ································································3-5 ENGINE OIL STRAINER SCREEN ································ 3-8

AIR CLEANER HOUSING ··············································6-5 ENGINE REMOVAL ····················································· 13-4
AIR SCREW ADJUSTMENT·········································6-11 EXHAUST PIPE/MUFFLER·········································· 2-16
AIR SUPPLY PIPE························································6-16 FLYWHEEL/STARTER CLUTCH ································· 10-6
F
ALTERNATOR INSPECTION ·······································17-7 FOOTPEG BAR···························································· 2-15

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS 1-7 FORK············································································ 14-8
BATTERY······································································17-5 FRONT FENDER···························································· 2-5
B
BATTERY/CHARGING SYSTEM SPECIFICATIONS ····1-9 FRONT TOP COVER ····················································· 2-4

BODY COVER ································································2-9 DISASSEMLY/ASSEMBLY········································ 2-9
BODY PANEL LOCATIONS ···········································2-2 FRONT WHEEL···························································· 14-5
BODY PANEL REMOVAL CHART ·································2-2 FRONT WHEEL/SUSPENSION/STEERING
BRAKE CALIPER························································16-11 SPECIFICATIONS·························································· 1-8
BRAKE FLUID·······························································3-13 FUEL FILTER ······························································· 6-13
BRAKE FLUID REPLACEMENT/AIR BLEEDING ········16-5 FUEL LINE ····································································· 3-4
BRAKE LIGHT SWITCH FUEL METER ····························································· 18-10
LIGHTS/METERS/SWITCHES·······························18-14 FUEL STRAINER SCREEN ········································· 6-13
MAINTENANCE ·······················································3-15 FUEL SYSTEM SPECIFICATIONS································ 1-5
BRAKE PAD/DISC ························································16-7 FUEL TANK ·································································· 6-12
BRAKE PEDAL ···························································15-17 GEAR POSITION SWITCH ········································ 18-14
G
BRAKE SHOES/PADS WEAR······································3-13 GEARSHIFT LINKAGE··············································· 11-27

BRAKE SYSTEM ··························································3-14 GENERAL SPECIFICATIONS········································ 1-4
BRAKE/TAIL LIGHT······················································18-6 GRAB RAIL ···································································· 2-8
CABLE & HARNESS ROUTING ···································1-15 HANDLEBAR······························································ 14-17
C H
CAM CHAIN GUIDE SPROCKET·······························12-16 HANDLEBAR COVER ·················································· 2-12

CAM CHAIN TENSIONER ············································8-20 HANDLEBAR REAR COVER ······································· 2-14
CAMSHAFT ····································································8-7 HANDLEBAR SWITCHES·········································· 18-13
CARBURETOR DISASSEMBLY/INSPECTION··············6-9 HEADLIGHT ································································· 18-5
CARBURETOR INSTALLATION ····································6-7 HEADLIGHT AIM·························································· 3-15
CARBURETOR REMOVAL ············································6-5 HORN ········································································· 18-17
CENTER COVER····························································2-6 HYDRAULIC BRAKE SPECIFICATIONS······················· 1-8
CENTERSTAND ···························································2-17 IGNITION COIL ······························································ 4-8
I
CHAIN CASE ································································2-16 IGNITION CONTROL MODULE (ICM)··························· 4-9

CHARGING SYSTEM INSPECTION ····························17-6 IGNITION SWITCH····················································· 18-12
CHOKE OPERATION ·····················································3-5 IGNITION SYSTEM INSPECTION ································· 4-5
CLUTCH········································································11-9 IGNITION SYSTEM SPECIFICATIONS ························· 1-5
CLUTCH SYSTEM························································3-16 IGNITION TIMING ························································ 4-10
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS ····1-7 INLET PIPE ·································································· 6-17
COMBINATION METER ···············································18-7 KICKSTARTER··························································· 12-18
K
COMPONENT LOCATION LEFT CRANKCASE COVER········································ 10-4

L
ALTERNATOR STARTER CLUTCH ························10-2 LEFT CRANKCASE REAR COVER····························· 2-15

CLUTCH/GEARSHIFT LINKAGE·····························11-2 LIGHTING SYSTEM INSPECTION ······························ 18-4
CRANKSHAFT/TRANSMISSION/KICKSTARTER···12-2 LIGHTS/METERS/SWITCHES SPECIFICATIONS········ 1-9
CYLINDER HEAD/VALVES ·······································8-2 LOWER SIDE COVER ··················································· 2-6
CYLINDER/PISTON ···················································9-2 LUBRICATION & SEAL POINTS·································· 1-13
ENGINE REMOVAL/INSTALLATION·······················13-2 LUBRICATION SYSTEM DIAGRAM ······························ 7-2
FRONT WHEEL/SUSPENSION/STEERING ···········14-2 LUBRICATION SYSTEM SPECIFICATIONS················· 1-5 20
FUEL SYSTEM···························································6-2 LUGGAGE BOX ··························································· 2-10
HYDRAULIC BRAKE················································16-2 MAIN PIPE COVER························································ 2-7
M
REAR WHEEL/BRAKE/SUSPENSION ····················15-2 MAINTENANCE SCHEDULE ········································· 3-3

CRANKCASE ASSEMBLY ·········································12-17 MANUAL CLUTCH SYSTEM ······································· 1-25
CRANKCASE BREATHER ·············································3-5 MASTER CYLINDER···················································· 16-9
CRANKCASE SEPARATION········································12-5 MODEL IDENTIFICATION ············································· 1-2
CRANKSHAFT······························································12-6 NUTS, BOLTS, FASTENERS······································· 3-16
N
CRANKSHAFT/TRANSMISSION/KICKSTARTER OIL PUMP ······································································ 7-4

O
SPECIFICATIONS ··························································1-7 OIL STOPPER PLATE ················································· 8-22

CYLINDER COMPRESSION TEST································8-5 PASSENGER FOOTPEG HOLDER····························· 2-15
P
CYLINDER HEAD ·························································8-10 REAR BRAKE ···························································· 15-11

R
CYLINDER HEAD COVER ·············································8-5 REAR FENDER ···························································· 2-11

CYLINDER HEAD/VALVES SPECIFICATIONS ·············1-6 REAR WHEEL ······························································ 15-5
CYLINDER/PISTON························································9-4 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS
CYLINDER/PISTON SPECIFICATIONS·························1-6 1-8
DRIVE CHAIN ·······························································3-11 REGULATOR/RECTIFIER ··········································· 17-7
D
ELECTRIC STARTER SYSTEM SPECIFICATIONS······1-5 RIGHT CRANKCASE COVER ····································· 11-5

E
EMISSION CONTROL SYSTEMS································1-24 SEAT ·············································································· 2-8

S
ENGINE & FRAME TORQUE VALUES··························1-9 SECONDARY AIR SUPPLY SYSTEM

ENGINE IDLE SPEED ··················································3-10 FUEL SYSTEM ························································ 6-14
ENGINE INSTALLATION··············································13-6 MAINTENANCE ······················································· 3-10
ENGINE OIL····································································3-8 SEPARATE AIR FILTER ·············································· 6-16
20-1
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INDEX
SERVICE INFORMATION BATTERY/CHARGING SYSTEM····························· 17-2
ALTERNATOR STARTER CLUTCH ······················· 10-3 ELECTRIC STARTER SYSTEM ································ 5-2
BATTERY/CHARGING SYSTEM ···························· 17-3 IGNITION SYSTEM···················································· 4-2
CLUTCH/GEARSHIFT LINKAGE ···························· 11-3 SYSTEM LOCATION
CRANKSHAFT/TRANSMISSION/KICKSTARTER ·· 12-3 BATTERY/CHARGING SYSTEM····························· 17-2
CYLINDER HEAD/VALVES······································· 8-3 ELECTRIC STARTER SYSTEM ································ 5-2
CYLINDER/PISTON ·················································· 9-3 IGNITION SYSTEM···················································· 4-2
ELECTRIC STARTER SYSTEM································ 5-3 LIGHTS/METERS/SWITCHES ································ 18-2
ENGINE REMOVAL/INSTALLATION ······················ 13-3 THROTTLE OPERATION··············································· 3-4
T
FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 2-3 TORQUE VALUE···························································· 1-9

FRONT WHEEL/SUSPENSION/STEERING··········· 14-3 TRANSMISSION··························································· 12-8
FUEL SYSTEM ·························································· 6-3 TROUBLESHOOTING
HYDRAULIC BRAKE ··············································· 16-3 BATTERY/CHARGING SYSTEM····························· 17-4
IGNITION SYSTEM ··················································· 4-3 CLUTCH/GEARSHIFT LINKAGE····························· 11-4
LIGHTS/METERS/SWITCHES ································ 18-3 CRANKSHAFT/TRANSMISSION/KICKSTARTER··· 12-4
LUBRICATION SYSTEM ··········································· 7-3 CYLINDER HEAD/VALVES ······································· 8-4
MAINTENANCE························································· 3-2 CYLINDER/PISTON ··················································· 9-3
REAR WHEEL/BRAKE/SUSPENSION ··················· 15-3 ELECTRIC STARTER SYSTEM ································ 5-4
SERVICE RULES··························································· 1-2 FRAME/BODY PANELS/EXHAUST SYSTEM··········· 2-3
SHOCK ABSORBER·················································· 15-17 FRONT WHEEL/SUSPENSION/STEERING ··········· 14-4
SIDESTAND ························································· 2-18,3-16 FUEL SYSTEM ·························································· 6-4
SPARK PLUG································································· 3-6 HYDRAULIC BRAKE ··············································· 16-4
STARTER MOTOR ························································ 5-5 IGNITION SYSTEM···················································· 4-4
STARTER RELAY ·························································· 5-9 LUBRICATION SYSTEM ··········································· 7-3
STATOR ······································································· 10-5 REAR WHEEL/BRAKE/SUSPENSION ···················· 15-4
STEERING HEAD BEARINGS····································· 3-17 TURN SIGNAL LIGHT ·················································· 18-5
STEERING STEM ······················································ 14-19 TURN SIGNAL RELAY ··············································· 18-18
SUSPENSION ······························································ 3-16 VALVE CLEARANCE ····················································· 3-7
V
SWINGARM ······························································· 15-12 WHEELS/TIRES ··························································· 3-17

W
SYSTEM DIAGRAM WIRING DIAGRAM······················································· 19-2
20-2

A Few Words About Safety: How To Use This Manual

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HOW TO USE THIS MANUAL

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

HOW TO USE THIS MANUAL

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

© Honda Motor Co., Ltd.

HOW TO USE THIS MANUAL

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use silicone grease.

Use fork or suspension fluid.

SERVICE RULES ··········································1-2 CRANKSHAFT/TRANSMISSION/

IGNITION SYSTEM SPECIFICATIONS ········1-5 REAR WHEEL/BRAKE/SUSPENSION

FUEL SYSTEM SPECIFICATIONS···············1-5 BATTERY/CHARGING SYSTEM

CYLINDER/PISTON SPECIFICATIONS ·······1-6 LUBRICATION & SEAL POINTS ··············· 1-13

CLUTCH/GEARSHIFT LINKAGE CABLE & HARNESS ROUTING················· 1-15

DESTINATION CODE REGION

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SYSTEM SPECIFICATIONS

FUEL SYSTEM SPECIFICATIONS

LUBRICATION SYSTEM SPECIFICATIONS

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

HYDRAULIC BRAKE SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES

FRONT BRAKE HOSE HEADLIGHT ASSEMBLY

FRONT BRAKE HOSE

AIR SUPPLY HOSE

IGNITION SWITCH 2P CONNECTOR

FRONT BRAKE HOSE

MAIN WIRE HARNESS

AIR VENT HOSE

AIR SUPPLY HOSE

AIR VENT HOSE

SEPARATE AIR FILTER

MAIN WIRE HARNESS

AIR SUPPLY HOSE

SPARK PLUG WIRE AIR SUPPLY PIPE

ALTERNATOR/IGNITION PULSE GENERATOR

IGNITION COIL WIRE (Black/ GROUND TERMINAL

SEPARATE AIR FILTER AIR SUPPLY HOSE

FUEL LEVEL SENSOR WIRE

IGNITION CONTROL FUEL HOSES

FUEL LEVEL SENSOR WIRE

MAIN WIRE HARNESS IGNITION CONTROL MODULE (ICM)

MAIN WIRE HARNESS

BATTERY WIRE HARNESS

REAR BRAKE LIGHT SWITCH WIRE

MAIN WIRE HARNESS

IGNITION CONTROL MODULE (ICM)

BATTERY NEGATIVE (–) CABLE BATTERY POSITIVE (+) CABLE

HEAD LIGHT WIRES

HEAD LIGHT ASSEMBLY

BRAKE/TAIL LIGHT WIRE

RIGHT REAR LEFT REAR

BRAKE/TAIL LIGHT UNIT

IGNITION PULSE GENERATOR