2002 HONDA CBR 900F (919) Service Repair Manual

A Few Words About Safety Service Information The ser vice and repai r information conta ined in this manual is intended for use by qualified, professional technicians.

Attempting service o r repai rs without the proper t raining, tools, and equipment could cause inj ury to you or others. It could

also damage the veh icle or create an unsafe condition .

•

This manual describes the prope r methods and procedu res for performing serv ice, maintenance, and repa irs. Som e proce-. dures require the use of specially designed tools and dedicated equipment. Any pe rson who intends to use a replacement part,

service procedure or a tool that is not recom mended by Honda , must determine the risks to their personal safety and the safe operation of the vehicle.

If you need to rep lace a part use gen uine Ho nda parts with t he correct part number o r an equivalent part. We st rong ly recommend that you do not use replaceme nt parts of inferior qu ali ty.

4

For Your Custom er's Saf ety Pro per se rv ice and mainten ance are esse nt ia l to th e cu st o mer's safety and the relia bi lity of the vehicle. Any error o r oversig ht w hile servic ing a ve hicle ca n resu lt in faulty ope ration, damage to t he veh icle, or injury to others.

For Your Safety Because this manual is i ntended for the professional service technician, we do not prov ide warn ings about many bas ic shop safety practi ces (e.g ., Hot parts - wear gloves ). If you have not received shop safety tra in ing or do not feel confident about your knowledge of safe servicing practice, we recommended that yo u do not attempt to perform the procedures described in this manual.

So m e of the most important general service safety preca utions are given be low. How ev er, we cannot wa rn yo u of eve ry conceiva ble hazard that can ar ise in pe rforming service and re pair p rocedures. Only yo u ca n decide w het he r o r not you sho uld pe rform a give n task.

Improper service o r repairs can create an un safe co ndit io n t hat can cause you r custo mer or others to be se rious ly hurt or ki lled.

Follow the procedures and precautions in this manual and othe r service materials carefully.

A WARNING Failu re to properly fo llow instructions and p recautions can cause you to be seriously hurt or killed.

Foll ow the proce dures and precaut io ns in th is ma nua l ca ref ully.

Important Saf ety Precautions

•

Make sure yo u hav e a clear u nder stand ing of all bas ic sho p safety practices and t hat you are wearing ap propriate clothing a n ~ using safety equ ipment. When performing any service task, be especially careful of the fo ll ow ing : Read all of the in structions before yo u beg in, 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 o r face shields any time you hammer, d rill . grind. pry or wo rk 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 w hen necessary, for example g loves or safety shoes. Hand ling hot o r sha rp parts ca n cause severe bu rns o r cuts. Befo re you grab someth ing that loo ks like it can hurt you. stop and p ut on gloves.

Protect you rse lf and others wheneve r you have the vehicle up i n t he ai r. Any time yo u lift the vehicle, eithe r wit h a ho ist o r a jack, make su re that it is always securely supported . Use jack stands.

M ake su re t he eng ine is off befo re yo u beg in any se rv ic ing p roce d u res, unless th e in str ucti on te lls yo u to do ot herwise.

This will hel p elim inat e severa l potent ia l hazards:

,. ,.

Carbon mo noxide poisoning from engi ne exhaust. Be sure t here is adequate ve nt ilation wheneve r you run t he engine.

Bu rn s from hot parts or coo lant. Let the engine and exhau st system cool before working in those area s.

Inj ury from moving parts. If the instruction te lls you to run the engine, be sure you r hands, fingers and clot hing are out o~ the way.

lIII

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful w hen working around gasol ine 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 f lames away from the battery and all fuel-related parts.

HOW TO USE THIS MANUAL This serv ice manual descr ibes the service procedures for the CB900F. Follow t he Maintenance Sched ule (Sect ion 3) reco m me ndat ions to ensu re that th e vehicle is in peak ope rat ing condition .

Perfo rm ing the fir st schedu led maintenance is very important. It compensates fo r the in itial w ear that occurs during the break -in per iod.

Sections 1 and 3 apply to the w ho le motorcycle . Section 2 i llustrates procedures for removal/insta llat ion of components that ma y be req ui red to perfo rm service descr ibed in the follo wing sect ions.

Sections 4 through 19 describe part s of th e motorcyc le, grouped according

to location.

Find the section you want on t his page. then t urn to the table of cont ents on the first page of that section.

Most sect ions start w it h an assembly or syst em ill ust rat ion, service information and trou bles hooting for the section. The sub seq uent pages give detailed proc ed ure.

If you don't kno w the source of the Troub leshooting .

trouble, go

to

sect ion 22,

Your safety, and the safety of others, is very important. To help you make informed decisions we have prov ided safety messages and other information thro ugho ut th is manual. Of course, it is not practica l or poss ible to warn you about all the hazard s assoc iated with servic ing th is vehicle.

You must use your own good judgement.

You w ill find important safety information in a va r iety of fo rms including: • Safet y Labels - on the vehicle and one of • Safety M essages - prece ded by a safety alert symbol thr ee signal words, DANGER, WARNING, or CAUTION .

These signal w or ds mean:

&.

~

You W ILL be KILLED or SERIOUS LY HURT if ~ you don't fo llo w instr ucti o ns. ~

You CAN be KILLED or SERIOUSLY HURT if

~ you do n't foll ow instr ucti ons. ~ : ou C~N be HURT if you

don't follow

~ Instructions.

• Instructions - how to service th is veh icle co rrectly and safel y.

As you read th is manual, you will find info rm at ion that is preceded by a ~~J symbol. The purpose of th is message is to help prevent dama ge to your vehicle, other property, or the environment.

ALL INFORM ATION , ILLUSTRATION S, DIRECTIONS AND SPECIFICAT IONS INCLUDED IN TH IS PUBLICA TION ARE BASED ON T HE LATEST PRODUCT IN FORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTI NG . Honda Motor Co., Lt d . RESERVES THE RIGHT TO M AKE CHA NGES AT ANY TIME WI THOUT NOTICE AND W ITHOUT IN CURRING AN Y OBLIGATION WHATEVER. NO PART OF TH IS PUBLICATION MAY BE REPRODUCED WITHOUT W RITTEN PERM ISSION. THIS M AN UA L IS W RITTEN FOR PERSONS W HO HAVE ACQ UIRED BASIC KNO WLEDGE OF M AINTEN AN CE ON Ho nda M OTORCYCLES, MOTOR SCOOTERS OR ATVS .

Hond a Moto r Co " Ltd, SERV ICE PUBLICATION OFFICE

Dat e of Issue: Decem ber 2001

© Honda M otor Co., Ltd.

SYMBOLS The symbols used through ou t this ma nual sho w specific serv ice procedures . If suppleme ntary in formation is requi red perta ining to the se sy mbols, it w ill be expl ai ned specifica lly in the te xt w ithout t he use of the symbols.

~~

Replace t he partts) with new onets) before asse m bly.

""jill

,

"71

. w::Ji

Use t he recommended engine oil , u nless otherwise spec ified .

Use m ol y bden um oi l soluti on (m ixture of the engine o il and molybde num grease in a rati o of 1:1)

Use multi-purpose grease (Lit hi um based multi-purpose g rease NLGI #2 or eq uivalent

~

Use m ol yb denum disul fide g rease (co ntaini ng more th an 3% m ol y bdenum d isulfi de, NLGI #2 or equ ivale nt .

Exam ple: Mo ly kote~ BR-2 plus man ufactured by Dow Corning U.S.A .

MUlti-purpose M -2 manufactured by Mitsu bishi Oil, Japan

~

Use molybdenum d isulfide paste (con tain ing more t han 40% molybdenum d isulfide, NLGI #2 o r equ iva lent .

Example: M ol v kot e" G-n Past e ma nufactured by Dow Corni ng U.S.A. Hon da Moly 60 (U.S.A. only) Rocol ASP m anufact ured by Rocol Limited, U.K. Roco l Paste man ufactured by Sum ico Lubri cant , Japan

~

Use silicone grease.

0

m

.-"1jIID

I

..

A pply a locking agent. Use a medium strength locking ag ent un less otherwise specified.

App ly sealant.

Use DOT 4 brake f luid . Use the recommended bra ke f luid unless ot herwise specified .

Use fork or suspension fluid .

1. GENERAL INFORM ATION SERVICE RULES

1-1

LUBRICATION & SEAL POINTS

1-18

MODEL IDENTIFICATION

1-2

CABLE & HARNESS ROUTING

1-22

SPECIFICATIONS

1-3

EMISSION CONTROL SYSTEMS

1-35

TORQUE VALUES

1-12

EMISSION CONTROL INFORM ATION

TOOLS

1-17

LABELS

III

1-38

SERVICE RULES 1. Use gen uine Hon da o r Ho nda-reco m me nde d parts and lubric ant s or their eq uivalents. Part s that don't m eet Ho nda 's desig n specifications may cause damage to the motorcyc le.

2. Use the specia l too ls designed fo r t his product t o avoid da m age and inco rrect assembly.

3. Use only m et ric tools whe n serv icing the motorcycle. Metric bolts. nuts and sc rews are not interchangeable with Eng li sh

fasteners .

4. Install new gaskets , O-rings. cotte r pins, and lock plates whe n reassembling.

5. When tightening bolts or nut s, begin with t he larger diameter or inner bolt fi rst . T hen tighten to the specified torque diagonally in inc remental steps unless a particular sequence is specified.

6. Clean parts in clea ning solvent upon disassembly. Lubr icat e any sliding surfaces bef or e reasse mbly.

7. After reassembly, check all parts fo r proper in st all ation and o peration.

8. Rout e all elect ric al w ires as shown o n pages 1 ~ 22 through 1-32, Cable and Harn ess Routin g.

1-1

GENERAL INFORMATION

MODEL IDENTIFICATION

The Vehic le Identi fi cation Num ber (VIN) is located on the left side of the f rame near the steering head.

ENGINE SERIA L NUM BER The engine serial number is stamped on the right side of the upper crankcase.

THROTILE BODY IDENTIFICATION NUMBER

The throttle body identification number is stamped on the intake side of the throttle body as shown.

Th e frame serial number is stamped on the rig ht side of the steering head.

COLOR LA BEL

The color label is attached as shown. When ordering color-coded parts, always specify the designated

color code.

1-2

GENERAL INFORMATION

SPECIFICATIONS r-

GENERAL IT EM

SP ECIFICATIONS

DIM ENSIONS

Overall length Overall width Overal l height Wheelbase Seat height Footpeg height

2,125 m m 183.7 inl 750 mm 129.5 in) 1,085 mm 142.7 inl 1,460 mm 157.5 inl 795 mm 131.3 inl 345 mm 113.6 inl Ground clearance 145 mm 15.7 in) Dry weight Except California type 194 kg 1428 lbs) 195 kg (430 Ibs) California type Curb weight Except California type 218 kg (481 Ibs) California type 219 kg (483 Ibs) 174 kg (384 Ibs) Ma ximum we ight capac ity

FRA ME

Frame type Front suspe nsion Fro nt axle trave l Rear suspension Rear axle travel Fro nt t ire size Rear t ire size Fro nt tire brand

Diam o nd Telescopic fork

109 mm (4.3 in) Swingarm

128 mm (4.7 inl 120/70 ZR 17 158WI, 120/70 ZR 17 M/C 158WI 180/55 ZR 17 173WI, 180/55 ZR 17 M/C 173WI BT56F RADIAL N (Bridgestonel TX 15 (Michelini BT56R RADIAL G (Bridgestonel TX25 (Michelin)

Rear t ire brand

Hydraulic double disc Hyd ra ulic single disc

Front brake Rear brake Caster ang le

25' 98 mm (3.9 in) 19.0 liter (5.02 US gal, 4.18 Imp gall

Trail leng th Fuel tank capacity

ENGINE

Cylinder arrangement Bo re and stroke Displacement Compression ratio Valve trai n

Intake valve

4 cy linders in- line, inclined 30° from vertica l

71.0 X 58.0 mm 12.80 X 2.28 in) 919 em' 156.1 cu-in) 10.8 : 1 Chain driven, DO HC

opens f

at 1 mm

closes

10.04 in) lift

Exha ust valve opens closes Lubrication system

Oil pump type Coo ling system Air filtrat ion Eng ine dry we ight Firing order

10' BTDC 30' A BDC 35' BBDC 5' ATDC Forced pressure and wet sump Trochoid

Liquid cooled Paper element

68 kg (150 Ibs) 1 -2 - 4 - 3

1-3

GENERAL INFORMATION r--'

GEN ERAL (Cant'd) · ITEM

SPECIFICAT IONS

CARBURATIDN

Type Throttle bore

PGM- FI (Programm ed Fuel Injection) 36 mm (1.4 in)

DRIVE TRAIN

Clutch system Clutch operation system Transmiss ion Prima ry reduction Final reduction Gear ratio 1st 2nd 3rd 4th 5th 6th Gearshift pattern

Multi-plate, wet Cable ope rating Consta nt mesh, 6-speeds 1.52 (76/50) 2.688 (43/16) 2.769 (36/13) 2.000126/13) 1.600 124/15) 1.368 126/19) 1.227 127/22) 1.130 126/23) Left foot operated return system, 1 - N - 2 - 3 - 4 - 5 - 6

ELECTRICAL

Ignition system Starting system Charging system Reg ulator/rectifier Lighting system

Computer-controlled digita l transistorized with electric advance Electric starter motor Triple phase output alternator SCR shorted/triple phase, full wave rectification Battery

1-4

GENERAL INFORMATION r-

Unit: m m l inl

LUBRICATION SYSTEM ITEM Engine oil capacity

STAN DARD

SERVICE LIMIT

A fte r draining

3.5 lit er (3.7 US qt, 3.1 Im p qt )

--

After dra ining/filter change

3.6 liter (3.S US qt , 3.2 Im p qt )

--

After di sassembly

4.4 liter (4.6 U S qt . 3.9 Imp qt)

--

Pro Hond a GN4 or HP4 (without m o ly bdenum ad ditives) 4-stroke oil IU SA & Can ada). or Hon da 4-stroke oil (Canada only), o r an equivalent motor o il A PI se rvice classification SG or Higher except oi ls labeled as ene rgy conserving on the API se rvice label.

JASO T903 stan dar d MA Viscosity: SAE 10W-40

Recommended eng ine oil

Oil pr essure at oil pressu re sw itc h

Oil pum p rotor

490 kPa (5.0 kgf/c m ' , 71 psi ) at 6,000 min" (rpm) /(SO' C/ 176' F)

--

- -

Tip clearance

0.15 10.006)

Bod y cl earan ce

0.15 - 0.22 10.006 - 0.009 )

0.35 10.014 1

Side cl earan ce

0.02 - 0.07 10.001 - 0.003 )

0.10 10.0041

0.20 (O.OOS)

- FUEL SYSTEM (Programmed Fuel Inj ection) ITEM Throttle bod y identification number

SPECIFICAT IONS Except California type

GQ34C

Californ ia type

GQ34B

Sta rte r va lve v acu um differe nce

Base thr ott le valv e for synchronizat ion Idle speed Thr ottl e g rip free pl ay Intake ai r t emper ature se nsor re sistance (at 20'C/6S0F )

2664 Pa 120 mm Hg i No .2 1,200 Âą 100 rni n' Ir pm) 2 - 4 mm (1/16 - 3/16 in) 1 - 4 kn

Engine coo lant tempe rature sensor resistance (at 20"Cl68"F)

2.3 - 2.6 kn

Fue l injec to r resistance (at 20'C/6S'F )

11.1-12.3 11

PAIR so leno id v alve resistance (at 20'C/68 'F)

20 - 24 n

Cam pulse generato r peak voltage (at 20'C/68'F)

0.7 V m inimum

Ignitio n pu lse ge nerator peak vo lt age lat 20'C/68'F )

0.7 V m inimum

Man ifold ab so lute pressure at id le Fuel pr essu re at idle Fuel pump flow (at 12 V)

200 - 250 mm Hg 343 kPa 13.5 kgf/c m ', 50 psi) 256 em ' (S.7 US OZ, 9.0 Imp OZ) mi nimum/1 0 seco nds

1-5

GENERAL INFORMATION COOLING SYSTEM SPECIFICATIONS

ITEM Coo lant capacity

Radia tor and e ngi ne

3.2 liter 13 .38 US qt. 2.8 2 Im p qt)

Reserv e tank

0 .8 liter (0.8 5 US q t. 0.70 Imp qt l 108 - 137 kPa 11.1 - 1.4 kqf/crn", 16 - 20 psi )

Rad iat or ca p rel ief pr essur e

-

80 - 84 ' C 1176 - 183 ' F)

Begin to o pe n

Th erm ostat

95 ' C 1203 ' F)

Fully open

~

8 m m (0.3 in) min imu m

Va lve lift

-

Recommended antifre eze

Pro Ho nda Coo lant o r an eq uiva lent high qua lity ethy lene gly-

co l antifreeze cont a ining co rr osio n prote ction inhibito rs spe cificall y recommended for use in aluminum engines Stan dard coo lant conce ntration

r-r-

50 - 50% mi xture w it h soft water Un it' m m (in )

CYLINDER HEAD/VALVES ITEM

STA N DA RD

Cy linde r com pression

1,275 kPa 113.0 kgf/em' , 18 5 psi )

SERVICE LIMIT --

at 350 rnin' (rpm )

Valve clea ra nce -

Cams ha ft

Cam lobe heig ht f-Run out

Valve lifter

Valve , va lve guide

0 .16 ± 0 .03 10.006 ± 0.001 )

- -

EX

0 .25 ± 0 .03 (0.0 10 ± 0.001 )

--

IN

36.040 - 36.280 11.419 - 1.428 )

36 .01 (1.42)

EX

35 .800 - 36 .040 11.409 - 1.419 )

35.77 (1.41 )

- -

0.0 5 10.002 )

Oil clea rance

0.020 - 0.062 10.00 8 - 0.002 5)

Va lve lifter O.D.

25 .978 - 25.993 (1.0228 - 1.0233 )

25.97 11.022)

Valve lifter bore I.D.

26.010 - 26 .0261 1.02 40 - 1.0246)

26.04 (1.025)

4.47 5 - 4.490 10.1762 - 0. 1768 )

4.46 5 (0.1758)

0.1010.004 )

Va lve s te m O.D.

IN EX

4.4 65 - 4.480 10.17 58 - 0.1764)

4.455 (0. 1754)

Valve guide I.D.

IN/EX

4.500 - 4.5 12 10.1772 - 0 .1776)

4.5 40 (0 .1787)

Ste m -ta -gu ide cleara nce

Va lve g uide proj ect ion a bo ve cyl inde r he ad

IN

0.010 - 0.037 10.0004 - 0.001 5 )

0.Q75 10.0030)

I EX

0.020 - 0.04 7 10.0008 - 0.001 9)

0.085 10.0033)

, IN

14.5 - 14.7 10.57 - 0.58)

I

Valve sea t wi dt h Va lve spring free le ngt h I

Cylind er hea d wa rpage

1-6

IN

--

EX

14.8- 15.0 (0.58 - 0.59 )

INIEX

0.90 - 1.10 (0.035 - 0.043)

1.5 10.06)

IN

40 .9 11.61)

40.08 11 .57 8)

EX

40.91 1.61 )

--

40.08 11 .578 )

--

0.10 10.004)

GENERAL IN FORMATION r-

Unit : mm (in)

CLUTCH/GEARSHIFT LIN KAGE ITEM

STANDARD

Clutch lever free pla y

SERV ICE LIMIT

-

10 - 20 (3/8 - 13/1 6 )

Clutch

Spring fre e le ngth

48.8 (1.92 )

47.5 (1.87)

Disc thickness

2.92 - 3.08 (0.1 15 - 0.121)

2.6 (0.10 ) 0.30 (0.012 )

-

Plate w arpage

1. 0.

24.994 - 25.004 (0.98 40 - 0.9844)

25.0 1 (0.98 5)

0.0.

34.975 - 34.99 1 (1.377 0 - 1.3776)

34.97 (1.377)

Ma inshaft 0 .0. at clutch outer guide

24.980 - 24.993 10.9835 - 0.9840)

24.96 (0.983)

1.0.

12.000 - 12.021 (0.472 4 - 0.4733)

12.03 (0.47 4)

Claw thickness

5.93 - 6.00 (0.233 - 0.236)

5.9 (0.23 )

Shift fork shaft 0 .0.

11.957 - 11.968 (0.4707 - 0.47121

Clutch ou te r gu ide

Shift fo rk, fork s haft

I

11.95 (0.470) Unit: mm (in)

r

ALTERNATOR/ STARTER CLUTCH STANDARD

ITEM

51.699 - 51 .718 (2.0354 - 2.0361)

Start e r dr iven gear boss 0 .0.

Cylinde r

Piston , piston rings

ST AN DARD

1.0 .

51.684 (2.0348)

Unit" mm (in)

- CRANKCASE/P ISTO N /CYLI ND ER ITEM

SERV ICE LIMIT

71.000 -7 1.0151 2.79 53 - 2.79631

SERV ICE LIMIT

71.10 12.795 )

Out of round

-

0.10 (0.0041

Taper

-

0.10 (0.004 )

Wa rpa ge

-

0.05 10.002)

Piston m ark directio n

" IN " mark facing towa rd the intake side

Piston 0 .0 .

70.965 - 70.985 (2.7939 - 2.794 7)

Piston 0 .0 . measurement point

15 mm (0.6 in) from bo ttom of s kirt

70.90 (2.79 1) -

Piston pin bore 1.0 .

17.002 - 17.008 (0.669 4 - 0.66961

17.03 (0.670 )

Pist on pin 0 .0.

16.993 - 17.000 (0.6690 - 0.66931

16.98 (0.669)

Piston-to-piston pin clearance

0.002 - 0.015 (0.0001 - 0.0006 )

-

Piston ring -to-ring g roo ve clea rance

Top

0.030 - 0.065 (0.00 12 - 0.0026 )

0.08 (0.003)

Secon d

0.015 - 0.045 (0.0006 - 0.001 8 )

0.07 (0.003)

Piston ring end gap

Top

0.28 - 0.38 (0.0 11 - 0.0 15)

I 0.5 (0.02)

Se cond

0.40 - 0.55 (0.01 6 - 0.022 )

0.7 (0.03)

Oil (side rail)

0.2 - 0.7 (0.0 1 - 0.03 1

0.9 (0.041

Cyli nder- to-piston clea rance

0.015 - 0.050 (0.0006 - 0.0020)

Connect ing ro d small end 1.0.

17.016 - 17.034 (0.6699 - 0.6706 )

Connectin g rod -to-pist on pi n clearance

0.016 - 0.04 1 (0.0006 - 0.00 16)

Crankpi n oil clearance

I 0.030 - 0.052 (0.0012 - 0.0020)

17.0 4 (0.67 11

0.06 (0.002)

1-7

GENERAL IN FORM AT ION r-'

Unit: mm (in)

CRANKSHAFT/TRANSM ISSION ITEM

Cra nks ha ft

Transmiss ion

STANDARD

0.05 - 0.20 (0.002 - 0.008)

Runout

-

0.30 (0.0 12)

M ain journa l oi l clearance

0.017 - 0.035 (0.0007 - 0.00 14)

0.0 4 (0.002)

28.000 - 28.021 (1.1024 - 1.10321

28.04 (1.104)

Ge a r 1.0 .

M5, M6 Cl

Bus hing 0 .0 .

Bus hing 1.0.

Gear-to-bushing clea rance

Ma ins haft 0 .0.

0.30 (0.012 )

24.000 - 24.02 1 (0.9449 - 0.95 471

24.0 4 (0.946)

31.000 - 31.025 (1.2205 - 1.22 151

31.04 (1.2221

M5, 6

27.95 9 - 27.980 (1.1007 - 1.1016)

27.94 (1.1001

C2

30.955 - 30.980 (1.2187 - 1.2197)

30.93 (1.2181

C3,4

30.950 - 30.97 5 (1.2185 - 1.2195 )

30.93 (1.218)

M5

24.985 - 25.006 (0.98 37 - 0.984 5)

25.02 (0.985)

.

C2,3,4

C2

27.985 - 28.006 (1.1018 - 1.1026 )

28.02 (1.103)

M5, 6

0.020 - 0.062 (0.0008 - 0.0024)

0.10 (0.004)

C2

0.020 - 0.070 (0.0008 - 0.0028)

0.11 (0.004)

C3,4

0.02 5 - 0.075 (0.0010 - 0.0030)

0.11 (0.004)

M5

24.967 - 24.980 (0.9830 - 0.983 5)

24.96 (0.983)

24.980 - 24.993 (0.9835 - 0.9840)

24.96 (0.983 )

Countershaft 0 .0 . C2

27.967 - 27.980 (1.1011 - 1.1016)

27.96 (1.101)

Bush ing-to-s haft

M5

0.005 - 0.039 (0.0002 - 0.00 15)

0.08 (0.003)

cleara nce

C2

0.005 - 0.039 (0.0002 - 0.0015)

0.08 (0.003)

Clutch outer guide

•

1-8

SERV ICE LIMIT

Side clea rance

GENER A L INFORMATI ON Unit : m m (in)

- FRONT WHEEL/SUSPENSION/STEERING ITEM

STANDARD

--

Minim um ti re t read dep th

Cold tire pressure

Driver on ly

250 kPa (2.50 kgl/em ' , 36 ps i)

Driver and passenger

250 kPa (2.50 kgl/em ' , 36 psi)

- -

2.0 (0.08)

Axia l

--

2.0 (0.08)

- -

60 g (2.1 oz) max.

Spring Iree length

282.3 (11.1)

276 .7 (10.89)

-Pro Hon da Suspension Fluid 55-8

Flu id level

155( 6.1)

Fluid capacity

463 ~ 2.5 em ' (15.7 ~ 0.08 US 16.3 ~ 0.09 Im p OZ ) 10 - 15 N' m (1.0 - 1.5 kgf)

OZ,

--- - -

Unit mm (in)

- REAR WHEEL/SUSPENSION ITEM

STA NDARD

--

Min imu m t ire t read dept h

SERVICE LIMI T 2.0 (0.08)

Dr iver o nly

290 kPa (2.90 kgf/em ' , 42 psi )

--

Dr iver and passeng er

290 kPa (2.90 kgl/em' , 42 psi)

--

--

0.2 (0.01)

Rad ial

- -

2.0 (0.08)

Axial

--

2.0 (0.08)

- -

60 g (2.1 OZ) max.

Axle runout

Wheel balance w eight Drive chain

0.20 (0.008)

Recom m ended for k flu id

Steering head bea ring pre -load

Wheel rim ru nout

--

- -

Tube runout

Cold ti re pressure

--

Radial

Wheel balance we ight

Fork

1.5 (0.06)

0.2 (0.01)

Axle ru nout Wheel rim runout

SERVICE LIM IT

Size/li nk

Slack

DID

DID50VA8-114LE

--

RK

RK50HFOZ5-114LE

--

30 - 40 (1.2 -1.6)

--

1-9

GENERAL IN FORMATION r-'

Unit: mm (in)

HYDRAULIC BRAKE ITEM Front

ST ANDARD

Rear

DOT 4

Brake disc thick ne ss

4.3 - 4.7 (0.17 - 0.19)

3.5 (0.14)

--

0.3 (0.012)

M aster cylinder I.D.

14.000 - 14.043 (0.5512 - 0.5529)

14.055 (0.5533)

Master piston 0 .0 .

13.957 - 13.984 (0.5495 - 0.5506)

13.945 (0.5490)

30.230 - 30.280 (1.1902 - 1.1921)

30.29 (1.193)

Cali per cylinde r 1.0.

A 8

27.000 - 27.050 (1.0630 - 1.06501

27.06 (1.065)

Cali per piston 0 .0.

A

30.148 - 30.198 (1.1869 - 1.1889)

30.14 (1.187)

8

26.918 - 26.968 (1.0598 - 1.06 17)

26.91 (1.059)

--

Specif ied bra ke fl uid

DOT 4

Brake disc t hickness

4.8 - 5.2 (0.19 - 0.20)

4.0 (0.16 )

--

Brake disc runout

r

--

Specified brake fl uid

Brake disc runcut

SERV ICE LIMIT

0.30 (0.012)

M aster cy li nde r 1.0.

12.700 - 12.743 (0.49999 -1J.5017)

12.755 (0.5022 )

Ma ster pisto n 0 .0.

12.657 - 12.684 (0.4983 - 0.4994)

12.645 (0.4978)

Calipe r cyli nder 1. 0 .

38.180 - 38.230 (1.053 - 1.505)

38.24 (1.506)

Caliper piston 0 .0 .

38.098 - 38.148 (1.4999 -1 .5019)

38.09 (1.5001

BATTERY/CHARGING SYSTEM ITEM

Battery

SPECIFICATIONS

Capacity

12V - B.6 Ah

Current leak age

1.2 rnA max .

Voltage (20' C/68"F)

Charging current

Fully charge d

13.0 - 13.2 V

Needs cha rging

Below 12.3 V

Norm al

1.2 N 5- 10 h

Qui ck

Alternator

Capacit y

5.0 N l h 0.38 kW/5,000 m in" (rp m)

Cha rg ing coil resistance (20' C/68'F)

0.1 - 1.0 Q

IGNITION SYSTEM ITEM

Spark plug

SPECIFICAT ION S

NGK OENSO

Spark plug gap

CR8EH,9 (Standard) I CR9EH,9 (Fo r hig h speed running) U24FER9 (Standard ) / U27FER9 (For high run ni ng) 0.8 - 0.9 mm (0.03 - 0.04 in)

Ig nitio n coil peak vo ltage

100 V mi nimum

Ig nit ion pulse generator peak vo ltage

0.7 V minimum

Ignition timi ng ("F" mark)

8' BTOC at id le

1-10

GE NERAL IN FORMATION Un it· mm (in)

ELECTRIC STARTER ITEM

I

STANDARD

I 4.5 (0.18)

12.0 - 13.0 (0.47 - 0.51)

Starter motor brush length

SERVICE LIMIT

LIGHTS / METERS/SWITCHES SPECIFICATIONS

ITEM Bulbs

Headli ght

Hi

12V- 60 W

La

12V - 55 W 12V - 21/5 W X 2

Brake/t ail light Turn signal light

License light

Fuse

12V -23/8WX2 12V-21 W 12V - 5 W

Inst rum e nt ligh t

12V-l .7W X3

Turn signal ind icato r

12V-l .7 W X 2

High beam ind icator

LED

N eut ral indicato r

LED

Oil pressure indi cator

LED

PGM-FI warn ing indicator

LED

Fue l reserve indi cator

LED

M ain fuse

30 A

PGM -FI fu se

20 A

Sub f use Tachometer peak voltage

ECT senso r resistr ati o n

Front Rear

80 ' C 120 ' C

20 A X 1, 10A X 4 10.5 V minimum

2.1 - 2.6 k n 0.62 - 0.76 k

n

1-11

GENERAL INFORMATION

TORQUE VALUES FASTENER TYPE 5 mm hex bolt and nut 6 mm hex bolt and nut 8 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut

• •

I

I

I

TORQUE N'm (kgf'm, lbf-ft)

FASTENER TYPE

510.5 ,3.6) 10 11 .0,7 ) 22 12.2, 16) 34 13.5,25) 54 15.5,40)

5 mm screw 6 mm screw 6 mm flan ge bolt 18 mm head , small flange) 6 mm f lange bolt (8 mm head , la rge flange) 6 mm flange bo lt (10 mm head ) and nut 8 mm flange bolt and nut 10 mm f lange bolt and nut

TO RQUE Nsm Ik qf-m, Ibf·ftl 4 (0.4, 2.9) 9 (0.9, 6.5) 10 11.0,7) 12 (1.2, 9) 12 11 .2,9) 26 (2.7, 20) 39 (4.0, 29)

Torque specifications listed be low are for im portant fastener s.

Others should be tightened to standard torqu e values listed above .

NOTES: 1. A pply sealant to th e th reads .

2. A pply a lockin g agent to the threads.

3. Stake.

4. App ly oi l to t he threads and flan ge surface.

5. U-nut.

6. ALOe bolt/screw : replace w ith a new one.

7. Ap ply g rease to th e threads.

8. A pply m oly bdenu m disul fide oil to t he th reads and seating surfa ce 9. CT bo lt ~

ENG INE ITEM MAINTENAN CE: Spark pl ug Tim ing hole cap Engine oil fi lter cartridge Engine oil drain bolt LU BRICATION SYSTEM : Oil main gal lery sealing bolt (20m m) Oil pump cover bolt Oil cooler bolt Ifilter boss) FUEL SYSTEM (Pro gra mmed Fuellnjecti onl: ECT IEng ine Coolant Temperature)/thermo sensor Thro ttle body insulator ba nd screw Starter val ve lock nut Starter valve cable stay screw Pressure regu lator mounting bolt COOLIN G SYSTEM : Wa ter pump cover flang e bolt ENG INE M OUNTING: Drive sprocket special bolt

1-12

Q'TY

THREAD DIA.(mml

TORQUE N'm Ik qf-rn, Ibf·ftl

4 1 1 1

10 45 20 12

12 (1.2, 91 18 (1.8, 13) 26 (2.7, 20) 29 (3.0, 22)

NOTE 7 NOTE 4

1 1 1

20 6 20

29 (3.0, 22) 810 .8,5.8) 64 16.5,47)

NOTE 2 NOT E 9 NOTE 4

1 8 4 4 2

12 5 10 3 6

23 12.3, 17) See page 1-14 2 10.1 8,1 .3) 1 (0.09, 0.7) 10 11.0,7)

2

6

12 (1.2, 9)

1

10

54 (5.5, 40)

REMARKS

NOTE 9

GENERAL IN FORMATION ~

ENGINE (Cont'd) ITEM

Q'TY

THREAD DIA. (mm)

TORQUE N'm (kgf. m, Ibf·ft)

10 20 6 3 4 4 2 8

9 6 6 6 6 7 6 8

48 (4.9, 35) 12 (1.2,9) 10 (1.0, 7) 12 (1.2, 9) 12(1.2,9) 20 (2.0, 14) 12 (1.2, 9) See page 1-14

1 5 1 1 1 1

22 6 6 8 6 8

128 (13.1, 95) 12 (1.2, 9) 15 (1.5, 11) 23 (2.3,17) 12 (1.2, 9) 22 (2.2, 16)

4 6 1 1

6 8 10 6

12 (1.2, 9) 16 (1.6, 12) 103 11 0.5, 76) 10 (1.0, 7)

2 2 10 1 14 2

6 6 9 10 6 8

12 (1.2, 9) 12 (1.2, 9) 27 (2.8,20) 39 (4.0, 29) 12 (1.2, 91 24 (2.4, 17)

NOTE 2 NOTE 2 NOTE 8

8

8

34 (3.5, 25)

NOT E 4

6 1

8 10

10 (1.0, 7) 59 (6.0, 43)

1

6

12 (1.2, 9)

1 1 1

PT 1/8 4 10

12 (1.2, 9) 2 (0.2, 1.4) 12 (1.2, 9)

REMARKS

CYLINDER HEADIVALVES : Cylinder head mounting bolt/washer

Camshaft holder flange bolt Cyl inder head cover bo lt

Breather plate flange bo lt PAIR reed va lve cove r SH bol t Cam sprocket flange bolt Cam pu lse ge ne rator rotor flange bolt

Cy lin der head st ud bo lt (exhaust pipe stud bo lt) CLUTCH/GEARSHIFT LINKAGE: Clutch cente r lock nut

Clutch spr ing bo lt Oil pump d riven sp rocket bo lt Sh ift drum cente r socket bolt Sh ift drum stopper arm pivot bolt Gearshift spindle return spring pin

NOTE 8 NOTE 4 NOTE 2, 9 NOTE 9 NOTE 2 NOTE 2

NOTE 3, 4 NOTE 2 NOT E 2

ALTERNATOR /STARTER CLUTCH: Alt ern ato r stator socket bolt Starter clutch outer socket bolt

Flywheel flange bo lt Starter w ire clamp flange bolt

CRANKCASE/TRANSMISSION: Ma inshaft bearing set plate bo lt Gearshift drum bear ing /fork shaft set bol t Cran kcase bo lt (Ma in journal )

Crankcase bo lt Crankcase bo lt Crank case bolt

NOTE 2 NOT E 4 NOTE 9

CRANKSHAFT/PISTON/CYLINDER: Connecti ng rod nut

IGNITION SYSTEM : Igniti on pulse generato r rotor cover bolt Ign ition pulse generator rotor special bo lt

ELECTRIC STARTER: Starter m oto r te rminal nut

LIGHTS/METERS/SWITCHES: Oil pressure sw itch Oil pre ssure switch wire terminal bo lt/washe r Ne utral switch

NOT E 1

1-1 3

GENERAL INFORMATION

Insulator clamp (Throttle body side) : 7 ± 1 mm (0.3 ± 0.04 in)

Exhaust pipe stud bolt:

42.5 ± 0.5 mm (1.67 ± 0.02 in)

1-14

Insulator clamp (Cylinder head sidel: 7 ± 1 mm 10.3 ± 0.04 in)

GENERAL INFORMATION FRAME - - -- - - - - - - -----,--- --.---- --,------ - - - - - , -- -----, ITEM FRAME BODY PANELS /EXHAUST SYSTEM: Exhaust pip e joint flang e nut Exhaust pipe moun ting nut M uffler mo unting flang e bolt Muffler band flange bol t FUEL SYSTEM IPro gr am m ed Fuel Injection): Fuel tube banjo bolt Ifuel tank side) Fuel tube sealin g nut (t hrottle bod y side) Fuel pump mounting nut

O'TY

THREAD DIA. lmml

8 1 2 3

6 8 8 8

20 27 27 27

1 1 6

12 12 6

22 (2.2, 16) 22 12.2, 16) 12 11 .2,9)

1 3

5 5

3 10.27, 2.0 ) 5 (0.5 , 3.6)

NOTE 2

2 1 1 1

10 10 10 5

50 (5.1, 37) j 50 (5. 1, 37 ) 50 (5.1, 37 ) 20(2.0,14 )

See page 7-10

2 12 1 4 1 1 2 2 2 2 1 1 1 1

6 6 14 8 6 6 8 39 8 10 26 26 24 6

10 (1.0, 7) 20 (2.0 , 14) 59 16.0,43) 22 12.2, 16) 12 11.2,9 ) 12 11 .2,9) 20 12.0, 14) 22 12.2, 161 22 12.2, 161 39 14.0,29 1 25 12. 5, 181

NOTE 6 NOT E 6

TOROUE N'm (kg f'm, Ibl ·ttl

(2.0, (2.8, (2.8, (2.8,

REMARKS

14) 20 ) 20 ) 20 )

FUEL PUMP MO UNTI NG NU T

COOLING SYSTEM: Cooling fan mounting nut Fan motor m ounting nut ENG INE MOUNTING : Front eng ine hang er bolt/nut Rear upper engine hanger bolt/nu t Rear low er engin e hanger bolt/ nut Gear shift linkage bolt FRONT WH EEL/SUSPENSION/STEERING: Handlebar we ight mounting screw Front brake disc bolt Front axle bolt Fro nt axle holder flange bolt Front bra ke hose clam p fl ange bo lt lIeft front) Front brake hose clamp flange bolt Irig ht front ) Fork socket bo lt Fork bol t Fork top brid ge pin ch socket bol t Fork bottom bri dg e pinch flange bolt Steering beari ng adjusting nut Steering bearing adjusting nut lock nut Stee ring stem nut Front brake hose clamp bo lt Isteering stem )

NOTE 2

See page 13·29

103110.5, 76 ) 101 1.0,7)

1-15

GENERAL INFORMATION r-

FRAM E (Cant'd) ITEM REAR WH EEL/SUSPENSION : Rear brake disc bolt Final driven sprocket nut Rear axle nut Rear shock absorbe r upper mounting bolt Rear shock absorber upper mounting nut Drive chain slider flange bolt Swi ngarm pivot nut HYDRAULIC BRAKE: Front master cylinder reservoir cap screw Front brake lever pivot bolt Front brake lever pivot nut Front brake light switch screw Front maste r cylinder mounting bolt Front brake caliper assemb ly torx bolt Front brake caliper mounting flange bolt Rear master cylinder push rod lock nut Rear master cylinder mounting bolt Rear brake cal iper bracket bolt Rear brake caliper pin bolt Pad pin Pad pin plug Brake hose oil bolt Brake caliper bleeder valve Step holder mounting bolt Rear master cylinder hose joint screw LIGHTS/METERS/SWI TCHES: Side stand sw itch bolt Ignition switch mounting bolt Fan motor switch OTHERS: Side stand pivot bolt Side stand pivot lock nut

1-16

Q'TV

THREAD DIA. (m m )

TORQ UE N'm {kqf-rn, Ibl·lt)

4 5 1 1 1 2 1

8 12 18 10 10 6 18

42 (4.3, 31) 108 (11.0,80) 93 (9.5, 69) 42 (4.3, 31) 42 (4.3,31 ) 9 (0.9, 6.5) 93 (9.5, 69)

2 1 1 1 2 8 4 1 2 1 1 3 1 3 3 4 2

4 6 6 4 6 8 8 8 6 8 12 10 10 10 8 8 6

1 (0.1,0.7) 1 (0.1, 0.7) 6 (0.6, 4.3) 1 (0.1, 0.7) 12 (1.2, 9) 32 (3.3, 24) 30 (3.1,22) 17 (1.7, 12) 10 (1.0, 7) 23 (2.3, 17) 27 (2.8, 20) 17 (1.7, 12) 3 (0.3, 2.2) 3413.5,25) 6 (0.6, 4.3) 27 (2.8, 20) 10 (1.0, 7)

1 2 1

6 8 16

10 (1.0, 7) 25 12.5, 18) 1811 .8,13)

1 1

10 10

10 (1.0, 7) 39 (4.0, 29)

REMARKS

NOTE 6 NOTE 5 NO TE 5 NOTE 5 NOTE 6

NOTE 2 NOT E 6

NOTE 6 NOTE 1

GENERAL INFORMATION

TOOLS NOTES: 1.

2.

3.

4.

Equivalent commercially available.

Alternative tool.

Newly designed tool.

Not available in U.S.A DESCRIPTION

Fuel pressure gauge

Oil pressure gauge set Oil pressure gauge attachment Clutch center holder Flywheel holder Rotor puller Attachment, 32 X 35 mm Attachment, 37 X 40 mm Attachment, 42 X 47 mm Attachment, 52 X 55 mm Attachment, 28 X 30 mm Attachment, 22 X 24 mm Inner driver C Attachment, 25 mm I.D. Outer driver, 37mm Pilot, 17 mm Pilot, 20 mm Pilot, 35 mm Pilot, 28 mm Bearing remover shaft Bearing remover head, 20 mm Driver Valve spring compressor Valve seat cutter Seat cutler, 27.5 mm 145' IN/EX) Flat cutter, 27 mm 132' EX) Flat cutter, 30 mm 132' IN) Interior cutter, 24 mm 160' IN/EX) Cutter holder, 4.5 mm Snap ring pliers Steering stem socket Ball race remover set - Attachment, 40 mm - Driver shaft Ball race remover, 40 x 245L Ball race remover, 44.5 mm Steering stem driver Fork seal driver weight Fork seal driver attachment Valve spring compressor attachment Oil filter wrench Peak voltage adaptor

I

TOOL NUMBER 07406-0040003 07506-3000000 07510-MJ10100 07724-0050002 07725-0040000 07733-0020001 07746-0010100 07746-0010200 07746-0010300 07746-0010400 07746-1870100 07746-0010800 07746-0030100 077 46-0030200 07ZMD-MBW0200 077 46-0040400 077 46-0040500 077 46-0040800 077 46-00411 00 07GGD-0010100 077 46-0050600 07749-0010000 077 57-0010000

REMARKS NOTE NOTE NOTE NOTE NOTE NOTE

2: 07406-0040002 1 1 1 1 2: 07933-3950000

NOTE 1

07780-0010200 07780-0013300 07780-0012200 07780-0010600 07781-0010600 07914-SA50001 07916-3710101 07953 -MJ 10000 07953-MJ10100 07953-MJ 10200 07953-4250002 07946-3710500 07946-M BOOOOO 07947-KA50100 07946-KA40200 07959-KM30101 07HAA-PJ70100 07HGJ-0020100

Tappet hole protector Drive chain tool set

07HMG-MR70002 07HMH-MR10103

Valve guide driver Valve guide reamer, 4.508 mm Compression gauge attachment Inspection adaptor ECM test harness Valve guide driver Driver shaft 8 Christie battery chrger

07HMD-ML00101 07HMH-ML00101 07RMJ-MY50100 07XM Z-MBW0101 07YMZ-0010100 077 43-0020000 07964-MB00200 MC1012/2

NOTE 2: 07916-3710100

NOTE 2 NOTE 3: Peak voltage tester (U .S.A. only) NOTE 3: 07HMH -MR1010B or 07HMH-MR1010C (U.S.A. only)

NOTE 1

Two required

U.S.A . only

REF. SEC.

5 4 4 9 10 10 9, 14 9, 14 13, 14 14 14 14 11 12 14 9, 14 13, 14 9 14 13, 14 13, 14 9, 13, 14 8 8

15 13 13

13 13 13 8 3 5, 17, 19 8

3

8 8 8 20 5 8 12 17

1-17

GENERAL INFORMATION

LUBRICATION & SEAL POINTS ENGINE LOCATION

MATERIAL

Crankcase ma ting surface

~

..

REMARKS

Liquid sealant (Three Bond 1207B or equiva lent)

---.----------- -- -- - -- ------------------------- -- -- - -- -- -- - ---------- -- -----------~- -- - - - - - -- - ---------- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

E ~ Em

~

0

E ~ Em

~ci

....

!il!l 0

0

~ ci

I

....

~~

I

~ci l

- - + -,fiI-- - - - - ---f,i!'

0

10

~l

[

~

- ,

"' 0

--

0

0

~

c9

, €I

@"\

I @

@

ci' Oil pressu re switch threads

..

Do not apply seala nt to the thread head 3 - 4 mm (0.1 - 0.2 in) .

..

Ignition pulse gene rator cover bolt threads

Appl y sealant to th e thread head 6.5 e 1 mm

1-18

"'0 ~

I ",

..-

Oil pan mating surface

Marked

E ~ E",

E E ",

LY

"6" ..,..---_ .;C§"-.

...._----------------------······ · · · · · · · · · 1

o

,

' ''' -0

0

I

GENERAL INFORMATION ENGINE (Cant'd) LOCATION Ignition pulse generator grommet ECT (engine coolant temperature sensor) threads Cam pulse generator rotor bolt threads Lower crankcase sea ling bolt threads Cylinder head sealing bolt threads AC generator bolt threads Cylinder head semi-circular Gut-out

MATERIAL Sealant

REMARK S Crankcase mating surface Coating w idth : 6.5 Âą 1 mm

APP LIED POSITION

Main journal bearing surface Piston pin sliding surface Connecting rod bearing surface Connecting rod small end inner surface Crankshaft thrust surface Camshaft lobes/journals and thrust surface Valve stem (valve guide sliding surface) Valve lifter outer sliding surface Clutch outer/primary driven gear slid ing su rface Clutch outer guide sliding surface M3/4, C5, C6 sh ifter gear (shift fork grooves) Starter reduction gea r shaft outer surface

Mol yb denum disulfide oil (a m ixture of 1/ 2 eng ine oil and 1/2 molybdenum disu lfide grease

Piston ring sliding area Oil strainer packing Clutch disc surface Starter o ne-wav clutch sliding surface Connecting rod nut threads Flywheel bolt threads and seating surface Main journa l 8 mm bolt threads and seating surface (after removing anti -rust oil additive) Clutch center lock nut threads Oil filter cartridge threads and a -r ing Camshaft holder bo lt threads and seating surface Cam chain tens ioner, tensioner co llar seat ing surface Oi l coo ler center bolt threads Each gear tooth and rotating surface Each bearing Each O-r ing Ot her rotating area and sl iding surface

Eng ine oil

1-19

GENERAL IN FORM AT ION ENGINE (e a nt 'dl LOCATION Timing hole cap threads

I

M ATERIAL M ulti-pu rpose grease

Each oil seallio Lower crankcase sealing bolt threads Cylinder head cover breather plate bolt th reads Cam pulse generator rotor bolt threads Starter one-way clutch outer bolt threads Oil pump driven sprocket bolt threads

Shift drum bearing set plate bolt threads Mainshaft bear ing set plate bolt threads Cam sprocket bolt threads

Shift drum center bolt threads Spindle plate tightening bolt threads Oil filter boss threads

1-20

Locking agent

-) -

-

-

I I

REM ARKS

Coating width: 6.5 e 1 mm

GENERAL INFORMATION ~

FRAME LOCATION Seat catch hook sliding area Front wheel dust seal lips Rear wheel dust seal lips Clutch lever pivot bolt sliding area Rear brake pedal pivot sliding area Gearshift pedal pivot

MATERIAL

REMARKS

Multi-purpose grease

Side stand pivot Steering head bearing sliding surface Steering head dust seal lips Swingarm pivot bearings Swingarm pivot dust seal lips Shock absorber needle bearings Shock absorber dust seal lips Throttle cable A, B outer inside Clutch cable outer inside

Cable lubricant

Handlebar grip rubber inside

Honda bond A, Honda Hand Grip Cement (U.S.A. only or equivalent)

Steering bearing adjustment nut threads

Engine oil

Front brake lever-to-master piston contacting area Front brake lever pivot Rear master brake master piston-to-push rod contacting area Brake caliper dust seals Rear brake caliper boot inside Rear brake caliper pin boot inside

Silicone grease

Brake master piston and cups Brake caliper piston and piston seals

DOT 4 brake fluid

Fork cap O-ring

Pro Honda Suspension

Fork dust seal and oil seal lips

Fluid SS-8

Rear brake reservoir hose joint screw threads Front brake caliper assembly bolt threads Rear brake caliper pin bolt threads

Locking agent

Front fork socket bolt threads

1-21

Thank you very much for your reading.

Please Click Here Then Get More Information.