Trx125 Service Manual Repair 1987-1988 Trx 125.pdf

B7-BB TRX125 FOURT.-._..

IMPORTANT SAFETY NOTICE - - - - - - CAUTION:

0/ severe personal injury or loss 0/ fife if instructions are not foJ/owed.

Indicates a possibility 0/ personal injury or equipment damage if instrllctions are 1101 followed.

NOTE:

Gives helpful information.

Indicates a strong possibility

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe . Please understand that those warnings could not cover atl conceivable ways in which service, whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thor(Jughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.

j

HOW TO USE THIS MANUAL

CONTENTS

Sections 1 through 3 apply to the whole Fourtrax, w hile sections 4 through 17 describe parts of the Fourtrax , grouped ae· cording to location .

LUBRICATION

Find the section you want on this page , then

MAINTENANCE

GENERAL INFORMAn ON

turn to the table of contents on page 1 of that section.

FUEL SYSTEM

Most sect ions start with an assembly or system illustration and all the required specifi ca tions, torque values. general instructions, tools and t roubleshooting for the section. The subsequent pages give detailed procedures .

ENGINE REMOVAL/INSTALLATION

If there is a problem with the Fourtrax and you

don't know the source of the trouble. see section 18, TROUBLESHOOTING .

•

1. GENERAL INFORMATION GENERAL SAFETY

1-1

TORQUE VALUES

1-5

SERVICE RULES

1-1

TOOLS

1-7

MODEL IDENTIFICATION

1-2

CABLE & HARNESS ROUTING

1-9

SPECIFICATIONS

1-3

NOISE EMISSION CONTROL SYSTEM

1- 12

GENERAL SAFETY '4@.iMiiJ!'

1/ (h~ ~ngin~ mu.u be running I() do some work, make sure the area is well-venti/aled. Nel'u run the engine in a closed area.

The exhaust contains poisonou~' carbon monoxide gas thai

Gasoline is extremely flammable and is explosi,·t under certain conditions. Do not smoke or allow flames Of sparks in your work area.

may cause loss 0/ conJciousness and lead to death.

, it The battery generales hydrogen gas which can be highly exp/osil',. Do not smoke or allow flamuor sparkl near the baUery. eSf)«ially while charging it.

The battery electrolyte cQtI(ains SUlfuric acid. PrOW.'1 your eyes. skin and clothing. In cast of contact, flush thoroughly with ""'our and call Q doctor if electro/Yle gt'ls ;n )'Ollr ,)·ts.

SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's design specifications may cause damage to the Fourtrax .

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing this Fourtrax. Metric bolts, nuts and screws are not interchangeable with English fasteners . Use of incorrect fasteners may damage the Fourtrax.

4 . Install new gaskets, O·rings cotter pins, and lock plales, elc. 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 2-3 steps. unless a particular sequence is specified.

6. Clean parts in non-flammable or high flash point solvent upon disassembly.

7. lubricate any sliding surfaces before reassembly .

8. After reassembly, check all parts for proper installation and operation.

9. Route all electrical wires and control cables as shown on page 1-9 through 1-11, Cable and Harness Routing .

1-1

GENERAL INFORMATION

MODEL INDENTIFICATION

11' FRAME SERIAL

(2) ENGINE SERIAL NUMBER The frame serial number is stamped on the bearing holder.

The engine serial number is stamped on the crankcase

lower leh side.

The carburetor identification number is on the carburet or body left side.

1-2

GENERAL INFORMATION

SPECIFICATIONS DIMENSIONS

Overall length Overall width Overall height

1,600 mm (63.0 in) 1,000 mm (39.4 in)

Wheelbase Tread

1,060 730 730 700

970 mm (38.2 in) Front Rear

Seat height Foot peg height Ground cl earance

FRAME

Front Rear

Exhaust valve Valve clearance (Cold) Idle speed CARBURETOR

Type Main jet No. Slow jet No. Pilot screw opening Jet needle clip setting Float level

Semi double cradle (transformation) 5.5xBDC 8.25 x 8 DC 20 x 7.00-8 2.5 psi (17 . 5 kPa, 0.175 kg /eml) AT22 x 10-8- 2.2 psi (15 kPa, 0.15 kg/ em") Internal expanding shoe, 102.0 em' (15.a 1 sq-in) Internal expanding shoe, 92.4 em2 (14.33 SQ-in) 7,5 liter (1.98 US gal. 1.65 Imp gall 1.5 liters (0 .40 US gal, 0.33 Imp gal)

80 o ± 1° 0:1: 10 mm (0 ::t 3/8 in) 32 mm (1.3 in) 136 kg (299.8 Ib)

Type Cylinder arrangement Bore x stroke Displacement Compression ratio Valve train Maximum horse power Maximum torque Oil capacity lUbrication system Cylinder compression Intake valve

mm (27.6 in)

115 mm (4.5 in)

Front tire size, pressure Rear tire size, pressure Front brake, swept area Rear brake, swept area Fuel cap acity Reserve capacity Caster angle Camber angle Toe in Trail length Dry weight ENGINE

rnm (28.7 in)

260 mm (10.2 in)

Type Rim size

mm 141.7 in) mm (28.7 in)

OPENS CLOSES OPENS CLOSES Intake Exhaust

Gasoline, air-cooled 4 -s troke Single cylinder, 25° inclined from vertical 54 x 54.5 mm (2.12 x 2.14 inl 124.8 cc P.61 cu in) 9.0; 1 Overhead camshaft chain driven 9.3 BHPI7,500 rpm 0.96 kg -m/ 6,000 rpm (16.9 ft-lb/ 6,000 rpm) 1.3 liters (1.4 US qt, 1.1 Imp qt) at draining Forced pressure and wet sump 13.3::t. 1.0 kg/c ml 089::t 14.2 psi, 1,330 ± 100 kPa) 0° BTDC 30° ABOC } ,11 mm 11ft 30° BBDC 0° ATDC 0.08 mm (0.003 in) 0.08 mm (0 .003 in ) 1,500::t. 100 rpm Piston valve

#92 -#35--#35 1 - 3/8 turns out 2nd groove from the top 10.7 mm (0.42 in)

1-3

GENERAL INFORMATION DRIVE TRAIN

Clutch Transmission Primary reduction Gear ratio

Wet multi-plate automatic

5·speed constant-mesh with re verse I

"

III IV V Reverse

Gearshift pattern

Ignition Ignition t iming

Alternator Battery Spark plug Spark plug gap

Headlight

Taillight Neutral indicator Reverse indicator

1-4

(71 / 19) (39112) (35116) (31120) (28/2 4 ) (24 /26)

4.593 (3 1, '2 x 32f18) 4 .000 (48 / 12 ) Left foot operated return system, Forward: N - SfL- l - Z- 3-4 Reverse: N - A

Final reduction

ELECTRICAL

3.737 3.250 2.188 1.550 1.167 0.923

Initial Full advance Capacity

CDI 10 0 ± 2° BTDC at idle

28° ± 2° BTDC at 5,000 ± 100 rpm 130W/ S,OOO rpm '2V - BAH NGK: OR8ES·L NO : X24ESA-U 0.6-0.7 mm (0.024 - 0.028 in) 12VA5W/45W 12V- SW 12V-3AW 12V-3AW

GENERAL INFORMATION

TORQUE VALUES ENGINE Item

Q' ty

Cvlinder head cap nut Spark plug Valve adjusting hole cap Valve adjusting screw lock nut Cam sprocket bolt Cam chain tensioner sealing bolt Tensioner pivot bolt Centrifugal clutch lock nut

4 1 2 2 2 1 1 1

Thread dis .

(mmJ

B 12

36 6 6 6 6 16

N·m

kg·m

ft· lb

Remark

28 - 30 12-19 9 - 15

2.B-3.0 1.2-1.9 0.9 - 1.5

20 - 22

Apply oil to cap nut

15 - 18 10 - 14

1.5 - 1.8 1.0 - 1.4

8 - 12

0 .8 - 1.2

10 - 14

1 .0 - 1.4

70 - 80

7.0 - 8 .0

9 - 14 7 - 11 11 - 13

r-- Apply oit to lock nut

7 - 10 6- 9 7 - 10 51 - 58

Apply oil to bolt

fT Apply

oil to lock nut

I L left hand thread

Manual clutch lock nut Clutch adjusting screw lock nut Gearshift return spring pin Starter driven pulley bolt Drum plate center bolt Pulse generator bolt Timing hole cap Oil drain bolt Cylinder head bolt Starter clutch bolt Alternator bolt Cylinder socket bolt Change switch bolt Drive sprocket bolt

1 1 1 1 1 2 1 1 1

3 3 4 1 1

16 B B B 6 5 14 12 6 B 6 6 6 B

50- 60 19 - 25 24 - 30 40 - 50 10 - 14 5- 7 10-14 20-30 10- 14 26 - 30 8 - 12 8 - 12 8 - 12 24-30

5.0-6.0 , .9-2.5 2 .4 - 3 .0 4 .0 - 5.0 1.0 - 1.4 0.5-0.7 1.0 - 1.4 2.0- 3 .0 1.0-1.4 2.6 - 3 .0 0 .8 - 1.2 0 .8 - 1.2 0 .8 - 1.2 2.4 - 3 .0

36 - 43

r

Apply oil to lock nut

14 - 18

17 - 22 29 - 36 7 - 10 4- 5 7-10 14 - 22 7 - 10 19 - 22 6- 9 6- 9 6- 9 17 - 22

f-App ly oi l to bolt

r

SH bolt

r-

SH bolt

1-5

GENERAL INFORMATION FRAME

Itam

Q' tv

Thread die. tmm)

24 40 35 30 70 -

30 48 43 36 80

Front axle nut

2 1 4 8 2

8 10 16 8 10 6 12 10 16

Rear wheel hub nut

8

10

50 - 60

Rear axle nut

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

18 30 30

110 - 150 40 - 50 140 - 150

10

70 - 80

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

70 - 80 35 - 43

Handlebar upper holder bolt Handlebar tower holder nul Steering shaft nut Engine hanger bolt Gearshift pedal bolt Foot peg bolt Front wheel hub nut

Rear brake drum nut Orillen sprocket nut Rear axle bearing holder bolt Tie-rod lock nut Exhaust muffler bolt Exhaust muffler prOteCtor bolt Front mud guard bolt 8all joint castle nut Kingpin nut Steering shaft bushing holder nut Front brake arm nut Rear brake arm nut Knuckle pipe bolt Throttle housing cover screw

..

4 2 1

kg-m

N'm

5

14 - 18

80 - 100 50 - 60 70 - 90

70 - 80 10 - 15

6- 9 35 50 24 8880 -

43 70 30 12 12 100

3- 4

2.4 4 .0 3.5 3 .0 7 .0 -

ft -tb

3.0 4 .8 4.3 3.6 8.0

17-22 29 - 35 25 - 31 22 - 26 51 - 58 10 - 13

, .4 - 1.8

8 .0 - 10.0 5.0 - 6.0 7 .0 - 9 .0 5.0 - 6.0 11 .0- 15.0 4.0 - 5.0 14.0 - 15.0 7.0 - B.O 7.0 - 8.0 3.5 - 4.3 7.0 1.0 0 .S3.5 5.0 2.4 0 .8 0 .8 8 .0 0 .3 -

Remarks

58 - 72

36 51 36 80 29 -

43 65 43 108 36

f- Inner 101 - tOB rOuter 51 - 58

8.0 1.5 0.9 4 .3 7.0 3.0 1.2 1.2 10.0 0.4

51 - 58 25 - 31 51 - 58 7 - 11

4- 7 25 - 31 3S - 51 17 - 22

6- 9 6- 9 58 - 72

2- 3 ..

Torque specifications listed above are for the most Important tIghtening POints. If a torque specif icatIOn the standards given below.

IS

not listed, follow

STANOARD TORQUE VALU ES Item

Torque N-m (kg-m. ft¡lb)

5 mm bolt, nut

4 .5 - 6 (0.45-0.6, 3-41

6 mm bolt, nut

8 - 12 (0.8 - 1.2. 6 - 9)

8 mm bolt, nut 10 mm bolt, nut 12 mm bolt, nut

1-6

18 - 25 (1.8 - 2.5,13-181 30 - 40 (3.0- 4 .0,22-29 ) 50 - SO (5.0-S.0, 3S-43)

Item 5 mm 6 mm fl ange S mm 8 mm 10 mm

screw screw, 6 mm bolt with 8 mm head fl ange bolt, nut flange bolt, nut flange bolt, nut

Torque N-m lkg-m, ft -Ibl 3.5 - 5 (0.35-0.5, 2- 4 ) 7 - 11 (0.7-1.1,5-8) 10 - 14 (1.0 -1.4, 7-10) 24-30 (2.4-3 .0,17-22) 35 - 45 (3.5 - 4.5, 25-331

GENERAL INFORMATION

TOOLS SPECIA L Description

Alternative

Number

Ref. Section

Tire breaker attachment

07GMF- HB30101

Not available in U.S .A .

11

Valve guide reamer, 5.485 mm Bearing remover set, 12 mm

07984 07936 07936 07741 -

or 07984 - 098000A (U.S.A . Only )

6 S S 8 10 10 10 10 10 S 10 12

- bearing remover shaft assy, 12 mm -

remover weight

0980001 1 660001 1660 100 0010201

Bearing remover . 1 5 mm - remover assy, , 5 mm - remover shaft , 15 mm

07936 - KC10DOO

- remover head, 15 mm - remover weight Clutch center holder Attachment, 45 x 50 mm Spanner wrench , 41 mm Attachment, 28 x 30 mm Wrench attachment , 41 mm Shaft protector

07936 - KC10200

07936 - KC10500 Q7936 - KC10 100 07741 - 0010201 07923-9580000 07946 - 6920100 07916 - 9580200 07946 - 1870100 07916-9580400 07960-1870100

Not available in U.S .A. or 07936 - 3710200

Not available in U.S.A.

P-

Not available in U.S.A.

r Of 07936 - 3710200

07916 - 958020A (U.S.A . Only )

11 r 07916 - 9580 10A (U.S.A. Only) r Equiv alent commercially available in U.S.A.

12 S

1-7

GENERAL INFORMATION COMMON Description

Alternative

Number

Float level gauge Flywheel holder

0740 1 - 0010000 07725 - 0040000

Flywheel puller Valve guide driver, 5.5 mm Bearing remover head, 17 mm Bearing remover shaft Valve spring compressor

07733 - 0010000 07742 - 0010100 07746 - 0050500

Attachment, 24 x 26 mm Attachment , 32 x 35 mm

07746 - 0010700 07746 - 0010 100

Attachment. 37 x 40 mm

Attachment, 42 x 47 mm Attachment, 52 x 55 mm Driver

07746 07746 07746 07749 -

0010200 0010300 0010400 0010000

Pilot, 12 mm Pilot. 15 mm Pilot. 17 mm Pilot, 20 mm Pilot. 22 mm Tire breaker set - Breaker arm compressor - Breaker arm

07746 07746 07746 07746 07746 07772 07772 07772 -

0040200 0040300 0040400 0040500 0041000 0050001 0050101 0050200

Ref. Section

4 9

r Equivalent commercially available in U.S.A.

07933 - 2000000

9

07942 - 3290100

6

p ~qUjValent commercially available

07746 - 0050100

in U.S.A.

11 11

07757 - 0010000

07957-3290001

6

'0 8, 10, 11

07949 - 6110000

11

'0 '2 8 , 10, 11.

'2 8

'0

"'0 '0

~Not ",;I,bl,;n U.S.A.

1 1. 12

VA LVE SEAT CUTTE R The valve seat cutters are commercially available in U.S.A. Therefore these cutters are not required in U.S.A. Description Valve Valve Valve Valve Valve

seat cutter. 24.5 mm (EX 45 °) seat cutter, 29 mm (IN 45°) flat cutter. 25 mm (EX 32 °) flat cutter, 30 mm (IN 32°) interior cutter, 30 mm /IN 60°) (EX 60° ) Valve seat cutter holder. 5.5 mm

1-8

Tool number

Ref . Section

07780-0010100 07780-0010300 07780 - 0012000 07780 - 0012200 07780 - 0014000 07780-00 14500 07781 - 0010101

6 6 6 6 6 6 6

GENERAL INFORMATION

CABLE & HARNESS ROUTING

o

NOle the following when routing cables and wire harnesses:

• A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure.

• Do not squeeze a wire against a weld or end of its clamp when a weld-on clamp is used.

X QW

• Secure wires and wire harnesses to the frame with their re spective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses .

• Aoute harnesses so they afe not pulled taut or have excessive slack.

• Protect wires and harnesses with electrical tape or tubes jf they contact a sharp edge or corner .

Clean the attaching surface thoroughly before applying lape.

• 00 not use wires or harnesses with a broken insulators.

Repair by wrapping them with protective tape or replace them.

• Route wire harnesses to avoid sharp edges or corners. A lso avoid the projected ends of bolts and screws.

• Keep wire harnesses away from the exhaust pipe and other parts that get hot.

• Be sure grommets are seated in their grooves properly.

x

x

• After clamping. check each harness to be certain that it is nOl interfering with any moving or sliding parts.

• Wire harnesses routed along the handlebars should nOt be pulled taut, have excessive slack, be pinched by, or inter· fere with adjacent or surrounding parts in all steering posi· tions.

• After routing, check that the wire harnesses are not twisted or kinked.

• Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind .

0: CORRECT )(: INCORRECT

1-9

GENERAL INFORMATION {31 (2 ) THROTTLE

PAR~ING

BRAKE CABLE

(4 1 REVERSE CABLE

(5) JUNCTION BOX (1 ) FRONT BRAKE

-~i"'::::;

CABLE

(6 ) CLAMP

(8) HANDLEBAR SWITCHES WIRES

(7) NEUTAAUAEVEASE

INDICATOR WIRES

(15) PARKING BRAKE CABLE

( 16\ BRAKE PEDAL CABLE (9) IGNITION SWITCH WIRES

a HIGH TENSION CORD (14 )

REAR-"R'~K~

BREATHER TUBE

113) CRANKCASE

BREATHER TUBE

1-10

(' ' ) CARBURETOR ) REVERSE CABLE

OVERFLOW TUBE

GENERAL INFORMATION

(11 THROTTLE

I REAR BRAKE CABLE

(3) REVERSE CABLE

~~<-----~------(4ICHOKECABLE (5) FRONT BRAKE CABLE

161 FRONT CABLE

(7)

(8 ) BATTERY GROUND CABLE

CABLE

(15) STARTER MOTOR CABLE

114 ) CHANGE SWITCH WIRE

1101

(111 ST,'R1"R

RA1,"'Y GROUND CABLE

RELAY

1131 ALTERINATOR WIRE

SWITCH

1-11

GENERAL INFORMATION

NOISE EMISSION CONTROL SYSTEM (U.S.A. only) â&#x20AC;˘ The U.S. Environmental Protection Agency reQuires manufacturers to certify that vehicles built after January 1, 1983 will comply with applicable noise emission standards for one year or 1,865 miles ~3,OOO km) after the lime of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Warranty for the Honda Vehicle Noise Emission Control System is necessary in order to keep the noise emission control system in effect . â&#x20AC;˘ TAMPERING W ITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replace ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or 12) the use of the vehicle after such device or element of design has been removed or rendered in operative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1.

2.

3.

4.

Removal of. or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

Removal of, or puncturing of any part of the intake system.

Lack of proper maintenance.

Replacing any moving parts of the vehicle. or parts of the exhaust or intake system. with parts other than those specified by the manufacturer.

1-12

MEMO

LUBRICATION LUBRICATION DIAGRAM

11) CAMSHAFT

(2) CRANKSHAFT

,5 , MAINSHAf'T

,6,

2-0

--rn

2. LUBRICATION SERVICE INFORMATION

2 -1

OIL FILTER SCREEN

TROUBLESHOOTING

2-1

OIL PUMP

2-3 2-3

ENGINE OIL LEVEL

2-2

LUBRICATION POINTS

2-7

ENGINE OIL & FILTER CHANGE

2 -2

SERVICE INFORMATION GENERAL • This section describes Inspection and replacement of the engine 011, oil filter and Olliliter screen and assembly and disassembly of the oil pump , • Be sure to fill the oil pump with clean engine oil when reassembling t he pump.

SPECIFICATIONS ENGINE Oil VISCOSITIES Engine oil capacity

1.5IiI11 .6 US qt, 1.31mp qUat disassembly 1.3 lit 11.4 US qt, 1. 1lmpqtl al drainIng

Engine oil recommendation Use Honda 4 -st roke oil or equivalent.

API Service Classification: SE or SF Viscosity : SAE 10 W- 40 Other viscosities shown In t he chart may be used when t he average temperature In your riding area is within the Indicated range.

I I

mm ITEM OIL PUM P

Cover-la-rotor clearance Aotor tip clearance End clearance

STANDARD

SERVICE LIMIT

0_ 1 5- 0 .21 10_006-0.008)

0 . 25 (0 .009)

0 . 15 10.006) 0.05 -0. l0 10.002 - 0 .004)

~inl

0 .20 (0.008) 0 .1 2 (0.005)

TORQUE V ALUE Oil dram bolt

20-30 N·m 12.0-3.0 kg -m. 14 - 22 It-Ib)

TROUBLESHOOTING Oil lellel too low - high 0 11 consumpt ion Normal oil consumption External oil leaks Worn piston rings Oil not changed often enough Faulty head gasket Oil contaminat ion Oil or filter not changed often enough Head gasket faully Worn piston rings

2-1

LUBRICATION

ENGINE OIL LEVEL Place the vehicle on level ground.

Check the oil level with the oil filler cap/dipstick, but do not screw it in when making this check.

If t he oil level is below or near the lower level line on the dipstick, add the recommended oil {page 2- 11 up to the upper level.

ENGINE OIL & FILTER CHANGE NOTE Drain t he oil w hile t he engine is warm to ensure rapid and complete draining.

Remove the oil filler cap and the drain bolt.

Remove t he oil filter cover attaching bolts, cover, spring and oil !liter .

Check the O-ring for damage or fatigue.

Install a new oil filter and t he spring, then install the cover with the attaching bolts.

Install the oil drain bolt with sealing washer.

TORQUE : 20 - 30 N¡m 12.0 -3.0 kg-m. 14 - 22 ft¡lbi Fill the crankcase with recommended oil (page 2 - 1).

ENGINE OI L CAPACITY : 1.3 lit (1 .4 USqt. 1. 1 Imp qt) at draining Install the oil liller cap/dipstick.

Start the engine and let it idle for 2 or 3 minutes.

St op t he engine and check tha t t he oil level is al the upper level line on the dipstick . Make sure t here are no oil leaks.

2-2

121 UPPER

/

~. ,~..

LUBRICATION

OIL FILTER SCREEN Drain the engine oillpage 2-1 L Remove the right crankcase cover Ipage 8-3), Remove and clean the oil filter screen.

Inspect the screen for damage and replace it if necessary.

Install the right crankcase cover with a new gasket in the reverse order of removal Ipage 8-16),

OIL PUMP REMOVAL Remove the right crank case cover (page 8 ¡3 ).

Remove the O-ring with collar, oil pump mounting bolts and oil

pump.

OIL PUMP DISASSEMBLY

(1) DRIVEN GEAR

Remove the oil pump driven gear, shah and dowel pin.

Remove the oil pump cover mounting bolts.

111 BOLTS

Remove the dowel pin, inner rotor, outer rotor and shaft from the pump body.

Clean the removed parts with the clean engine oil.

~ "

2-3

LUBRICATION OIL PUMP INSPECTI ON Install the outer rotor and inner rotor to the pump body.

Measure the oil pump cover-ta-rotor clearance.

SERVICE LIMIT; 0 .25 mm 10 .0 0 9 in)

Install the oil pump drive gear shaft and measure the pump

rotor tip clearance.

SERVICE LIMIT; 0 .20 mm (0 .008 in)

Remove the oil pump driven gear shaft and measure the pump end clearance.

SERVICE LIMIT ; 0 . 12 mm (0. 005 in )

(5) DRIV EN GEAR

OIL PUMP ASSEMBLY /INSTA LLAT ION (2 ) OUTER AOTOR

~I

11) OIL PUMP COVER

~O

() o

~~

~~ 2-4

0 (8) COLLAR

1410-RING

PI INNER ROTOR

\

(6) SHAFT

LUBRICATION Install the dowel pin to the oil pump body.

,1 lOll PUMP COVER

Install the oil pump cover.

(2) DOWEL PIN

Tighten the oil pump cover bolts.

Install the oil pump drive shaft.

COVEA

Install the dowel pin.

Install the oil pump driven gear.

Install the new O-ring onto the oil pump body.

(11 DRI~" GEAR

(4) DOWEL PIN

SHAFT

(3) O-RING

Install the oil pump onto the crankcase.

NOTE

â&#x20AC;¢

Pour a clean engine oil inside the oil pump.

2-5

LUBRICATION Tighten the oil pump mounting bolts.

Install the O¡ring with collar onto the oil pump.

Install the new right crankcase cover (page 8¡16).

2-6

LUBRICA nON

LUBRICATION POINTS Use general purpose grease when no other specification is given. Apply oil or grease to any two sliding surfaces and cables not shown here.

.-

(3) RIGHT AND lEFT BRAKE LEVER PIVOT/ FRONT AND REAR BRAKE CABLE END/ REVERSE CABLE END

.-

(2) THROTTLE CABLE END/THROTTLE LEVER SHAFT

\

,, ,

(4) BRAKE COVEA DUST SEAL

I

\

(5) BRAKE CAM/ANCHOR PIN DUST SEALS

/ I

(1) STEERING SHAFT

I

DUST SEAL AND BUSHING

,

-,

\ \

/ /

-

I I

--

(6) AXLE HOLDER DUST SEALS

\

\

\

n

/

\

\

\ \ \

---

\ \

('1) BRAKE CAMI ANCHOR PINfKtNGPIN (10) FRONT WHEEL HUB BUSHINGS AND DUST DUST SEALS AND SEALS RUBBER SEALS

,

\

\ \ \

\

\ \

\

\

-., -\

\

\

\

\

\

\

\

(9) BRAKE PEDAL PIVOTI DUST SEAUCABLE END

\

m

REAR AXLE SPLINES

18) DRIVE CHAIN (SAE 80 - 90

GEAR OIl)

2-7

MEMO

3. MAINTENANCE SERVICE INFORMATION

3- 1

CYLINDER COMPRESSION

3-7

MAINTENANCE SCHEDULE

3-2

DRIVE CHAIN

3-8

FUEL LINE

3-3

BRAKE SHOE WEAR

3-9

FUEL STRAINER SCREEN

3-3

BRAKE SYSTEM

3- 10

THROTTLE OPERATION

3-3

REVERSE LOCK SYSTEM

3- 1 1

CARBURETOR CHOKE

3-4

CLUTCH SYSTEM

3-12

AIR CLEANER ELEMENT

3-5

SPARK ARRESTER

3-12

AIR CLEANER CASE DRAIN TUBE

3-6

NUTS, BOLTS, FASTENERS

3-13

SPARK PLUG

3-6

WHEELS/TIRES

3-13

VALVE CLEARANCE

3-6

HEADLIGHT AIM

3-13

CARBURETOR IDLE SPEED

3-7

STEERING SYSTEM

3- 13

SERVICE INFORMATION SPECIFICATI ONS Engine Ignit ion timing: Initial Full advance Idle speed Spark plug: Spark plug gap Recommended spark plugs

Valve clearance rcoldl: Intake Exhaust Throttle lever free play Cylinder compression : Standard

Chassis Front brake lever free play Rear brake peda l free play Rear brake (parking brake) lever free play Reverse lock cable free play Drive chain slack

Front/rear rim size Front/rear tire size Front/ rear tire pressure

10 ° ± 2 ° Bl OC at idle 28 0 ± 2 0 BTDC at 5,000 ± 100 rpm 1,500 ± 100 rpm 0.6 - 0 .7 mm jO.024 - 0 .028 in) DR8ES-L (NG K) X24ESR-U (NO) 0.08 mm (0.003 in ) 0.08 mm (0.003 in) 3-8 mm (1/8-5/1 6 in ) 13.3 ± 1.0 kg /cm 2 ( 189 ± 14.2 psi , 1,330 ± 100 kPa )

15 - 20 mm (5/ 8 - 3/4 in) 15 - 20 mm (5 / 8 - 3/4 in ) 15 - 20 mm (5/ 8 - 3 /4 in) 2 - 4 mm (1/16 - 1/8 in ) 10 - 20 mm (3/ 8 - 3/ 4 in) 5.5 x 8 DC/8.25 x 8 DC 20 x 7 .00-8/ AT22 x 10-8* 2 .5 psi ( 17.5 kPa, 0 . 175 kg /cm2)/ 2 .2 psi 115 kPa , 0.15 kg/cm 2)

T OROUE V ALUE S Spark plug Valve adjusting screw lock nut Valve adjusting hole cap

Timing hole cap Rear axle bearing holder bolt Tie-rod lock nut

Clutch adjusting screw lock nut Front brake secondary cable lock nut

12 - 19 N'm 0 .2 - 1.9 kg -m, 9- 14 ft -Ib ) 15 - 18 N·m 11 .5 - 1.8 kg -m, 11 - 13 ft -Ibl 9 - 15N·m(0.9 - 1.5kg-m, 7-11 ft -Ib) 10 - 14 N·m (1.0-1.4 kg -m , 7-10 ft-Ib ) 70- 80 N·m (7.0-8.0 kg-m, 51 -58 ft -lbJ 35 - 43 N·m 13.5-4.3 kg-m, 25-31 ft-Ib ) 19-25 N·m ( 1.9 - 2.5 kg -m , 14 - 18 ft -lb) 8-12 N·m 10.8 - 1.2 k.g -m, 6 - 9 ft -Ib )

3-1

MAINTENANCE

MAINTENANCE SCHEDULE Perform the Pre-ride Inspection at each scheduled maintenance period.

I, Inspect and Clean , Adjust , Lubricate or Replace, jf necessary C, Clean R: Replace L, Lubricate A: Adjust EVERY

·•

INITIAL

REGU LAR

SERVICE PERIOD

SERVICE PERIOD

(First week of operation)

(Ellery 30 operating days)

page

FUEL LINE

YEAR I

3-3

FUEL STRAINER SCREEN

YEAR C

3-3 3-3 3-4

•

THROTTLE OPERA nON

·

CARBURETOR CHOKE

I

I I

AIR CLEANER

NOTE {1 )

C

AIR CLEANER CASE DRAIN TUBE

NOTE (2)

I

VALVE CLEARANCE

I

I

3-5 3-6 3-6 3-6

ENGINE Oil

R

R

2-2

ENGINE Oil FILTER

R

R

2-2

CARBURETOR IDLE SPEED

I

I

I, L

I, L

3-7 3-8 3-.

I

SPARK PLUG

·

Refer to

· · · ·•

BRAKE SYSTEM

I

I

3-10

REVERSE LOCK SYSTEM

I

I

3-11

I

-

•

NUTS, BOLTS, FASTENERS WHEELS /TIRES

·. ·. ·. ·

DRIVE CHAIN BRAKE SHOE WEAR

NOTE (1 , 2 1 YEAR I, NOTE 121

SKID PLATE, GUARD PLATE

I

CLUTCH SYSTEM SPARK ARRESTER

I

3- 12

C

3 - 12

I

I

3-13

I

I

3-13

NOTE (3)

STEERING SHAFT HOLDER BEARING

YEAR I

STEERING SYSTEM

YEAR I

-

3-13

Should be servIced by an authorIZed Honda ATV dealer, unless the owner has proper tools and servIce data and chanically qualified .

•• In the interest of safety, we recommend these items be serviced only by an authorized Honda ATV dealer .

NOTES: 1. Service more frequently when riding in dusty areas, sand or snow.

2 . Service more frequently after riding in very wet or muddy conditions.

3. U.S.A . only.

3-2

IS

me-

MAINTENANCE

FUEL LINE

11) FUEL LINE

Check the fuel line .

Replace any parts which show signs of deterioration, damage or leaks .

FUEL STRAINER SCREEN Turn the fuel valve OFF. Remove the fuel cup, O-ring and filter screen, and drain the gasoline into a suitable container .

Gasoline ;s flammable and ;s explosil't under certain condi¡ tions. Do not smoke or alloM' flames or sparks near the equip. mml ~'hjJt draining futl.

Wash the cup and filter screen in clean non-flammable or high flash point solvent.

Reinstall the screen, aligning the fuel passage of the fuel valve body with the hole of the f ilter screen. Install a new O-ring into the fuel valve body.

(1 ) FILTER SCI"'N

121

Reinstall the fuel cup, making sure the new O-ring is in place.

Hand tighten the fuel cup and then torque it.

CA UTION

â&#x20AC;˘ Do not overtighten the fuel cup.

After installing, turn the fuel valve ON and check that there are no fuel leaks.

THROTTLE OPERATION Check throttle lever for smooth full opening and automatic full closing operation In all steering positions. Make sure there is no deterioration , damage or kinking in the throttle cable. Re place any damaged parts.

If it is necessary to adjust the opening position, loosen the lock nut , turn the adjusting screw and then retighten the lock nut.

3-3

MAINTENANCE Disconnect the throttle cable at the upper end.

Thoroughly lubricate the cable and pivot point with a commercially available cable lubricant to prevent premature wear.

Install the throttle cable in the reverse order of removal.

Make sure the throttle lever free play is 3 - 8 mm (1 / 8 - 5/ 16 in) at the tip of the throttle lever.

Adjust as follows: Slide the rubber boot off the cable adjuster.

Loosen the lock nut and adjust the throttle cable free play by turning the cable adjuster.

Tighten the lock nut and install the rubber boot securely.

CARBURETOR CHOKE Check for smooth choke knob operation.

Pull the choke up all the way to "fully closed" and make sure the choke valve is fully closed by trying to move the choke lever on the carburetor.

The choke lever on the carburetor should not be able to be moved.

To adjust the choke, remove the seat.

Loosen the choke cable clamp on the carburetor .

Then tighten the clamp. holding the choke lever "fully closed. " Push the choke knob down all the way to fu lly open.

Make sure the choke valve is fully open by checking for f ree play between the lever and cable casing .

Recheck the choke operation.

The choke knob must move smoothly and stay where positioned .

Adjust the choke operating friction by turning t he adjuster.

Install the seat.

3-4

(31 CHOKE KNOB (41 RUBBER COVER

(51 ADJUSTER

MAINTENANCE

AIR CLEANER ELEMENT

11) RE1~"IING CLIPS

Remove the seat by pulling the seal latch lever.

Release the retaining clips holding the air cleaner csse cover, and remove the air cleaner case cover.

(2) AIR CLEANER

loosen the band screw.

....

,

Remove the air cleaner element assembly from the case.

(2) AIR CLI'A"ER ELEMENT

Remove the element holder cover by turning the screw counterclockwise.

Remo ve the element from the core.

Wash the element in non-flammable or high flash point solvent, squeeze out the solvent thoroughly, and allow to dry.

Soak the element in gear oil {SAE 80-90) and squeeze out the slIcess.

~

,~-) - ~- ~~Y · c~) - ~ )5) (1) WASH IN (2) SQUEEZE OUT SOLVENT SQUEEZE OUT (4) GEAR OIL EXCESS OIL SOLVENT THOROUGHLY (SAE 80-901

Place the element onto the element core.

Install the element holder cover as shown.

Install the air cleaner element in the case.

Tighten the band screw securely.

Install the air cleaner case cover and clips.

Install the seat.

3-5

MAINTENANCE

AIR CLEANER CASE DRAIN TUBE Remove the clip and drain tube from the air cleaner case to empty.

Install the drain tube.

NOTE

Service more frequently when riding in rain or at full throttle .

SPARK PLUG Disconnect the spark plug cap and remove the spark plug.

Visually inspect the spark plug electrodes for wear, The center electrode should have square edges and the side electrode should have a constant thickness.

Oiscard the spark plug if there is apparent wear or if the insula-

0.6 - 0 .7 mm (0.024-0.028 in)

11) CENTER ELECTRODE (2) CHECK: GAP

DEPOSIT WEAR (3) SIDE ELECTRODE

tor is cracked or chipped.

Measure the gap with a wire-type feeler gauge and adjust if necessary by carefully bending the side electrode.

L r-;

(5) CHECK :

I DAMAGE

SPARK PLUG GAP:

0 .6- 0 .7 mm 10.024 - 0 .028 inl RECOMMENDED REPLACEMENT PLUG : OR8ES·l INGKI X24ESR-U (NO) Check the sealing washer and replace with a new one if damaged.

With the sealing washer attached, thread the spark plug in by hand to prevent crossthreading. Tighten the spark plug.

TORQUE : 12 - 19 N·m 11.2-1 .9 kg-m, 9 - 14 ft·lbl

VALVE CLEARANCE NOTE Inspect and adjust valve clearance while the engine is cold (below 35°Cf95°F).

Remove the timing hole cap and recoil starter cover .

Rotate the crankshah counterclockwise with the recoil starter driven pulley and align the "T" mark on the rotor with the index mark. The piston must be at TDC on the compression stroke.

Remove the fuel tank {page 4-3J. Remo ve the valve adjusting hole caps.

Inspect the intake and exhaust valve clearances by inserting the feeler gauge between the adjusting screw and valve stem.

VALVE CLEARANCES Intake: 0 .08 mm (0.003 Inl Exhaust : 0 .08 mm (0 .003 In)

3-6

(4) CHECK : CRACKS

,;

,,

MAINTENANCE Adjust by loosening the lock nut and turning t he adjusting screw until there is a slight drag on the feeler gauge.

Hold the adjusting screw and tighten the lock nut.

TORQUE : , 5 - 18 N·m 11.5 - 1 .8 kg-m , 11 - 13 fl -Ibl Recheck the valve clearance and install the valve adjusting hole caps.

TORQUE: 9 - 15 N' m 10.9 - 1.5 kg-m, 7 - l' fl-Ibl Install the timing hole cap.

TORQUE: 10 - 14 N·m (1 .0 - 1.4 kg -m , 1 - 10 fr·lb) Install the removed parts.

CARBURETOR IDLE SPEED NOTE

Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifi-

cations.

The engine must be warm for accurate idle speed inspection and adjustment.

Warm up the engine for about t en minutes, shift the transmis sion into neutral and connect a tachometer.

Turn the throttle stop screw as required to obtain the specified idle speed.

IDLE SPEED : 1,500 :l: 100 rpm

CYLINDER COMPRESSION Warm up the engine.

Stop the engine and remove the spark plug.

Install a compression gauge.

Make sure the choke is fully closed, and turn the ignition switch "ON".

Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising.

NOTE The maximum reading is usually reached within 4 - 7 seconds.

.R ...~

COMPRESSION PRESSURE: 13.3 ~ 1.0 kg/ cm 2 (189 ± 14.2 psI. 1,330 :l: 100 kPa) Low compression can be caused by: - Blown cylinder head gasket - Improper valve adjustment - Valve leakage - Worn piston ring or cylinder High compression can be caused by: - Carbon deposits in combustion chamber or on piston head

3-7

MAINTENANCE

DRIVE CHAIN Stop the engine and shift the transmission into neutral.

Remove the drive chain inspection hole cap.

Check the amount of chain slack through the inspection hole .

DRIVE CHAIN SLACK ; 10-20 mm (3 /S- 3 f4 in)

CHAIN SLACK ADJUSTMENT Loosen the feafaxle bearing holder bolts.

Turn the adjusting nut to obtain the specified chain slack.

Retighten the rear axle bearing holder bolts.

TORQUE : 70 - 80 N·m 17 .0 - 8 .0 kg -m. 51 - 58 ft -Ib) Check the feaf wheels for free rotation.

Adjust the rear brake (page 3 · 11 ).

Lubricate the drive chain with SAE 80 or 90 gear oil lubricant through the inspection hole.

Install the inspection hole cap.

When the drive chain becomes extrem ely dirty, it should be re moved and cleaned prior to lubrication.

INSPECTION/LUBRICATION Loosen the rear axle bearing holder bolts and adjusting nut; then move the holder forward.

Remove the chain cover and chain.

Inspect the drive chain and O-rings for possible wear or damage. Replace the chain if it is worn e){cessively or damaged.

Measure the drive chain length with the chain held so that 40 pins are straight.

40 PINS lENGTH: STANDARD: 508 mm 120,0 in) SERVICE LIMIT: 510.5 mm 120.1 Inl

3-8

(1)

(

-<0

40 pins

I..

OlJO O)JO . Clr---\»)({) r

OJ. ))

MAINTENANCE Clean the drive chain with a small amount of kerosene and wipe dry.

(11 WIPE DRY

CAUTiON Do not use a steam cleaner, high pressure wushers or aerosol chain lubricants as Ihese wiff damage the D-rings.

"711 121 Lubricate the drive chain with SAE 80 or 90 gear oil.

. â&#x20AC;˘

LUBRICATE WITH SAE 80 OR SAE 90 GEAR Oil

Inspect the sprocket teeth for excessive wear or damage . Re place if necessary .

Never install a new drive chain on worn sprockets or a worn chain on new sprockets. Both chain and sprockets must be in good condition, or the new replacement chain or sprockets will wear rapid ly.

)(

X

NOTE (1)

DAMAGE

(2) WEAR

(31 NORMAL

o

INSTALLATION

(1) CHAIN CASE

Install the drive chain.

Adjust the drive chain slack and tighten the bearing holder bolts.

Install the drive chain cover.

(2) CHAIN COVER BOLTS

BRAKE SHOE WEAR Replace the brake shoes if the indicator plate aligns with the brake panel index mark when the front brake lever, rear brake lever or pedal is applied.

3-9

MAINTENANCE

BRAKE SYSTEM

t 1) FRONT BR'IKE CABLE

FRONT BRAKE Check the cable and brake lever for loose connections, 8l1CeS siva play. or other damage. Replace or repair if necessary.

Disconnect the brake cable at the upper end .

Thoroughly lubricate the cable and pivot point with a commer -

cially available cable lubricant to prevent premature wear.

Install the brake cable.

Make sure brake lever free play is 15 -20 mm (5/B- 3/4 in) at the brake lever tip.

FRONT BRAKE LEVER FREE PLAY: 15-20 mm t51B - 3/4 1nl

Adjust the brake lever free play by turning the primary cable adjuster.

NOTE

Make sure the cut-out of the adjuster is seated on t he brake

arm pin.

If the braking action is uneven. loosen the lock nuts and turn the secondary cable adjusting nuts as required to equalize the brake effect.

If the equalizer arm had inclined excessively t o one side, inspect the brake drum and brake lining on that side.

Tighten the secondary cable lock nuts and adjust the front brake lever free play .

TORQUE : 8 - 12 N¡m 10.8- 1.2 kg¡m, 6 - 9 ft-Ibl

( 1) REAR BR,'KE CABLE

REAR BRAKE Check the brake lever c~ble and brake pedal for loose connec tions, excessive play, or other damage.

Replace or repair If necessary.

Disconnect the brake cables at the brake lever or pedal ends.

Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant to prevent premature wear.

Install the cables.

3-10

MAINTENANCE Measure the rear brake (parking brake) lever free play at the end of the brake lever.

REAR BRAKE LEVER FREE PLAY; 1 5 - 20 mm (518-3/4 in)

Measure the brake pedal free play at the end of the brake pedal.

BRAKE PEDAL FREE PLAY: 15 - 20 mm 15/8- 3/4 in)

Adjust the lever and pedal free play by turning the adjusting nuts at the lower end of the cables.

NOTE

Make sure the cut-out of each adjusting nut is seated on the brake arm pin.

REVERSE LOCK SYSTEM Check the lever and cable for loose connections, excessive play, or other damage.

Replace or repair as necessary.

(1)

R""FIS' LOCK CABLE

3-11

MAINTENANCE Measure the reverse selector lever free plav at the lever end of the cable side .

REVERSE CABLE FREE PLAY : 2-4 mm (1,16- 1,B inl

(2) 2 - 4 mm

(1116 - 118 in) (3)

111

To adjust, loosen the lock nut and turn the adjusting nut.

Tighten the lock nut securely.

111

CLUTCH SYSTEM Stop the engine .

(1) LOCK NUT

Loosen the clutch adjusting screw lock nut.

Slowly turn the adjusting screw counterclockwise until tance is felt.

resis~

Then turn the adjusting screw clockwise 1/8-1 /4 turn, and tighten the lock nut.

TORQUE: 19-25 N'm (1.9-2.5 kg-m , 14- 18 ft-Ibl A her adjustment, start the engine and check for proper clutch

operation.

SPARK ARRESTER , i. ' Do nQt touch the exhaust components wh(fe the exhaUJ" S)'Slem is hot.

Per/arm thh 0lUra/ion in a well-yentilated urea,/ree from /ire hazard.

Use

adeqllat~ ~}'~ prot~ction.

Remove the muffler bolt.

Start the engine with the transmission in neutral, and purge ac¡ cumulated carbon from the spark arrester system by momen¡ tarily revving up the engine several times.

Stop the engine and allow the exhaust system to cool. Install the muffler bolt.

3-12

.......,. (1) SPARK ARRESTER

LEVER

MAINTENANCE

NUTS, BOLTS, FASTENERS Tighten bolts, nuts and fasteners at regular intervals shown in the Maintenance Schedule (page 3-21 .

Check that all chassis nuts and bolts are tightened to their cor-

rect torque values (page 1-51 . Check that all cotter pins and safety clips are in place.

WHEELSITIRES Check the tires for cuts, imbedded nails or other damage .

Check the tire pressure.

Adjust accordingly .

TIRE PRESSURES:

Recommended

pressure Max . pressure Min . pressure

Front

Rear

2 .5 psi ( 17.5 kPa, 0 . 175 kg fc m 2)

2.2 psi (15 kPa, 0 . 15 kg /cm 2)

2.9 psi (20.5 kPa,

0 .205 kg /cm 2)

2.6 psi (18 kPa, 0.18 kg /em 2)

2.' psi (14.5 kPa , 0 . 145 kg/e m2)

1.8 psi (12 kPa, 0 . 12 kg /em 2)

NOTE

â&#x20AC;˘

Tire pressure should be checked when the tires are COLD.

HEADLIGHT AIM Adjust the vertical beam with the headlight mounting bolts, aligning the center line of the headlight with the index marks of the headlight case.

..-.1.'111)HEA~L~\CASE BOLTS

.,

STEERING SYSTEM Inspect the steering shaft free play with the front wheels turned straight ahead.

If there is excessive play. inspect the tie-rod, kingpin bushing and bait joint (Section 11).

Raise the front wheel off the ground and make sure that the handlebar rotates freely .

If the handlebar moves uneyenly, binds or has vertical movement , inspect the steering shaft upper bushing and lower bearing (Sect ion 11).

NOTE

Make sure the cables do not interfere with the rotation of the handlebar.

3-13

MAINTENANCE TOE-IN Place the vehicle on level ground with the front wheels facing

straight ahead.

Mark the centers of the tires with chalk to indicate the axle center height .

\.

I

I I~~~f-\ n)

TOE-IN GAUGE

Align the toe· in gauge with the marks on the tires as shown.

Check the readings on the gauges or scales.

SlowlV move the vehicle back until the wheels have turned 1 BO o so the marks on the tires are aligned with the gauge height on the rear side.

Measure the toe-in on the reaf part of the tires at the same points .

A (1) FRONT

TOE-IN : 0 ± 10 mm (Q ± 3 /B in)

7

* I

When the toe-in is out of specification, adjust it by changing the length 01 the tie-rod s equally by turning the tie-rod while holding the ball joint .

NOTE

•

Should adjust while measuring the toe-in .

Tighten the lock nuts.

TORQUE : 35 - 43 N·m !3.5 - 4 .3 kg.m , 25 - 31 ft-Ib) After finally tightening the lock nuts, make sure the ball joints operate property by rotating the tie-rods.

3-14

1\ fS\

8

1 I

MAINTENANCE CAMBER/CASTER Remove the cotter pin and front axle nut (page 11 -6).

Install a attachment onto the front 8xle.

Set the camber and caster gauge to the attachment.

Measure the camber.

CAMBER : 0° ± 1 0

TOOL: Camber/caster gauge attachment 07910 - MJ30100 (Not available in U.S.A.) (1) CAMBER/ CASTER GAUGE ATTACHMENT

Set the turn gauge under the front wheels.

Measure the caster.

CASTER: 8 ° Camber and caster are not adjustable. If they are out of specification, check the frame for damage and replace any parts nec· essary, then recheck alignment .

m CAMBERICASTER GAUGE ATTACHMENT Pump grease into the kingpin pivot through the grease fittings on the knuckle pipe .

3-15

FUEL SYSTEM

4-0

4. FUEL SYSTEM SERVICE INFORMATION

4 -1

CARBURETOR

4-5

TROUBLESHOOTING

4 -2

THROTTLE VALVE ASSEMBLY

4-9

FUEL TANK

4 -3

PILOT SCREW ADJUSTMENT

4 -10

AIR CLEANER CASE

4 -3

HIGH ALTITUDE ADJUSTMENT

4 -11

THROTTLE VALVE DISASSEMBLY

4 -5

III

SERVICE INFORMATION GEN ERAL

Use caution when working with gasoline. Always ....ork in a welll'entilated area away from sparks or flames.

When disassembling fuel system parts, note the locations oj the O-rings. Replace them during reassemhly.

CAUTION

â&#x20AC;¢ Do not bend or twist COlf/rol cables. Damaged control cables will nor operate smoothly and may stick Or bind.

SPECIFICATONS < Fuel tank> Fuel tank capacity

7.5 lit (1.98 US gal, 1.65 Imp gal)

Fuel reserve capacity

1.5 lit (O.40 US gal, 0.33 Imp gal)

<Carburetor> Identification mark

PBSSB

Main jet

#92

Slow jet

#35 - #35

Jet needle clip setting

2nd groove from the top

Pilot screw opening

, -3/8 turns out

Float level

10.7 mm (0.42 in)

Idle speed

1,5oo:t 100 rpm

TOOL Common Float level gauge

07401 - 0010000

4-1

FUEL SYSTEM

TROUBLESHOOTING Engine cranks but won't start No fuel in tank No fuel to cy1inder Too much fuel getting to cylinder No spark at plug (ignition malfunction) Air cleaner clogged Engine idles roughly. slalis, or runs poorly Idle speed incorrect Ignition malfunction Rich mixture

Lean mixture Air cleaner dirty

Insulator leaks

lean mixture Carburetor fue l jet clogged Fuel cap vent blocked Fuel filter clogged Fuel line kinked or restricted Float valve faulty Float level too low

Rich mixture Carb uretor choke stuck closed Float valve faulty Float level too high Carburetor air jet clogged

Air cleaner dirty

4 -2

FUEL SYSTEM

FUEL TANK REMOVAL Remove the seat by pulling the seat release lever.

Remove the front fender (page 13-'), Turn the fuel valve OFF and disconnect the fuel line from the fuel valve.

Remove the fuel tank mounting bolt and fuel tank.

Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once.

Use a drain pan and check that fuel flows freely out of the fuel valve.

(1) FUEl TANK

~CAP

INSTALLATI ON Install the fuel tank and tighten the bolts.

Connect and clamp the fuel line securely _ Install the front fender (page 13- 1).

Install the seat.

" ,: tJ--

NOTE Be sure the fuel tank front brackets are on the rubber cushions.

After assembly, make sure there are no fue l leaks.

@'@

) (3) FUEL TANK MOUNTING BOLT

(6) O-RING -

__

AIR CLEANER CASE REMOVAL Remove the battery holder mounting bolts and move the holder toward the rear.

4-3

FUEL SYSTEM Loosen the connecting tube bands.

Remove the air cleaner case as shown.

For air cleaner element service, see page 3 -5.

For air cleaner case drain tube service, see page 3-6.

INSTALLATI ON Install the air cleaner case in the reverse order of removal.

(2) AIR CLEANER ELEMENT

(1) AlA CLEANER CASE COVEA

(6) CONNECTING TUBE BANOS

ELEMENT HOLDER

(4) AlA CLEANER CASE

(5) AIR CLEANER CASE DRAIN TUBE

4-4

FUEL SYSTEM

THROITlE VALVE DISASSEMBLY NOTE

You can service the carburetor without removing the fue l tank.

Remove the rear fender .

Remove the carburetor top from the carburetor.

CAUTION The carburelor top is on illff'rgra! por' oj Ihe throffle cable as¡ sembly. The carburetor top cannot be separaled from the assembly wi/houl causing damage to Ihe coble.

Never kink or fwis/ control cables. They will nOI operate smoothly and may Slick if Illey Ofe kinked or twisted.

Remove the throttle cable from the throttle valve while depressing the throttle valve spring .

Remove the needle clip retainer.

Remove the jet needle and needle clip .

" I THROTTl.'

(2) NEEDLE CUP

Inspect the throttle valve and jet needle surface for dirt , scratches or wear.

/

(4) JET NEEDLE

r

(3) RETAINER

CARBURETOR REMOVA L Remove the carburetor top. loosen the choke cable clamp screw and disconnect the choke cable from the carburetor. loosen the carburetor connecting tube band .

Remove the intake pipe attaching bolts and remove the carburetor With the intake pipe.

4-5

FUEL SYSTEM Separate the intake pipe from the carburetor .

(11 OVERFLOW TUBE

Remove the insulator plate, gasket and O-ring from the carbu -

retor.

Remove the air vent, overflow and fuel tubes from the carbure -

tor.

INT,,"' PIP'

FLOAT, FLOAT VALV E AND JETS 111 DRAIN SCR'\.

Loosen the drain screw and drain the gasoline.

Remove the float chamber by removing the screws.

Remove the float arm pin.

Remove the float and float valve.

VALVE

Inspect the float valve and seat for wear or damage.

(2) FLOAT VALVE SEAT

4-6

FUEL SYSTEM Remove the slow jet .

Remove the main jet, needle jet holder and needle jet.

(3) NEEDLE JET HOLDER

Before removing the pilot screw, record the number of turns until the screw seats lightly, then remove the screw.

Blow open all jets and body openings with compressed air.

Inspect the pilot screw, needle jet, needle jet holder and main jet.

;..o'~

!

Check each part for wear or damage .

(6) PILOT SCREW

(5) SLOW JET

Clean the passages and jets with compressed air.

ASSEMBLY

(4) O-RING

(5) THROTTLE

(2) GASKET (1 ) INTAKE PIPE

~

\

STQPSCREW

-~-~ ~~""''''''-'''''~~:::

/ _ _ _ _ _ (6) PILOT SCREW (7) NEEDLE JET (8) NEEDLE JET HOLDER

/'~~ n

(9) MAIN JET

(11) DRAIN SCREW

(10) FLOAT CHAMBER

4-7

FUEL SYSTEM NOTe Handle all jets and needles with care. They can be easily scored or scratched.

Set the pilot screw at the position recorded during disassembly.

(1) NEEDLE JET HOLDER

Install the needle jet, needle jet holder, main jet, slow jet, throttle stop screw and pilot screw.

(5( T""nTT' STOP SCREW (4) PilOT SCREW

Install the float valve, float and f loat arm pin.

,,

(2) FLOAT VALVE

(1(

FLOAT LEVEL MEASUREMENT Measure the float level with a float level gauge as shown.

FLOAT lEVEL: 10.7 mm (0.42 in) If the float level is out of specification, install a new float. The float is not adjustable.

TOOL: Float level gauge

07401-0010000

lEVEL GAUGE

Install the float chamber.

Install the new D-ring.

( 1(

O-RI~G

121 FLOAL CHAMBER

4-8

T

FUEL SYSTEM INSTALLATION

(1) OVERFLOW T U B E 7

(2) INSULATOR

Install the air vent tube, overflow tube and fuel tube.

Install the insulator plate, new gasket and intake pipe onto the

carburetor, and tighten the nuts.

Install a new D-ring onto the intake pipe.

I (3) TUBE

r~

I VENT TUBE

Install the carburetor top (page 4 - 10).

Connect the choke cable to the carburetor and fix the choke cable with the cable clamp screw .

Connect the carburetor connecting tube and clamp it with the tube band.

Install and tighten the intake pipe attaching bolts.

Route the tubes properly (page 1- 10).

NOTE After installing the carburetor, perform t he following adjustments: - throttle lever free play (page 3-3).

- carburetor pilot screw adjustment (page 4 - 10). if the car buretor was overhauled or cleaned.

- carburetor choke (page 3 ¡41.

111 TH"nTTLE

THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle.

STANDARD SETTING: 2nd groove from the top

/

(2) JET NEEDLE

Install the jet needle into the thrOllle .... alve and secure it with the needle clip retainer.

~?

\

(3) CLIP

(1) NEEDLE CLIP RElrAII"R

4-9

I ~

FUEL SYSTEM

j Install the throttle cable, spring and throttle valve.

Align the throttle valve slit with the locating pin in the carburetor body and install the carburetor top onto the carburetor.

Adjust throttle lever free play (page 3-4),

PILOT SCREW ADJUSTMENT NOTE The pilot screw is factory pre-set. Adjustment is not necessary unless the carburetor is overhauled or cleaned.

CAUTION

Damage /0 the pilot screw seat will occur if /he pilot sereII' IS lighlened againsf the seat.

Turn the pilot screw clockwise until it seats lightly and back it

out 1 ¡318 turns.

This is an initial setting prior to the final pilot screw adjustment.

Warm the engine up to operating temperature.

Stop the engine and connect a tachometer.

Stan the engine and adjust the idle speed with the throttle stop screw.

IDLE SPEED: 1,500

j; ,

00 rpm

Turn the pilot screw in slowly until the engine slops, and then back it out 1¡112 turn . Start the engine and readjust the idle speed with the throttle stop screw , if necessary.

4-10

m SPRING

FUEL SYSTEM

HIGH ALTITUDE ADJUSTMENT

SPECIFICATIONS

The carburetor must be adjusted for high altitude riding (above 6,500 ft /2,OOO m).

STANDARD SETT ING : 4 ,900 ft ( 1,500 ml max .

HIGH ALTITUDE SETTING : 3 ,300 ft (1,000 ml min .

High altitude carburetor adjustment is performed as follows:

Below 4,900 ft (1,500 ml

Above 3,300 ft 11 ,000 ml

No. 92

No. 88

Pilot screw openmg

Factory preset

Screw in 7 /8 turn

Jet needle

20d

20d

Main jet

Remove and disassemble the carburetor (page 4-5 , and 4 ¡6).

Replace the standard main jet with the high altitude type til/88).

Assemble and install the carburetor.

Start the engine and adjust the idle speed at high aftitude to ensure proper high altitude operation.

CAUTION

Sustained operation lx>/Ok', 3,JOOjeel (1,000 m) with the high alriwde sellings may calise engine ol'erheo/ilig and dumage. In slafl/he #92 main jel, when riding be/ow 3,300jeel (1,000 m),

4-11

ENGINE REMOVAL/INSTALLATION

30 - 36 N' m (3.0 - 3 .6 kg-m, 22 - 26 ft-Ibl 70- 80 N'm 17.0 - 8.0 kg -m , 51 - 58 ft -Ibl

70 - 80 /7.0 - 8.0 kg-m, 51 - 58 ft -lbl 80 -

N·m IB.0 - l0.0 kg-m , 58 - 72 ft -Ib)

30 N'm (2.4 - 3 .0 kg -m , 17 - 22 ft -Ib)

5-0

5. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION

5-1

ENGINE REMOVAL

5-2

ENGINE INSTALLATION

5-3

SERVICE INFORMATION GENERAL • The following parts or components can be serviced with the engine installed in the frame: Carburetor Section 4 Starter motor Section 16 Oil pump Section 2 Clutch Section 8 Alternator Section 9 Gear shift linkage Section 8 Camshaft Section 6 Cylinder head cover Section 6

SPECIFICATIONS Engine dry weight

31.2 kg (68.78Ibl 1.51it 11.6 US qt, 1.31mp qt) after disassembly 1.3 lit (1 .4 US qt, 1.1 Imp qt) after draining

Engine oil capacity

TORQUE VA LUES Engine hanger bolt

8 mm

10 mm Foot peg bolt Exhaust muffler bolt Gearshift pedal bolt Drive sprocket bolt

30 - 36 N-m 13.0- 3.6 kg-m . 22 - 26 ft-Ibl 70 - 80 N-m 17.0 - 8.0 kg -ro , 51 - 58 h -lbJ 80 -100 N·m (8.0 - 10.0 kg -m . 58 - 72 h-Ib) 70-80 N·m 17 .0 - 8 .0 kg-m. 51 - 58 ft-Ibl , 4- 1 8 N·m 11.4 - 1.8 kg -m , 10 - 13 ft -Ib) 24-30 N·m (2. 4 - 3.0 kg -m , 17-22 ft-Ib)

5-1

ENGINE REMOVAL/I NSTALLATION

ENGINE REMOVAL Remove the front and rear fender !Section 131.

Drain the engine oil (page 2¡21.

Disconnect the battery negative cable at the batlery .

Remove the left foot peg and gearshift pedal.

Remove the junction box cover and disconnect the alternator and change switch wires.

Remove the drive chain cover.

Remove the battery ground cable .

Loosen the reaf bearing holder mounting bolts and drive chain adjusting nut.

Remove the drive sprocket bolt , washer and drive sproc ket.

Remove the drive c ham case by removing the four mounting bolts.

Tum the fuel valve OFF, disconnect the fuel line and remove the fuel tank (page 4 ¡ 31.

Remove the exhaust pipe (page 13-31 .

Remove the lock nUl , reverse shaft arm and reverse cable .

5-2

ENGINE REMOVAL/INSTALLATION Disconnect the spark plug cap from the spark plug.

Disconnect the starter cable at the starter motor.

Disconnect the crankcase breather tube from the crankcase.

Re move the rig ht foot peg.

Remove the carburetor with the insulator.

Remove the engine mounting bolts and nuts, and remove the engine from the right side 01 the frame.

ENGINE INSTALLATION Install the engine in the reverse order of removal.

NOTE

Be sure to use the coueet bolts in the proper position.

Tighten the engine hanger bolts after they a re all installed loosely.

T ORQUE: 10 rnm han ger bolts: 70 - 80 N-m 17 .0 - 8 .0 kg -m, 51 - 58 ft -Ib) 8 mm hange r bolts: 30 - 36 N·m 13.0 - 3 .6 kg -m, 22 - 26 ft -Ib) Foot peg bolts: 80 - 100 N-m 18 .0 - 10.0 kg -m , 58 - 72 ft-Ib) Exhaust muffler bolt s: 70 - 80 N·m 17 .0 - 8 .0 kg·m. 51 - 58 ft·lbl Gearshift pedal bolt : 14 - 1 B N· m 11.4 - 1.8 kg·m. 10 - 13 ft·lb l Dri ve sprocket bolt : 24 - 30 N·m (2 .4 - 3 .0 kg ·m, 11 - 22 ft· lbl

NOTE Alter installing the engine, perform the following inspections and adjustments: Engine oil level (page 2·2).

Throttle lever f ree play Ipage 3·4).

Drive chain slack (page 3-81Carburetor choke operation (page 3-4).

Check tha t exhaust gas is not leaking.

Check the electrical equipment performance.

Route the wire and cable properly Ipage 1-101.

5-3

CAM CHAIN TENSIONER/CYLINOER HEAOIVAlVES

28 - 30 N·m (2.8 - 3 .0 kg-m, 20 - 22 h -Ibl 8 - 12 N·m (0.8 - 1.2 kg-m,

'"

6 - 9 ft-Ibl

~

~

",fJ 15- 18N·m

11 .5 - 1.B kg-m. 11 - 13 ft -Ibl ----..g

I~,

I

I

~

i~

,

10 - 14 N·m 11 .0 - 1.4 kg -m , 7 - 10 ft·lbl

o

~

1 - 14 N·m 11 ,0- 1.4 kg -m ,

7 - 10 h -Ibl

B -1 2N·m 10.8 - 1.2 kg -m , 6 - 9 h -Ibl

6-0

6. CAM CHAIN TENSIONER/CYLINDER HEAD/VALVES SERVICE INFORMATION

6- 1

CYLINDER HEAD COVER

6-5

TROUBLESHOOTING

6-2

CYLINDER HEAD

6-7

CAMSHAFT/CAM CHAIN TENSIONER

6-3

SERVICE INFORMATION GENERAL

• This section covers cylinder head, valves, camshaft, rocker arms and cam chain tensioner maintenance.

• The engine must be removed from the frame to service cylinder head. To remove the cam chain tensioner, camshaft, cylin der head cover and rocker arms, engine remo val is not required.

• Camshaft lubrication oil is fed to the cylinder head through an oil control orifice in the engine case. Be sure this orifice is not ~. clogged and that the O-rings and dowel pins are in place before installing the cylinder head. .:.

• Before assembly. apply molybdenum disulfide grease to the camshaft bearings to provide initial lubrication.

Pour clean engine oil into the oil pockets in the cylinder head during assembly to lubricate the cam lobes.

SPECIFICATIONS mm(in) ITEM

STANDARD

SERVICE LIMIT

13.3 ± 1.0 kg/cm2 (189 ± 14.2 psi, 1,330 ± 100 kPa)

--

Right

19 .967-19.980 (0.786 1 - 0.7866)

19.90 (0.783)

L,ft

33.959 - 33.975 (1.3370-1 .3376 )

33.90 (1.335)

IN

31.083-31.243/1.2237-1.2300)

30.98 (1.220)

EX

30.681 - 30.841 (1.2079- 1.2142 )

30.58 (1.204)

Rocker arm 1.0.

12.000-12.027 10.4724-0.4735)

12.05 (0.474 )

Rocker arm shaft 0.0.

11.977-11 .995 10.4715-0.4 722)

11.93 (0. 470)

---

0.08 (0.003)

39.4 (1.55)

35.5 (1.40)

45 .5 (1.79)

41.0 (1.61)

Cylinder compression Camshah journal 0.0.

Cam labe height

Rocker arm shaft clearance Cylinder head warpage Valve spring free length

Valve stem 0.0.

Valve guide 1.0.

Stem-ta-guide clearance

0.10 (0.004)

IN OUT IN

5.450 - 5.465 10.2146 - 0.2152)

5.42 (0.213)

EX

5.430 - 5.44510.2138 - 0.2144)

5.40 (0.213)

IN/EX

5.475-5.485 1O.2156-0.2159J

5 . 50 (0.2 17 )

IN

0.010 - 0.0351O.0004 - 0.0014J

0.08 (0.003)

EX

0 .030-0.05510.0012-0.0022)

0.10 (0.004)

1. 1 - 1.5 /0.04 - 0.06)

1.8 (0.07)

1.210.05)

1.5 (0.06)

Valve face width

IN/EX

Valve seat width

IN

EX

1.510.06)

1.8/0.07)

Camshaft bearing 1.0. (left side)

34.000 - 34.025 (1.3386-1.3396)

34.05 (1.341)

Camshaft bushing 1.0. (right side)

20.005 - 20.026 (0.7876-0.7884 )

20.05 (0.789)

CamshafHa-bearing clearance

0.025 - 0.064 (0.0010 - 0.0025)

0.15 (0.006)

Camshaft-ta-bushing clearance

0.025 - 0.059 (O.0010 - 0.0023)

0.15 (O.006)

6-1

CAM CHAIN TENSIONER/CYLINOER HEAO/V ALVES TORQUE VALUES Cylinder head cap nut 6 mm socket bolt Cylinder head bolt Cam sprocket bolt Timing hole cap bolt Cam chain tensioner sealing bolt Valve adjusting hole cap

28 - 30 N -m 12.8 - 3.0 kg -m, 20 - 22 ft -Ibl 8 - 12 N-m (0.8 - 1 .2 kg -m , 6 - 9 ft -Ib) 10 - 14 N'm 11.0-1.4 kg-m. 7-10 ft -Ibl 10 - '4 N'm 11 .0-' .4 kg-m, 7 - , 0 ft -fb) IAPPLY OIL TO THE THREADS) 10 - 14N-mll .O- l ,4kg-rn,7 - 10ft-lb) 8 - 12 N·m (0 .8 - 1.2 kg -rn, 6 - 9 ft·rb) 9-15N.mIO.9-1.5kg-m, 7-" ft -Ibl

TOOLS Special Valve guide reamer, 5 .485 mm

07984-0980001 or 07984-098000A (U.S.A. Only)

Common

Valve guide driver, 5.5 mm

Valve spring compressor Cutter holder, 5.5 mm Valve seat cutter (page 1-81

07742 - 0010100 or 07942 - 3290100 07757 - 001 0000 or 07957 - 3290001 07781 - 0010101 or Equivalent commercially available in U.S.A. or Equivalent commercially available in U.S.A .

TROUBLESHOOTI NG Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by t racing engine noises to the top end with a sounding rod or stethoscope .

Low compressIon Valve - Incorrect valve adjustment - Worn Of damaged valve seats - Burned or bent valve - Incorrect valve timing - Weak valve spring Cylinder head - Leaking Of damaged head gasket - Warped or cracked cylinder head Faulty cylinder or piston (Section 7)

6-2

Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Damaged or worn rocker arm or camshaft Worn or damaged cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Excessive sm oke Damaged valve stem seal • Faulty cylinder or piston rings (Section 7 )

CAM CHAIN TENS lONER/CYLINDER HEAD/VALVES

CAMSHAFT/CAM CHAIN TENSIONER RE MOVAL NOTE You can service the camshaft except the camshaft bushing without removing the cylinder head cover.

Remove the front fender (page 13-' ).

Remove t he cam sprocket cover and gasket.

Remove the cam chain tensioner and gasket by removing the two bolts.

Remove the recoil starter (page 9·2).

Remove the timing hole cap.

~RK

Turn the crankshaft counterclockwise wi t h the starter driven pulley unt il the cam sprocket "0" mark and cylinder head bolt align, and " T " mark and index mark align.

Remove the cam sprocket bolts, sprocket with the cam chain from the camshaft .

Remove the cam chain from the cam sprocket.

Suspend the cam chain with a piece of wire to prevent it from fa lling into the crankcase.

Remove the camshah and washer .

INSPE CTI ON Measure the camshah journal 0.0.

l.

11) EX);AlJST LOBE

SERVICE LIMITS ; R; 19.90 mm {0.783 in) L: 33 .90 mm {1.335 in ) Measure the height of cam lobes and inspect them f or wear or damage.

SERVICE LIMITS : IN : 30.98 mm ( 1.220 in) EX; 30 .58 mm (1 .204 in) (2)

LOBE

Measure the camshaft bushing 1.0.

SERVICE LIMIT: 20 .0 5 mm 10. 789 in) Calculate the camsahh bushing-ta-camshaft clearance.

SERVICE LIMIT: 0 .15 mm (0.006 in ) Measure lhe bearing 1.0.

SERVICE LIMIT: 34.05 mm 11 .341 in) Calculate the camsha ft -ta-bearing clearance.

SERVICE LIMIT: 0 .15 mm (0 .006 in)

6-3

CAM CHAIN TENSIONER/CYLINDER HEAD/V ALVES INSTALLATI ON When you service the camshaft bushing, remove the cylinder head cover (page 6-5), Install the camshaft bushing onto the cylinder head, aligning the pin on the bushing with the hole on the cylinder head .

lm:~~~~:!"BUSHING Install the washer onto the camshaft.

Install the camshaft in the cylinder head.

Align the " T" mark on the flywheel with the index mark on the alternator cover by turning the flywheel counterclockwise.

Position the cam sprocket with cam chain so that its "0" mark aligns with the cylinder head bolt.

Apply oil to the bolt threads and torque the cam sprocket bolts.

TORQUE : 10 - 14 N¡m (1 .0 - 1.4 kg-m, 7 - 10 ft-Ibl Install and tighten the timing hole cap bolt.

TORQUE: 10 - 14 N' m 11.0 - 1.4 kg-m, 7 - 10 ft-Ib)

Install a new gasket and cam sprocket cover, and tighten the bolts.

6-4

,..,.

CAM CHAIN TENSIONER/CYLINOER HEAO/V ALVES CAM CHA IN TE NSIONER INSTALLATION

\

(11 CAM CHAIN TENSIONER

Remove the tensioner sealing bolt and washer.

9

(4) GASKET

(21 SEALING BOLT

\

;;

(3) WASHER

Screw in the tensionel shaft all the way through the hole in the tensioner head.

Wedge the tensional shaft with a piece of wire or plate as shown to hold the tensionar.

Install the cam chain tensioner with a new gasket into the cyl. inder head.

Tighten the attaching bolts.

Remove the piece of wire and install the washer and sealing bolt.

FTTACH ING

Tighten the tensioner sealing bolt.

TORQUE : 8 - 12 N·m fO .8 - 1.2 kg-m. 6- 9 ft·lbl Adjust the valve clearance (page 3·6).

Install the front fender (page 13- 1).

CYLINDER HEAD COVER REM OVA L NOTE You can service the cylinder head cover without removing the engine.

Remove the front fender (page 13-11, Remove the cam sproket cover and cam chain tensioner (page

6-3)_ loosen the cylinder head bolt.

Remove the valve adjusting hole caps.

Remove the socket bolts. cylinder head cap nuts and washe rs.

Remove the cylinder head cover and dowel pins.

6-5

CAM CHAIN TENSIONER/CYLINOER HEAO/VALVES Remove the rocker af m shaft stopper plate f rom the head

cover.

Screw a 6 mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms.

INSPECTION Inspect the rocker arms for damage. wear or clogged oil holes.

NOTE If either rocker arm requires servicing or replacement, inspect the cam lobes for scoring. chipping or flat spots.

Measure the 1.0. of each rocker arm.

SERVICE LIMIT: 12.05 mm 10 .474 in)

Inspect the rocker arm shafts for wear or damage.

Measure the 0.0. with a micrometer.

SERVICE LIMIT: 11 .93 mm 10.470 In) Calculate the rocker arm-t e-shaft clearance.

SERVICE LIMIT : O.OB rnm 10.003 in)

INSTALLATIO N Inst all t he rocker arms and rocker arm Shafts.

Align the grooves on the rocker arm shahs with the bolt holes on the cylinder head cover .

6-6

ROI:K EA ',RM SHAFT

CAM CHAIN TENSIONER/CYLINDER HEADIVALVES Install the rocker arm shaft stopper plate.

Apply liquid sea lant to the mating surfaces of the head cover and cylinder head.

NOTE •

Do not apply sealant to the camshaft bearing surfaces.

Fill the oil pocket in the cylinder head with fresh oil.

Install the two dowel pins onto the cylinder head, then install the cylinder head cover.

Install the new copper washers, cylinder head cover cap nuts and socket bolts.

Tighten the cylinder head cover bolts in a crisscross pattern in 2 or 3 steps.

TORQUE: 6 mm socket bolt : 8-12 N·m (0.8-1.2 kg-m, 6 - 9 ft -Ibl Cap nuts : 28 - 30 N-m 12.8 - 3.0 kg-m, 20 - 22 ft -fbi Tighten the cylinder head bolt.

TORQUE: 10- 14 N-m 11 .0 - 1 .4 kg-m , 7 - 10 It-Ibl Tighten the valv e adjusting hole caps.

TORQUE : 9 - 15 N-m 10 .9 - 1.5 kg -m, 7 - 11 ft·lbl Install the cam sprocket cover and cam chain tensioner (page 6-61.

CYLINDER HEAD REMOVAL Remove Remove Remove Remove

the t he the the

engine (page 5-2). camshaft (page 6-3). cylinder head cover (page 6-51. cylinder head bolt and the cylinder head.

6-7

CAM CHAIN TENSIONER/CYLINDER HEAD/V ALVE S Remove the gasket, dowel pins and O-ring.

Remove the cam chain guide.

CYLINDER HEAD WAR PAGE IN SPECT ION Remove carbon deposits from the combustion chamber.

Clean off any gasket material from the cylinder head surface.

Check the spark plug hole and valve area for cracks.

Check the cylinder head diagonally for warpage with a straight edge and feeler gauge.

SERVICE LIMIT : 0.10 mm 1O .0041nl

DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor.

TOOL: Valve spring compressor

6-8

07757 - 001 0000 or 07957-3290001

CAM CHAIN TENSIONERICYLINOER HEADIVALVES VALV E SPRIN G IN SPECTI ON Measure the free length of t he inner and outer valve springs.

SERVICE LIMIT: INNER : 35.5 mm (1 .40 inl OUTER : 4 1. 0 mm (1 .61 inl

VALVEIVALV E GUIDE INSPECTI ON Inspect each valve for trueness, burning, abnormal stem wear.

Check the valve movement in the guide.

Measure and record each valve stem 0.0.

SERVICE LIMIT : IN : 5 .42 mm (0 .21 3 in) EX : 5 .40 mm (0 .2 13 in)

scratches or

Measure and record the valve guide 1.0 .

NOTE

•

Ream the guides to remove any carbon build up before checking the valve guide 1.0.

SERVICE LIMIT: IN/EX: 5 .50 mm (0.217 in)

Calculate the stem.le-guide c learance.

SERVICE LIMIT: IN : 0 .08 mm 10.003 in) EX: 0 . 10 mm 10.004 in) NOTE If the stem-Ie-guide clearance exceeds the service limit, determine jf a new guide with standard dimensions would bring the clearance within tolerance. If so, replace guides as necessary and ream to fit.

If the valve guide is replaced , the valve seat must be refaced.

VALVE GUIDE REPLACEMENT Heat the cylinder head to 100° - 150°C {2 12 0_ 302°FI with a not plate or oven .

CAUTION

Do not use torch to heat fhf' cylinder head; if may cause warping .

To avoid burns, wear heal'Y gfol'f'S when handling the heated

cylinder head.

Support the cylinder head and drive out the guide from the valve port with a valve guide driver.

NOTE •

When driving out the guide, do not damage the head .

TOOL: Valve guide driver , 5.5 mm

07142 - 0010100 or 07942 - 3290100

111 VALVE

6-9

CAM CHAIN TENSIONER/CYLINDER HEAD/VALVES Install an O-ring on the new valve guide and drive in the guide from the top of the head .

111 VALVE GUIDE DRIVER, 5.5 mm

-' •

<!!O

NOTE

•

Inspect the valve guide for damage.

TOOL: Valve guide driver, 5.5 mm

01742 - 00 10100 or 07942-3290 100

Ream the new valve guide after installation.

•

NOTE •

Use cutting oil on the reamer during this operation Always rotate the reamer in th e same direciton .

Clean the cylinder head thoroughly to remove any metal parti-

cles .

Rafsee the valve seat.

TOOL: Valve guide raamer, 5.485 mm

07984 - 0980001 or 07984 -098000A IU.S.A. only)

VA LVE SEAT INSPECTION Clean all intake and 811haust valves thoroughly to remove carbon deposits.

Apply 8 light coating of Prussian Blue to each valve soat. Lep each valve and seat using 8 hand-lapping tool .

Remove and inspect each valve .

STANDARD: IN/ EX : 1 . 1 - 1 .5 mm (0.04-0.06 inl SERVICE LIMIT: IN/EX : 1 .8 mm (0.07 Inl CAUTION

The valves connot be ground. If (l valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve.

Inspect each valve seat.

STANDARD : IN 1.2 mm (0.05 EX 1 .5 mm (0 .06 SERVICE LIMIT: IN 1 .5 mm 10.06 EX ' .8 rnm (0.07

inl Inl In) Inl

If the seat is too wide, too narrow, or has low spots, the seat must be refinished to seal properly.

6-10

o

CAM CHAIN TENSIONER/CYLINDER HEAD/VALVES VALVE SEAT GRINDING

(11 CUTTER " ,('CUtH

Follow the refaeer manufacturer's operating instructions .

Use a 45 degree cutter to remove any roughness or irregularities from the seat.

NOTE Refses the seat with 8 45 degree cutter when the valve guide is replaced.

TOOL : Cutter holdef. 5.5 mrn

07781 - 0010101

Valve seat cutter (page

or Equivalent commercially available in U.S. A . or Equivalent commercially

' ¡a)

..

available in U.S.A .

(1) OLD SEAT WIDTH Use a 32 degree cutter to remove 1/4 of the existing valve seat material.

Use a 60 degree cutter to remove the lower 1/ 4 of the old seat.

Remove the cutter and inspect the area you have just cu t .

(1) OLD SEAT WIDTH

Install a 45 degree finish cutter and cut the seat to the proper width. Make sure that all pitting and irregularities are removed.

Refinish jf necessary.

1.2 mm (0.05 jn)

6-11

CAM CHAIN TENSIONER/CYLINDER HEADIVAlVES Apply a thin coat of Prussian Blue to the valve seat. ill CONTACT TOO HIGH

(2) CONTACT TOO LOW

Without rotating the valve, insert the valve through the valve guide and onto the seat to make a clesr pattern.

NOTE

The location of the valve seat in relation to the valve face is very important for good sealing.

If the contact area is too high on the valve, the seat must be lowered using a 32 degree flat cutter.

If the contact area is toallow on the valve, the seat must be raised using a 60 degree inner cutter.

Refinish the seat to specifications using a 45 degree seat cut·

ter.

After cutting the seat, apply lapping compound to the valve face and lap the valve using light pressure.

After lapping, wash all residual compound off the cylinder head and valve.

NOTE

•

Do not allow lapping compound to enter the guides.

11) COTTERS (2) OUTER

ASSEMBLY NOTE Install new lIalve stem seals after disassembling .

Install the lIalve springs with the tightly wound coils facing the cylinder head .

Lubricate each lIalve stem with oil.

Insert the valves into the guides.

.~

Install the lIalve spring seats and springs.

(7) RETAINER

Install the lIalve spring, retainers and the cotters, CAUTION

To prew!nl loss oj I(>nsion, do nO! compress the more than necessary .

~'afl'e

springs

•

TOOL : Valve spring compressor

6-12

07757 - 0010000 or 07957 - 3290001

~. o O

161INNER~ SPRING

IS) SPRING SEATS

CAM CHAIN TENS lONER/CYLINDER HEAD/V ALVES Tap the valve stems gently with a plastic hammer to firmly seat the cotters.

-

CAUTION

Support the cylinder head above the work bench sur/ace /0 prevent possible valve damage.

.

-

INST A LLATI ON Clean off an y gasket material from the cylinder surface.

Make sure that the cam chain guide is installed with its lower end aligned with the groove in the crankcase and with its

bosses aligned with the grooves in the cylinder upper surface.

â&#x20AC;˘ Install the O-ring, dowel pins and a new gasket.

13) O-RING

6-13

CAM CHAIN TENSIONER/CYLINDER HEAD/VALVES Install the cylinder head and raise the cam chain.

Install the cylinder head bolt .

Reinstall the oil stopper rubber jf it was removed during disassembly.

Install the camshaft (page 6-4), Install the cylinder head cover (page 6-6), Install the engine (page 5-31.

6-14

MEMO

CYLINDER/PISTON

7-0

7. CYLINDER/PISTON SERVICE INFORMATION

7-1

PISTON REMOVAL

7-3

TROUBLESHOOTING

7-1

PISTON INSTALLATION

7-5

CYLINOER REMOVAL

7-2

CYLINDER INST ALLAnON

7-6

SERVICE INFORMATION GENERAL • Camshaft lubrication oil is fed to the cylinder head through an orifice in the cylinder head and crankcase. Be sure that this orifice is not clogged and that the O-rings and dowel pins are in place before installing the cylinder head.

SPECIFICATIONS mm(in)

STANDARD

SERVICE LIMIT

54.000 - 54.01012.1260-2.1264)

54,1012 . 130)

ITEM Cvlinder

1.0.

-- --

Taper Qut of round

Warpage across top Piston, piston pin, piston rings

0 .10 (0.004 ) 0.10 (O.OO4)

0.10 /0.004)

Piston 0.0 .

53.955- 53 .985 (2.1242-2.1254)

53.90 (2.122)

Piston pin bore

, 5.002 - 15 .00810.5906 - 0.5909)

15.02 W.591 )

Piston pin 0.0 .

14.994 - 15.000 10.5903-0.5906)

14 .98 (0 .590)

0 .002 - 0.01410.0001 - 0.0006)

0.02 (0 .001 )

TOP

0.010 - 0 .04510.0004 - 0.0018)

0.12 (0 .005 )

SECOND

0 .015 - 0.050 (0.0006 - 0.0020)

O. t 2 (0.005 )

TOP/ SEC

0.10- 0.3010.004 - 0.012)

0 .50 (0.020)

OIL

0.20 - 0.80 (0.008-0.031)

Piston-Io-pin clearance Piston ring-to·ring groove clearan ce Piston ring end gap

0.015-0 .05510.0006 - 0 .0022)

0 . 10 (0.004)

15.016- 15.034 10. 5912-0.5919)

15.06 (0.593)

Cylinder-to·piston clearance Connecting rod small end 1.0.

- -

TROUBLESHOOTING Low or unstable compression • Worn cylinder or piston rings Excessive smoke Worn cylinder. piston, or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Damaged valve stem seal Overheating Excessive carbon build·up on piston or combustion chamber wall Knocking or abnormal noise Worn piston and cylinder • Excessive carbon build-up

7-1

CYLINDER/PISTON

CYLINDER REMOVAL Remo .... e t he cvlinder head (Section 6).

Remove the cylinder.

Remove the gasket and dowel pins.

Clean off any gasket material hom the cylinder surface.

NOTE â&#x20AC;˘

Be care f ul not t o damage the gasket surf ace.

INSPECTI ON Inspect the cylinder walls for scratches and wear.

Measure and record the cylinder 1.0 . at three levels in both an X and Y axis. Take the maximum rea ding to determine the cylinder wear .

SERV ICE LIMIT: 54 ,10 rnm (2 ,130 in) Calculate the piston-la-cylinder clearance. Take the maximum reading to determine the clearance.

Refer to page 7-3 for measurement of the piston 0.0.

SERVICE LIMIT: 0.10 mm (O.004 in)

Calculate cylinder taper at three levels in an X and Y axis. Take the maximum reading to determine the taper.

SERVICE LIMIT; 0 .10 mm 10.004 in) Calculate the cylinder out-of-round at three levels in an X and Y axis . Take the maximum reading to determine the out-ofround.

(1) IN ¢:J

(3) TOP

7-2

'---

, .-

SERVice LIMIT; 0 .10 mm 10.004 inl The cylinder must be rebored and oversize piston fitted if the service limits are exceeded.

The following oversize pistons are available: 0.25 mm (0.010 in), 0.50 mm (0.020 in), 0.75 mm 10.030 in) and 1.00 mm (0.040 in) The cylinder must be rebored so that the clearance to an oversize piston is 0 .015 - 0.055 mm (0.0006 - 0.0022 in).

?'

(4) MIDDLE

r--..

-

(5) BOTTOM

Y

<:'-1-:;,

t'--'-

j

./ -.

-, _/

./

c=:> (2) EX X

CYLINDER/PISTON Inspect the top of the cylinder for warpage.

SERVICE LIMIT: 0 . 10 mm (0.004 Inl

PISTON REMOVAL St uff a shop towel into the crankcase.

Remove the piston pin clips with needle nose pliers.

NOTE â&#x20AC;¢

00 not allow the clips fait into the crankcase .

Press the piston pin out of the piston .

Remove the piston.

Spread each piston ring and remove it by lifting up at a point opposite the gap .

PISTON/ PISTON RING INSPECTION Measure the piston skirt diameter at , 0 mm (0 .4 inl from the bottom and 90 0 to the piston pin bore .

SERVICE LIMIT : 53.90 mm (2.122 In) Compare t his measurement against the service limit and calcu late piston-to-cylinder clearance.

Refer to page 7-2 for cylinder bore inspection.

7-3

CYLINDER/PISTON Measure the piston ring-ta-groove ctearance.

SERVICE LIMIT: TOP: 0 .12 mm (0 .005 In) SECOND: 0. 12 mm 10,005 in ) Inspect the piston for wear or damage.

Insert each piston ring into the cylinder and m easure t he ring end gap.

NOTE

Push t he rings into the cylinder with the top of the piston to be sure they afe squarely set in the cylinder.

SERVICE LIMIT :

TOP:

0 .50 mm (0 .020 in) SECOND: 0 .50 mm (0 .0 20 in)

Measure the piston pin bore.

SERVICE LIMIT: 15.0 2 mm (0.591 in)

Measure the piston pin 0.0.

SERVICE LIMIT: 14.98 mm (0 .590 inl Calculate the piston-Io-piston pin clearance .

SERVICE LIMIT: 0 .0 2 mm (0 .001 Inl

7-4

(1) PISTON

CYLINDER/PISTON Measure the connecting rod small end 1.0.

SERVICE LIMIT : 15.06 mm (0.593 in!

PISTON INSTALLATION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks lacing up.

11) '"R" or "T" MARKS

NOTE •

(71

Avoid piston and piston ring damage during installation .

Do not interchange the top and second rings.

SECOND SIDE RAIL

Space the piston ring end gaps 120 degrees apart. Do not align the gaps in the oil rings (side rails).

SIDE RAIL

After installation, the rings should be free to rotate in the ring grooves.

(6)20 OR MORE

Q

~

PISTON INSTALLATION Install the piston with its "IN" mark on the intake valve side.

Install the piston pin with new pin clips.

Do not align the piston pin clip end gap with the piston cutout.

NOTE •

Do not allow the clip to fall into the crankcase.

12iPis1'Q"N PIN ~LlP

7-5

CYLINDER/PISTON

CYLINDER INSTALLATION Clean off any gasket material from the crankcase surface.

NOTe

â&#x20AC;˘

Be careful not 10 damage the gasket surface.

Install the dowel pins and a new gasket.

C08t the cylinder bore and piston rings with engine oil and install the cylinder.

NOTE

Avoid piston ring damage during installation. â&#x20AC;˘

00 not allow the cam chain to fall into the crankcase .

Install the cylinder head {page 6- 13).

7-6

MEMO

CLUTCH/GEARSHIFT LINKAGE

10 - 14N-m

(1.0 - 1.4 kg-m , _ _~..tY 7 - 10 ft -Ibl

50- 60 N' m (5 .0 - 6 .0 kg-m ,

36-43ft~~~ ~ .~ o

•

C)~

70 - 80 N·m p .0 - 8.0 kg-m, 51 - 58 ft-Ibl

19 - 25 N·m (1.9 - 2.5 kg -m , , 4 - 18 ft -Ib)

8-0

,

•.

...

~G ,;) L!iJ \~ ~r '"

.,..,0

~",<Y

~~ W

8. CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING

8· 1 8·2

RIGHT CRANKCASE COVER REMOVAL

8·3

CENTRIFUGAL CLUTCH

8·5

SERVICE INFORMATION

MANUAL CLUTCH GEARSHIFT LINKAGE

8·9 8·13

RIGHT CRANKCASE COVER INSTALLATION

8·16

SERVICE INFORMATION GENERAL • This section covers removal and installation of the right crankc ase cover, centrifugal clutch , manual clutch and gearshift linkage.

SPECIFICATIONS mmOn) STAN DARD

ITEM Centrifugal clutch

1.510.06)

Weight lining thickness

Bushing

I I.D.

M anual clutch

Outer 1.0.

Outer bushing

1.3(0 .05)

102.0- 102.214.016 - 4 .024 )

102.4 14 .03)

23 .000 - 23.021 10.9055 - 0.9063)

23.0510.907)

22.959 - 22.980 (0.9039 - 0 .9047 )

22.93 (0.903 )

28.000-28.02 1 (1.1024 - 1.1032)

28 .0511 . 10 4 )

Drum 1.0.

Crankshaft 0 .0 .

SERVICE LIMIT

1.0.

19 .979 - 20.000 10.7866 - 0 .7874)

20 .03 (0.789)

0 .0.

27 .959 - 27 .980 11.1007 - 1. 1016)

27.93(1. laO)

27 .6 11.09)

26.5/1 .04)

Spring

2.9 - 3.0 (0. 11 - 0.12)

DISC thickness

--

Disc and plate warpage

19.959- 19.980 10.7858 - 0 .7866)

Mainshafl 0 .0 .

2.6 (0.101 0.2 (0.0 1) 19.93 (0.785)

TORQUE VA LUES Centrifugal clutch lock nut Manual clutch lock nut Drum plate center bolt Clutch adjusting screw lock nut

70 50 1019 -

80 60 ,4 25

N· m N·m N'm N' m

(7.0 (5 .0 11.0 11 .9 -

8.0 6.0 1.4 2.5

kg·m , kg·m , kg·m, kg·m,

51 - 58 ft·lb) (APPLY Oil TO THE THREADS ) 36 - 43 ft-Ib) )APPlY Oil TO THE THREADS) 7-10 ft-Ib) 14 - 18 It-Ib)

8-1

CLUTCH/GEARSHIFT LINKAGE TOOLS Special Bearing remover s8t, 12 mm - Bearing remover shaft assy, 12 mm - remover weight Shah protector Clutch center holder Common Attachment, 32 x 35 mm Pilot, 12 mm Driver

07936-166000 1 Not available in U.S.A.

07936 - 1660100 07741 - 00 10201 or 07936 - 3710200 07960 - 1870100 or Equivalent commerciaJly available in U.S.A. 07923 - 9580000

07746 - 0010100 07746 - 0040200 07749 - 0010000

TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch.

Clutch slips when accelerating Faulty clutch lifter mechanism Discs worn Weak. spring Incorrect clutch adjustment

Clutch will not disengage Faulty clutch lifter

Incorrect clutch adjustment Plates warped ATe creeps with engine idling • Faulty centrifugal clutch Clutch operation feel s rough Rough manual clutch out er slots • Worn or damaged centrifugal clutch shoes or drum Gearshift pedal will not return Weak or broken gearshift spindle return spring • Binding gearshift spindle

8-2

CLUTCH/GEARSHIFT LINKAGE

RIGHT CRANKCASE COVER REMOVAL Drain the oil from t he engine (page 2-2).

Remove the foot peg mounting bolts, and right foot peg/ brake pedal assy .

(1) FOOT

Remove the Loosen the cable.

Remove the Aemove the

lock nut and reverss shaft arm. reverse cable lock nut and remove the reverss righ t crankcase cover bolts and cover. gasket and dowel pins.

BEA RI NG AND DU ST SEA L REPLAC EM ENT inspect the reverse shaft dust seal in the right crankcase cover

•

for wear or damage.

Replace t he dust seal, if necessary.

•

Ie ( 1) DUST SEAL

Inspect the crankshaft bearing on the right crankcase cover for wear or damage, if necessary.

Remove the bearing using bearing remover.

TOOL: Bearing remover set, 12 mm

07936 - 1660001 Not available in U.S.A .

- Bearing remove r s haft aSlY. 12 mm 07936 - 1660100 - remover weight

07741 - 0010201 or 07936 - 37102 00 (1) BEARI NG REMOVER SET, 12 mm

8-3

CLUTCH/GEARSHIFT LINKAGE Install the new crankshaft bearing with sealed face down.

111 DRIVER

Drive in a new bearing.

TOOLS :

Driver Attachment , 32 x 35 mm

Pilot, 12 mm

07749 - 0010000 07746 - 0010100 07746 - 0040200

• PILOT, , 2 mm

LIFTER

CLUTCH LIFTER DISASSEMBLY /ASSEMBL Y Remove the dutch adjusting screw lock nut and washer.

Remove the clutch lifter from the right crankcase cover.

Check the disassembled parts for wear or damage.

Replace the parts if necessary.

Refer to page 8·9, for ball retainer and clutch cam plate re moval.

/

(5) LOCK NUT

Screw t he adjusting screw into the clutch lifter and install a new O-ring.

Install the clutch lifter, aligning the pin on the clutch lifter with

the hole in the right crankcase cover .

Install the washer and lock nut.

8-4

(4) WAS HER

(3) D-RING

CLUTCH/GEARSHIFT LI NKAG E

CENTRIFUGAL CLUTCH WEIGHT LIN ING INSPECTION Measure the weight lining thickness.

SERVICE LIMIT: 1.3 mm (0.05 in'

WE IGHT REMOVAL Remove the E-ctips, plate, friction spring and washer .

Remove the cen trifugal clutch weights.

CLUTCH DRUM IN SPE CTION Check the inside of the clu t ch drum for scratches or excessive wear . Replace jf necessary.

Measure t he 1. 0 . of th e clut ch d rum.

SERVICE LI MIT : 102.4 mm (4 .03 in )

FRI CTION SPRI NG INSPECTION Inspect the friction spring for wear or damage.

Replace the friction spring. jf necessary .

8-5

CLUTCH/GEARSHIFT LINKAGE WEIG HT IN STA LLATION Instatl the weights 85 shown.

InSlalithe washer and friction spring .

Install the plate and E-clips securely as shown.

CENTRIFU GAL CLUTCH REM OVAL Remove the recoil starter (page 9 -21, Hold the starter driven pulley as shown.

Unstake the lock nut center punch with a drill or grinder.

Remove the lock nut and washer.

NOTE

â&#x20AC;¢

The lock nut has left hand threads.

8-6

CLUTCH /GEARSHIFT LINKAGE Align the clutch outer cutout with the drive gear on the clutch drum.

Remove the centrifugal clutch assembly using the bearing puller and shaft protector.

TOOL: Shaft protector

07960 - 1870100 or Equivalent commercially available in U.S.A.

Remove the clu t ch weights and the hub.

Remove the oneway clutch bearing from the drum.

(1) ONEWAY

Inspect the onaway clutch bearing fo r excessive wear or damage and replace it if necessary .

(1) ONEWAY CLlJTC:H BEARING

8-7

CLUTCH/GEARSHIFT LINKAGE CENTRIFUGAL CLUTCH BUSHING INSPECTION

(11 BUSHINGS

Inspect the bushings for wear or damage.

Measure the 1.0. of the centrifugal clutch bushings.

SERVICE LIMIT: 23.05 mm (0.907 inl Measure the 0.0. of the crankshaft at the two points.

SERVICE LIMIT: 22.93 mm (0.903 inl

CENTRIFUGAL CLUTCH INSTALLATION Install the oneway clutch bearing with the flange facing down .

Assemble the weight, washer, friction spring, plate and E·clips onto the drum.

Install the centrifugal clutch onto the crankshaft, aligning the cutout on the manual clutch outer with the centrifugal clutch drive gear.

Install the washer.

8-8

(1) DRUM

CLUTCH/GEARSHIFT LINKAGE Hold the starter driven pulley (page 8-6 ) and install the lock

nut .

NOTE

•

The lock nut has left hand threads .

Tighten the lock nut .

TORQU E: 70 - 80 N·m (7 .O- B.O kg-m , 51 - 58 ft -Ibl IAPPl Y OIL TO THE THREADS) Stake the lock nut into the hole in the crankshaft with a center punch.

Install the recoil starter {page 9- 5).

MANUAL CLUTCH RE MOVAL Remove the cen t rifugal clutch (page 8 -6).

Remove the clutch lifter lever. clutch cam plate and ball retain af with the spring.

13)

Remove the clutch bolts , springs and lifter plate .

Unstake the lock nut center punch.

Install the clutch center holder 85 shown and remove the lock nul and washer.

TOOL : Clutc h cente r holde r

07923 - 958000 0

8-9

CLUTCH/GEARSHIFT LINKAGE Remove the clutch center. discs, plates and clutch pressUl8

plate.

Remove the thrust washer and clutch outer.

Remove the clutch outer guide from the mainshaft.

IN SPECTIO N

(1)

CLUTCH mrrFRGUIDE

Check the slots of the clutch outer for wear or damage made by the clutch discs.

Replace the outer if necessary.

Measure the I.D. of the clutch outer.

SERVICE LIMIT: 28.05 mm (1.104 In) Measure the 1.0. and 0 .0. of the clutch outer guide.

SERVICE LIMIT: 1.0. 20.03 mm 10.789 in)

0 .0 . 27 .93 mm 11.100 Inl

W " C H OUTER

Measure the 0.0. of the mainshaft.

SERViCE LIMIT: 19.93 mm (0.785 in)

Inspect the clutch lifter plate for wear or damage.

Turn the bearing inner face with your finger.

The bearing should turn smoothly and gentty.

Also check that the bearing outer face fits tightiV in the clutch liher plate.

III CLUTC H LIFTER PLATE

8-10

(2) BE,"RING

CLUTCH/GEARSHIFT LINKAGE Measure the clutch spring free length.

SERVICE LIMIT: 26.5 mm (1.04 inl

Replace the clutch discs if they show signs of scoring or discoloration.

Measure the disc thickness.

SERVICE LIM IT: 2.6 mm (0 . 10 Inl

Check each plate and disc for warpage on a flat surface using a feeler gauge.

SERVICE LIMIT: 0 .2 mm (0.0 1 in)

INSTALLAT ION Install" the clutch outer guide onto the mainshaft with the flange side toward the crankcase.

8-11

CLUTCH/GEARSHIFT LINKAGE Install the clutch outer and thrust washer.

NOTE

Install the thrust washer with the chamf ered surface

toward the clutch outer.

Assemble the clutch pressure plate, discs, plates and clutch (1) THRUST

center.

(2) CLUTCH DISCS (4 PIECES)

WASHER NOTE

•

Stack the discs and plates alternately.

Coat new clutch discs with the engine oil.

Install the clutch assembly into the clutch outer.

141 PLATES (3 PIEC ES)

Install the washer and a new lock nut.

Inst all t he clutch center holder with the clutch bolt s.

TOOL: Clutch c enter holder

07923 - 9580 000

Tighten the lock nut.

TORQUE: 50 - 60 N·m (5 .0 - 6 .0 kg.m , 36 - 43 h ·lb) (APPLY Oil TO THE THREADS)

Stake the lock nut into the hole in the mainshaft w ith a center punch.

8-12

(3) CLUTCH PRESSURE PLATE

CLUTCH/GEARSHIFT LINKAG E Install the clutch springs and lifter plate with the bearing.

T ighten the dutch bolts.

Install t he clut c h lifter lever with t he shift spindle pin in the end hole.

Install the clutch cam plate on the clutch lifter bearing.

Install the spring and ball retainer to the cam plate, aligning the steel balls in the ball retainer with the lug on clutch cam plate .

Install the centrifugal clutch {page 8- 81.

GEARSHIFT LINKAGE REMOV AL Remove the following; - gearshift pedal.

- centrifugal clutch (page 8-6).

- manual clutch (page 8-9), Unhook t he spring from the guide plate and pull the gearshift spindle out of the crankcase .

8-13

CLUTCH/GEARSHIFT LINKAGE Remove the drum plate center bolt, stopper plate and guide

plate .

Remove the drum plate and dowel pin .

Remove the stopper arm bolt, stopper arm, spring and washer.

Remove the reverse shaft.

INSPECTION

(1) R"CURNSPRING

Check the gearshift spindle for wear or damage.

Inspect the return spring f or damage or fatigue.

(2) GEARSHIFT SPINDLE

Inspect the reverse shaft, stopper arm and spring for wear or damage.

111 ST'OPF"R ARM

131 RE\IER'"

8-14

CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the reverse shaft and washer.

Install the dowel pin into the shift drum .

Assemble the stopper arm, spring and washer, and install

them.

Tighten the stopper arm bolt.

Install the drum plate by aligning the hole in the plata with the

dowel pin.

Install the guide plate and set the stopper plate by aligning the cutout of the drum plate with the tab of the stopper plate.

Install the drum plate bolt securely.

TORQUE: 10 - 14 N¡m t 1.0 - 1.4 kg-m , 7 - 10 f t ¡lb)

Install the washer of the gearshift spindle between the crank case and the guide plate as shown.

Install the gearshift spindle .

Insert the end of the return spring into the return spring pin .

Hook the spring onto the guide plate .

NOTE

The shih spindle hole in the left crankcase cover has an oil seal . When installing the spindle, use care not to damage it .

Install the gearshift pedal (page 9-111.

14 , GE,'R',H"FT SPINDLE

8-15

CLUTCH/GEARSHIFT LINKAGE

RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket.

Install the right crankcase cover and bolts.

Tighten the right crank case cover bolts securely.

Connect the reverse cable to the reverse shaft arm and install the reverse shaft arm onto the reverse shah.

Install and tighten the lock nut.

Install the reverse cable and adjust the reverse selector lever free play (page 3- 111.

Install the right foot p'eg mounting bolts.

Adjust the clutch (page 3¡ 12).

FiJI the engine with recommended oil.

Check the clutch and reverse lock mechanism for smooth op-

eration.

Check for oil leaks.

8-16

MEMO

RECOIL STARTER/ ALTERNATOR

8 - 12 N·m

10 ,8 - 1 .2 kg -m , 6 - 9 ft -lbJ

26 - 30 N·m

12.6 - 3.0 kg-m , 19 - 22 ft-lbJ 5- 7 N'm

to.S - 0 .7 kg-m, 4 - 5 ft -Ib) 40 - 50 N·m 14.0 - 5 .0 kg-rn,

29 - 36 ft -Ib)

=~

14-18 N·m

11.4 - 1.8 kg -m , 10 - 13 ft -Ib)

9-0

80 - 100 N·m 18.0 - 10.0 kg-m, 58 - 72 It-Ib)

9. RECOIL STARTER/ALTERNATOR SERVICE INFORMATION

9-'

ALTERNATOR

9 -5

TROUBLESHOOTING

9-' 9-2

FLYWH EEL/STARTER CLUTCH

9-7

RECOIL STARTER

SERVICE INFORMATION GENERAL • This section covers the removal and installation of recoil starter, left crankcase cover, starter gears, alternator and starter c lutch.

• Refer to Section 14 and 15 for alternator inspect ion.

TORQUE VALUES

Gearshift pedal bolt

40~50 N' m 14.0-5.0 kg -m, 29 - 36 fl -rb ) (apply oil to bolt threadsl 26-30 N'm (2.6-3.0 kg-m , 19 - 221t-lb) 14 - 18 N·m (1 .4 - 1.8 kg -m, 10 - 13 It -Ib)

Foot peg bolt Alternator bolt (S H bolt) Change switch bolt (SH boltl Pulse generator bolt

8-12 N·m (0.8 - 1.2 kg -m. 6 - 9 fl -rb) 8-12 N·m (0.8-1.2 kg -m, 6 - 9 ft -Ib) 5- 7 N· m (0.5 - 0.7 kg-m, 4 - 5 ft-Ib )

Starter driven pulley bolt

Starter c lutc h bolt

80-100 N·m 18.0 - 10.0 kg -m, 58 - 72 tr -tb)

TOOLS Common Flywheel pulier Flywheel holder

07733 - 0010000 or 07933-2000000 07725 - 0040000 or EQuivalent commercially available in U.S.A .

TROUBLESHOOTI NG Engine does not t urn Faulty oneway starter clutch • Starter gear broken Engine does not turn w hen operating recoil starter Faulty starter ratchet Faulty starter driven pulley Faulty starter drive pulley Starter rope does not recoil • Faulty recoi l spring

9-1

RECOIL STARTER/ ALTERNATOR

RECOIL STARTER REMOVAL Shift the transmission into neutral.

Remove the recoil starter.

DISASSEMBLY Remove the bolt and ratchet cover.

Remove the ratchet, ratchet guide, spring seat and spring.

Check the ratchet, ratchet guide and spring for wear or dam-

(1) RATCHET

GUIDE.~_-~12)

SPRING SEAT

age.

11) HANDLE COVER

Remove the starter handle cover.

Untie the starter rope and remo ve the starter handle.

Aelease the starter rope slowly.

Remove the starter drive pulley.

CAUTION

Wear eye protection and use core when removing the drive pulley and starler spring. The spring can pop Oll{ of Ihe housing

if CUfe

is nO! used.

(3) DRIVE PULLEY

9-2

RECOIL ST ARTERI AL TERNATOR Remove the starter rope from the drive pulley.

Check the starter rope for wear or damage.

/

--,,_

......... \

::'"'-

(11 DRIVE PULLEY

(2) ROPE

-

Check the recoil starte r spring.

Remove the spring if it is broken.

(1) STARTER SPRING

A SSEM BLY Install the starter rope and tie a square knot in the end.

Wrap the rope around the drive pulley in a counterclockwise direction as viewed from the housing side.

/ -----_.......

(1) DRIVE PULLEY

\

(2) ROPE

Install the spring by hooking the end on t he housing hook.

CAUTION

Wear eye protection and use care when installing the starter spring. The spring con pop QUI oj rhe housing if cure is not IIsed.

9¡3

RECOIL STARTER/ALTERNATOR ill DRIVE PULLEY

Apply grease to the pulley shaft and drive pulley, and install the drive pulley by hooking t he end of the spring on the housing.

/

Preload the starter spring by turning the pulley 2 turns clockwise.

(1) HANDLE

Route the rope end through the starter housing hole and install the handle.

Tie the rope end and install the handle cover.

NOTE â&#x20AC;˘

Do not lift the pulley up when inst alling the rope.

(3) STARTER HOUSING HOLE

Apply grease to the ratchet and install the ratchet onto the drive pulley.

Install the spring, spring seat and ra tchet guide.

9-4

(1)

RATC HET

->11

(2 ) HANDLE COVER

GU ID E

RECOIL STARTER/ALTERNATOR Install the ratchet cover and t ighten the bolt.

Check recoit starter operation by pulling the starter handle.

(2) BOLT

INSTALLATION Install the recoil starter with four botts.

ALTERNATOR LEFT CRANKCASE COVER REMOVAL Drain the engine oil (page 2-2), Remove the recoil starter (page 9-2).

Shift the transmission into neutral.

Remove the left foot peg and gearshift pedal.

Disconnect the alternator and change switch wire connectors.

Remove the drive chain cover .

FOOT PEG

Hold the starter driven pulley with suitable tool and remove its mounting bolt, and then remove the pulley_

9-5

RECOIL STARTER/ALTERNATOR Remove the left crankcase cover bolts and cover.

Remove the gasket and dowel pins.

LEFT CRANKCASE COVER DU ST SEALS INSPECTION

•

n-

Inspect the dust seals for wear or damage. replace if neces·

sary .

LEFT CRANKCASE COV ER DISASSEMBLY/ ASSEMBLY

•

Alternator Remove the three bolt s and the stator from the left crankcase

cover.

Pulse generator Remove the pulse generator by remov ing the socket bolts and disconnecting the connector.

Change switch Remove the change switch by removing the bolt.

Install them in the reverse order of removal.

TORQUE: Alternator/Change switch ISH bolts) 8 - 12 N·m (0.8-1 .2 kg -m, 6 - 9 ft-Ib)

Pulse generator 5 - 7 N·m (0.5 - 0.7 kg-m, 4 - 5 fl -Ib) NOTE

Install the wire grommets in the groove of the cover properly.

9-6

(1) DUST SEALS

111 COI'NECJ"R

"'--0

RECOil STARTERJAl TERNATOR

flYWHEEL/STARTER CLUTCH REMOVAL Remove the starter/reduction gear and starter idle gears.

Hold the flywheel with the flywheel holder or band strap wrench and remove the flywheel with the flywheel puller.

TOOLS :

Flywheel puller

07733 - 0010000 or 07933 - 2000000

Flywheel holder

07725-0040000 or Equivalent

commercially

available in U.S.A. Refer to page 9-9 for flywheel installation.

Remove the starter driven gear.

1~~""~ DRIVEN GE~

Remove the needle bearing and washer.

9-7

RECOIL STARTER/ ALTERNATOR Remove the woodru ff key.

INSPECTI ON

,

(1 ) OUTER STARTER

(2) INNER STARTER GEAR

(3) BUSHING

,

Inspect the starter/reduction gear, inner starter idle gear and outer starter idle gear for wear or damage.

,,

NOTE

00 not interchange the inner startar idle gear ~ 1 aTl and the outer starter idle gear (22 T) at installation .

Inspect the reduction gear shaft and the shaft bushing for wear or damage.

'5, STA,RTERIR"DU'OTlCIN GEAR

Install the starter driven gear inlo the onaway clutch outer by turning it counterclockwise.

Check the operation of the onaway clutch by turning the driven gear . You should be able 10 turn the driven gear counterclockwise smoothly. but should not be able to turn it

clockwise.

Inspect the starter driven gear and needle bearing tor wear or damage.

(1)

9-8

STARTER

nR"v," GEAR

!

(21 NEEDLE BEARING

RECOIL STARTER/ALTERNATOR ONEWAY CLUTCH DISASSEMBLY/ASSEMBLY Remove the oneway clutch bolts, oneway clutch and clutch outer from the flywheel.

Check the onaway clutch rollers for wear or damage.

Apply locking agent to boft threads and assemble the clutch outer, oneway clutch and bolts to the f lywheel.

Tighten the bolts.

111

OUTER

(3) ONEWAY

TORQUE; 26 - 30 N·m 12.6-3. 0 kg-m, 19 - 22 ft-Ib)

Recheck the oneway dutch operation.

INSTALLATION Install the woodruff key.

Install the washer and needle bearing ont,p the crankshaft.

Install the starter driven gear.

Align the key way in the flywheel with the key on the crankshaft and install the flywheel.

Install starter/reduction gear shaft and bushing.

Install the inner starter idle gear (, BT).

9-9

RECOIL STARTER/ALTERNATOR Install the inner starter idle gear shaft and the reduction gear.

Install the outer starter idle gear .

NOTE Install the inner starter idle gear 118T) and outer starter idle gear (22T) correctly.

Incorrect engagement could damage gears.

LEFT CRANKCASE COVER IN STALLATION Install the dowel pins and a new gasket.

Align the slit on the shift drum with the pin on the change swit ch.

9-10

RECOil STARTER /Al TERNATOR Install the left crankcase cover and tighten the cover bolt s.

Apply grease to the oil seal lip and install the starter driven pulley by aligning its flats with the groove in the flywheel.

Install the O-ring onto the pulley bolt.

Hold the driven pulley with suitable tool and tighten the pulley bolt.

TORQUE: 40 - 50 N·m (4 .0- 5 .0 kg·m. 29 -36 ft-Ib) (apply oil to bo lt thread s)

BOLT

Install the following: - recoil starter (page 9· 5).

- drive chain cover - left f oot peg - gearshift pedal with aligning the punch marks Tighten the gearshift pedal bolt.

TORQUE : 14 - 18 N·m 11.4 - 1.8 kg -m , 10 - 13 ft·lb) Connect the alternator and change switch wire connectors.

Fill the crankcase with the recommended oil (page 2·2) .

PEG

(4) PUNCH MARKS

9-11

TRANSMISSION/CRANKSHAFT

10 N-m 11.0- 1.4 kg-m. 7-10ft-lb)

10-0

10. TRANSMISSION/CRANKSHAFT SERVICE INFORMATION

10-1

TRANSMISSION DISASSEMBLY

10-5

TROUBLESHOOTING

10-2

BEARING REPLACEMENT

10-7

CRANKCASE SEPARATION

10-3

TRANSMISSION ASSEMBLY

10-9

CRANKSHAFT

10-4

CRANKCASE ASSEMBLY

10- 10

SERVICE INFORMATION GENERAL • For crankshaft and transmission repair, the crankcase must be separated .

• Remove the following parts before separating the crankcase.

Engine Section 5 Clutch and gearshift linkage Cylinder head Section 6 Oil pump Cylinder and Piston Section 7 Starter motor Section 16 Recoil starter Section 9

Section 8 Section 2

SPECIFICATI ONS mm!in}

STANDARD

ITEM Crankshaft

Aunout

Right

L,tt Connecting rod big end side

---

0.10 10.004)

0.08 (0.003)

0.05 - 0.50 (0.002-0.020)

0.80 {O.031J

0 - 0.008 (0 - 0.0003)

0.05 (0.002)

Shift fork shaft 0.0.

1 2.966 - 1 2.984 10.5105-0.51121

12.96 (0.510)

Shift fork

13.000 - 13,02110.5118 - 0.51261

13.04 {0.513)

clearance Connecting rod big end radial clearance Transmission

SERVICE LIMIT

1.0.

Claw thickness

Aeverse idle gear Gear 1. 0.

Bushing 1.0. and 0.0.

Bushing 0.0.

1.0.

4.93 - 5.00

to. 1 94 -

0. 197)

13.000 - 13.018 (0.5118 - 0.5125)

4.50 (0.177) 13.0510.514)

Shaft 0.0.

12.972 - 12.987 (0.5107-0.5113)

12.93 {0.509)

M' M5

23.000-23.021 (0.9055-0.9063)

20.05 (0.789)

T5.000-15.018 (0.5906 - 0.5913)

15.07 {0.593)

C1

18.016 - 18.034 (0.7093 - 0.7 100)

18.07 (0.711)

CR

23.020 - 23 .041 (0.9063-0.9071)

23.07 (0.908)

C2

23.020 - 23.041 (0.9063 - 0.9071)

23.07 (0.908)

C3

23.020 - 23.041 (0.9063 - 0.9071)

23.07 (0.908)

Ct 1.0.

15.016 - 15.034 (0.5912 - 0.5919)

15.06 (0 .593 )

Cl0.o.

17.966 - 17.984 (0.7073-0.70BO)

17.93 (0.706)

C3, M4 1.0.

20.000 - 20.021 (0.7874-0 .7882 )

20.05 (0.7891

C30.O.

22.979 - 23.000 (0.9047 - 0.9055)

22.95/0.904)

M4,0.0.

22.959 - 22.980 (0.9039-0.9047)

22.93 (0.903)

CA, C2

22.959 - 22.980/0.9039 - 0.9047)

22.9310.903)

10-1

TRANSMISSION/CRANKSHAFT mm(inl ITEM Mainshaft and Countershaft 0.0.

STANDARD

SERVICE LIM IT

M4

19.959 - 19.980 (0.7858-0.7866)

19.93 (0.785)

M5

14.966- 1 4 .984 (0.5892-0.5899)

14.93 (0.588)

C3

19.959 - 19.980 (0.7858-0.7866)

19.93 (0.785)

C1

14.983 - ' 4.994 10.5899 - 0.59031

14.93 (0. 588)

TORQUE VA LUE T ensioner pivot bolt

10 - 14 N·m (1 .0 - 1.4 kg -m , 7 - 10 ft -Ib)

TOOLS Special Bearing remover, , 5 mm - remover 8SSV. 1 5 mm - remover shaft. 15 mm - remover head , 15 mm

07936-KC 10000

Not available in U.S.A.

07936 - KC10500 07936-KC10100~

.

.

07936 _ KC10200~ Not available In U.S.A.

- remover weight

07741 - 0010201

Attachment, 45 x 50 mm

07946 - 6920100

or 07936 - 3710200

Common

Driver

Attachment, 24 x 26 mm Attachment, 32 x 35 mm Attachment, 42 lC 47 mm Pilot, 15 mm Pilot , 20 mm Pilot , 22 mm

07749-0010000 07746 - 0010700 07746 - 0010100 07746 - 0010300 07746 - 0040300 07746 - 0040500 07746 - 0041000

TROUBLESHOOTING Hard 10 shUt Shift fork bent • Shift fork shaft bent Transmission jumps out of gear Gear dogs worn • Shift fork bent or damaged

10-2

Crankshaft noisy Worn connecting rod big end bearing Bent connecting rod Worn crankshaft main journal bearing Gears noisy • Worn transmission gear

TRANSMISSION /CRANKSHAFT

CRANKCASE SEPARATION Remove the following : - counlershaft chain c ase stay - tensioner - cam chain

Remove the eleven bolts and two breather tube dips .

Place the engine with the right crankcase side down .

Remove the left crankcase w hile tapping the cases at several locations with soft hammer.

CAUTION

â&#x20AC;¢ Do 1101 pry between Ihi'le/f and right crankcases.

(1)

LEFT CRANKCASE

-

_... --- ""'"

Remove the dowel pins and gasket.

,21 GASK"T

10-3

TRANSMISSION/CRANKSHAFT

CRANKSHAFT REMOVAL Remove the crankshaft.

IN SPECTION Set the crankshaft on a stand or V-blocks and read the runout

using a dial indicator.

SERVICE LIMIT:

A lEFT:

0 .08 mm (0.003 in)

BRIGHT; 0 . 10 mm (O.OD4 in )

Measure the side clearance 8t the connecting rod big end with a feeler gauge.

SERVICE LIMIT: 0 .80 mm (0.0 3 1 in)

Measure the radial clearance at the connecting rod big end, at two points in the direction indicated by the arrows.

SERVice LIMIT : 0.05 mm 10.002 Inl

10-4

~x

TRANSMISSION /CRANKSHAFT Turn the outer race of each bearing with your f inger. The bearings should turn smoothly and quietly. Also check that the bearing inner race fits tigh tl y on the crankshaft.

Check the sprocket teeth for wear.

Make sure that the sprocket is positioned correctly. with one tooth end aligned with the keyway center in the crankshaft .

INSTA LLATION Install the crankshaft in the reverse order of removal.

13) TIMING SPIROIOK!:T

TRANSMISSION DISASSEMBLY

(1) SHIFT FORK

.

---- - - ' " KEY WAY

<",'"

Pull the gearshift fork shah out and remove the shift forks and shift drum.

or

Remove the mainshaft and countershah assemblies as shown.

11) CC)UI"TE~~t~,,-

'"' "",'_." GEAR

Remove the washers, reverse idle gear and shaft .

Remove the C 1 gear, C 1 bushing and washer.

INSPECTION Inspect the shift drum for scoring , scratches, or lack of lubrication.

Check the shift drum grooves for damage.

- --

...........,-~-~ â&#x20AC;¢

10-5

TRANSMISSION /CRANKSHAFT Check the shift fork shaft fo r wear or damage.

Measure the shift fork shaft 0.0.

SERVICE LIMIT: 12.96 mm (0 .510 lnl

Check the shift forks fo r we ar or damage.

Measure t he 1.0. of the shift fork.

SERVICE LIMIT: 13.04 mm 10.513 inl

Measure each fork claw thickness.

SERVICE LIMIT: 4 .50 mm 10. 177 inl

Check the gear dogs, dog holes and teeth for abnormal wear, or lack of lubrication .

Measure the I.D. of the reverse idle gear hole.

SERVICE LIMIT: 13.05 mm (0.514 in) Measure the 0. 0 . of the reverse idle gear shaf t.

SERVICE LIMIT: 12.93 mm (0 .509 in)

Calculate the shaft' la-gear clearance.

SERVICE LIMIT: 0 . 10 mm (0.004 in)

10-6

TRANSMISSION/CRANKSHAFT Measure the 1.0. 01 each gea r.

SERVICE LIMIT ; M4 ; 2 0 .05 M5 : 15.07 C1 : 18.07 C Reverse : 2 3 .07 C2 : 23 .07 C3 : 23 .07 Measure the 1.0 . and

mm (0 .789 inl mm (0 .593 inl mm (0 .711 inl mm (0 .908 inl mm (0 .908 Inl mm (0.908 in) 0.0. 01 each gear bushing.

SERVICE LIMIT: C1 : 1.0 . : 15.06 mm (0 .59 3 inl 0 .0 . : 17 .93 mm (0 .706 inl C3 . M4 1.0 . : 2 0 .05 mm (0 .789 inl M4 0 .0 . : 2 2 .93 mm (0 .903 in) C3 0 .0 . : 2 2 .95 mm (0 .904 inl Measure the 0.0 . 01 remaining bushing.

( 1) Cl BUS HI NG

(2) C3 BUSHING

SERVICE LIMIT: C Reverse and C2 : 22 .93 mm (0 .903 In) Calculat e the gear bushing-to·gear clearance.

SERVICE LIMIT : 0 , 10 mm 10.004 In) Measure t he 0.0. 01 the mainshaft and countershaft.

SERVICE LIMIT: M4 BUSHING : 19.93 mm (0 .785 In) M5 GEAR : 14.93 mm 10.588 inl C3 BUSHING : 19.93 mm (0 .78 5 inl C1 BUSHING : 14.93 mm (0 .588 in) Calculate the shah·to·bushing or gear clearance.

SERVICE LIMIT: 0 , 10 mm 10.004 inl Turn the inner race of the bearings with your f inger.

The bearings should turn smoothly and quietly.

Also check that the outher races 01 the bearings fit tightly in the crankcase.

Replace the bearings il they are abnormal.

BEARING REPLACEMENT LEFT CRANK CASE Remove the mainshaft needle bearing from the left crankcase.

i 1) COUNTEI"' TOOLS: Mainshaft bearing : Bearing remover. 15 mm

07936 - KC10000 Not available in U.S .A .

07936 - KC10500 - remover assy . '5 mm - remover shaft. 15 mm 07936 - KC10100 Not available in U.S.A , 0 7 936 - KC10200 - remover head, 15 mm Not available In U.S.A .

- remover weight 07741 - 0010201 or 07936 - 3710200 Drive t he oil see I and countershaft bearing out of the left crankcase.

10-7

TRANSMISSION/CRANKSHAFT Install t he new countershaft bearing with special toots.

TOOLS:

Driver Attachment, 45 )( 50 mm Pilot, 22 mm

07749 - 0010000 07946 - 6920100 07746 - 0041000

ApplV grease to the oil seal lips and inst all the oil seal.

---

ATT";;;:;;;'NT, 45 :50 mm AND PILOT, 22 mm

-

- -

Install the mainshaft needle bearing plate as shown .

Press the needle bearing into the left crankcase with special tools.

TOOLS:

Driver Attachment. 24 • 26 mm

07749 - 0010000 07746 - 0010700

(1) SET PLATE

RIGHT CRANKCASE Remove the mainshah bearing set plate, mainshaft bearing and countershaft bearing from the right crankcase.

•

•

•

tl-

""i3j"cc)uliii' RSH,'FT BEARING

Drive new bearings in with the following tools: TOOLS : Mainshaft bearing: Driver Attachment. 42 II 41 mm Pilot. 20 mm

07749 - 0010000

07746 - 0010300 07746 - 0040500

Install the mainshaft bearing set plate and tighten the screws.

Countershaft bearing: Driver Attechment, 32 x 35 mm Pilot, 15 mm

10-8

07749 - 0010000 07746 - 0010100 07746 - 0040300

•

TRANSMISSION/CRANKSHAFT

TRANSMISSION ASSEMBLY Align t he oil holes on the bushings and shahs.

Install the C2 lock washer by aligning its tabs with the grooves in the spline washer.

A ssemble t he mainshaft, countershaft and reverse idler in the reverse order of disassembly.

III MAINSHAFT

(3lT)

M2 116T)

®

M4 (24T)

M3

Oi6wlJo ci"OTI

[(O@

f)O~IJ()O C2 135T)

'P'of)~~~

@Y'C4(28T)

C1 139T) / (5) REVERSE

I \lY'1)

(SlIGEAA

~~

M5

126T)

JA.

fl9@

(2) REVERSE IDLE GEAR

~/ ·

C3(31T)

@~_

~ \ <O:::)@

I'BT)

C5124T) (3) COUNTEASHAFT

\

SHIFTER

CR (32T) (4) SPLINE COLLAR

Install the washer onto the right crankcase countershaft bearing.

Install the C 1 gear with the bushing.

(1) WASHERS

(3) I

GEAR

Install the washers, reverse idle gear and shaft.

, ) C2. GEAR

10-9

TRANSMISSION/CRANKSHAFT Install the mainshah and countershah assemblies together In

III MAIINSH''''

the right crankcase.

NOTE

The shift fork marks are: L for left, C for center and R for fight.

Install the shift forks With theif marks facing up.

III MAAKS

Install the shift drum and align each shift fork guide pin with the groove in the drum.

Insen the shift fork shaft through the shift forks into the hole in the right crankcase.

CRANKCASE ASSEMBLY Install a new gasket and dowel pins.

10-10

TRANSMISSION /CRANKSHAFT Assemble the right and left crankcase halves.

(1) LEFT CRANKCASE

Install t he breather tube clips and tighten all the crankcase bolts.

Install the chain case stay and the cam chain.

Install the washe r, tensioner and tensioner pivot bolt .

Tighten the tensioner pivot bolt.

TORQUE : 10- 14 N·m !1.0 - 1.4 kg-m , 7 - 10 ft -Ibl

10-11

FRONT WHEELS/ BRAKES/STEERING SYSTEM

24 - 30 N'm (2.4-3.0 kg-m ,

17-2 2 ft -Ib)

24 - 30 N·m 12.4 - 3.0 kg-rn, 17 - 22 tt·lb)

80 - 100 N·m

(8 .0 - 10.0 kg-rn, 58 - 72 ft-Ib )

35 - 43 N·m (3.5 - 4 .3 kg-m , 25 - 31 h -Ibl

35 - 43 (3. 5-4.3 kg -m .

25-31 ft-Ibl

70-- 90 N'm

• .:., . . : : ' - - - - - 17.0 - 9.0 kg-m , 51 - 65 I

8 - 12 N·m

(0.8 - 1.2 kg-rn,

6 - 9 ft-Ib) 35 - 43 (3. 5 - 4 .3 kg-m, 25 - 31 ft -Ibl 50 - 70 N·m

15.0 - 7.0 kg-m , 36 -51 ft -Ib) 15.0 - 6 .0 kg-m, 36 - 43 ft-Ibl

11-0

11. FRONT WHEELS/BRAKES/STEERING SYSTEM ,,-, " -6

SERVICE INFORMATION

FRONT WHEELS

TROUBLESHOOTING

" -2

TIRES

"-6

HANOLEBAR

" -3

FRONT BRAKES

" -5

" -'0

THROTILE LEV ER

STEERING SYSTEM

"-'5

SERVICE INFORMATION GENERAL

Brake dust may contain asbestos which can be harmful to your health. Do nor use compressed air to clean brake drums or brake panels. Use a vacuum with a sealed dust collector. Wear a prorectil·t! face mask and thoroughly wash your hands when finished .

• This section covers maintenance of the front wheel, front brake and steering system .

• A jack or other support is required to support the vehicle.

SPECIFICATIONS mmUn)

ITEM Front brake drum 1.0.

STANDARD

SERVICE LIMIT

110 (4.3 )

111(4.4)

4 (0.2)

Front brake lining thickness

2 (0.1)

Kingpin 0.0.

17.966-17.984 (0.7073-0.7080)

17,90 (0. 705)

Kingpin bushing I.D.

18.045 - ' 8.075 (0.7 104 -0.7 116)

18.17 (0.7 15)

Kingpin bushing thickness

2.9 - 3.0 (0.11 - 0.12)

Steering bushing thickness

2.90 - 3.20 W.114 - 0.126)

2.85 10.112)

28.48 - 28.7211.121 - 1 .131 )

28.43(1.119)

Steering shaft 0.0.

Tie-rod ball joint-to-ball joint distance Wheel rim run -out

Radial Axial

2.75 (D.l08)

3 10 ( 12.2))

- --

4.0 (0.16) 4.0 (0.16)

TORQUE VALUES Handlebar upper holder bolt Steering shaft nut Front axle nut Front wheel nut Tie rod lock nut 8all joint castle nut Kingpin nut Steering shaft bushing holder nut Front brake arm nut Knuckle pipe Handlebar lower holder nut Throttle housing cover

24 - 30 N·m /2.4-3.0 kg-m. 17-22 It-tb) 35 - 43 N·m /3. 5 -4.3 kg-m, 25-31 ft-Ib) 70-90 N·m (7.0 - 9.0 kg -m. 51 - 65 fI-lb) 50-60 N-m /5.0 - 6 .0 kg -m. 36 - 43 fl-Ib) 35-43 N·m (3.5 - 4 .3 kg-m, 25-31 ft-Ib ) 35-43 N·m (3.5-4.3 kg-m. 25-31 fHb) 50- 70 N·m (5.0-7.0 kg-m, 36-51 fl-Ib) 24 - 30 N·m (2.4 - 3.0 kg -m , 17 - 22 ft-Ib) 8-12 N·m /0.8 - 1.2 kg -m, 6 - 9 ft -Ib) 80-100 N·m /8. 0 - 10.0 kg-m. 58- 72 ft-lb) 40 - 48 N' m /4 .0 -4.8 kg-m, 29 - 35 ft -tb) 3 - 4 N'm W.3-0.4 kg-m, 2 - 3 ft -tb)

TOOLS Special Attachment. 28 x 30 mm Tire breaker attachment

07946 - 1870100 07GMF - HB30101 -Not available in U.S.A.

11 -1

FRONT WHEELS/BRAKES/STEERING SYSTEM Common Driver

Attachment, 32 x 35 mm Attachment, 37 x 40 mm PHot, 17 mm Bearing remover shaft Bearing remover head, 17 mm Universal bead breaker Tire breaker set - Breaker arm compressor - Breaker arm

TROUBLESHOOTING Hard steering Steering shaft nut too tight Faulty steering shaft lower bearings Insufficient tire pressure Steers to one side or does not track straight

Bent tie rods â&#x20AC;˘ Wheel installed incorrectly Front wheel wobbling

Bent rim Worn front brake drum bearing

Faulty tire Axle nut not tightened properly Poor brake performance Improper brake adjustment

Worn brake shoes Brake linings oily, greasy or dirty Worn brake cam

Worn brake drum Brake arm serrations improperly engaged Brake shoes worn at cam contact area

Brake drag Incorrect brake adjustment Sticking brake cam Sticking brake cable

11-2

07749 07746 07746 07746-

0010000 0010100 0010200 (07949 - 6110000) 0040400

07746 - 0050100 ] ' I ' II 'I bl ' USA 07746 - 0050500 Of equlva ents commercia y aval a e In , , , GN-AH-958 -BBl (U,S.A. only) 07772 - 0050001 } 07772 - 0050101 Not available in U.S.A. 07772 - 0050200

FRONT WHEELS/BRAKES/STEERING SYSTEM

HANDLEBAR

111 T",mTT>

REMOVAL Remove the following:

- throttle lever housing - front brake lever bracket and holde r

121 SR.AC IKET AND HOLDER

-

12 ) BANDS

wire bands

- switch housing -

rear brake lever bracket and holder

(3) BRACKET

Remove the handlebar upper holder cover cap.

Remove the dips and bolt attaching the upper holder cover

HOLDER

,

and the cover.

'2' CAP

jI ,,

(4 ) CUP

(3) BOLT

Remove the handlebar holder and hand lebar.

INSTALLATION Place the handlebar on the lower holders.

A lign the handlebar punch mark with t he top of the handlebar lower holders.

Install the handlebar upper hoders with t he L or A marks f acing forward.

Tighten the forward bolts first, t hen tighten the rear bolts.

TORQUE: 24 - 30 N¡m 12.4 - 3 .0 kg -m , 17 - 22 ft -Ibl

11 -3

FRONT WHEELS/BRAKES/STEERING SYSTEM

,

Install the handlebar upper holder cover.

Install the cover cap.

(21 CAP

~

, , )4) CLIPS

If the handlebar grips were removed, apply Honda Bond A or Honda Hand Grip Cement (U.S.A. only) to the inside of the grip and to the clean surfaces of the right and left handlebar.

Wait 3 - 5 minutes and install the grip.

Rotate the grip for even application of the adhesive.

11)

NOTE

â&#x20AC;˘ Allow the adhesive to dry for an hour before using.

Install the handlebar weigh t and tighten the bolt securely.

(3) WEIGHT

Install the switch housing, aligning the boss with the hole.

Tighten the upper screw first then tighten the lower one.

Install the rear brake lever bracket and holder with the punch mark up.

Tighten the upper screw fi rst. aligning the punch mark with the split line.

Tighten the lower screw securely.

11 -4

(3) BOLT

FRONT WHEELS/BRAKES/STEERING SYSTEM Tighten the forward screw first, aligning the split line of the throttle housing and holder with the punch mark.

Tighten the rear screw securely.

Install the front brake lever bracket and holder with the punch

mark up.

Tighten the upper screw first, aligning the punch mark with the split line.

Tighten the lower screw securely.

THROTTlE LEVER OISASSEMBL Y Remove the serews and throttle lever cover .

Remove the gasket.

Bend down the lock washer tab and remove the nut and lock washer, Remove the throttle lever, arm and spring from the throttle housing.

(11

~~T--'ÂŁQ*[Jr-'

(5) LEVER

11-5

FRONT WHEELS/BRAKES/STEERING SYSTEM ASSEMBLY

!1) ARM

(2) CAIBlE END

Apply grease to the throttle cable end and connect the cable to the throttle arm.

Install the throttle arm, spring and lever into the throttle housing.

Tighten the throttle lever using the nut and a new rock washer.

Bend up the lock washer tab against the nut head.

NOTE Take care of the throttle arm spring not to bind and check for it.

Install the new gasket.

Install the cover and tighten the screws to the specified torque.

TORQUE : 3 - 4 N·m (0. 3- 0.4 kg-m , 2 -3 ft·lb)

FRONT WHEELS REMOVAL Raise the front wheels off the ground by placing a block work stand under the engine.

Remove the front wheel nuts and wheel.

Of

IN STA LLATION Install and tighten the four front wheel nuts.

TORQUE : 50-60 N·m (5.0- 6 .0 kg -m , 36-43 ft -Ib)

RIM RUNOUT INSPECTION Measure the front wheel rim ru nout.

SERVICE LIMIT: 4 .0 mm (0. 16 inl

TIRES REMO VA L (U.S.A. ONLY) NOTE This service requires the Universal Bead Breaker (GN-AH 958-8Bll available in U.S.A. only.

Remove and install tires from the rim side opposite the valve stem.

"7

Remove the core from the valve stem.

CAUTION Use oj the Bead Breaker fool is required jor fire removal.

Do no/ damage the bead sealing orea oj the rim.

Use a Coats 220 Tire Changer or equivalent fO remove Ihe lire from lhe rim. If a tire changer is nOI available, rim protectors and lire irons may be used.

11-6

f-J

"

(2) BREAKER ARM ASSEMBLY BLOCK

I

FRONT WHEELS/BRAKES/STEERING SYSTEM Install the short blade for 7" /8 " rims onto the breaker arm assembly.

CAUTION

Use 0/ an improper size blade /flay result in damage /0 IIIe rim, lire or blade.

Place the proper size adapter onto the threaded shaft and then put the wheel over the threaded shaft and adapter.

Lube the bead area with water, presSing down on the tire side-

wall/bead area

In

several places, to allow the water to run into

and around the bead. Also lube the area where the breaker arm will contact the side wall of the tire .

. . iii!

Ust! only water as Q lubricant when relnDl';ng or mounting lir(,l" Soap or some mountillg IllbricallfS IIIUY feal 'f' a slippery residllrf! which can cause the tire to shift all the rim and lose oir presS/ut!

during riding.

While holding the breaker arm assembly at an appro)(imate 45 ° position, insert the blade of the breaker arm between the me and rim. Push the breaker arm inward and downward until it is In the horizontal position with its press block in contact With the rim.

(31 BREAKER ARM ASSEMBLY 0 ) TIRE

.",

(2) RIM

\

.'

. .. ,

(41 THREADED SHAFT (51 ADAPTER

With the breaker arm in the horizontal position, place the breaker press head assembly over the breaker arm press block .

Make sure the press head bolt is backed out all the way and then position Ihe nylon buttons on the press head agamsllhe inside edge of Ihe rim .

(3) PRESS HEAD ASSEMBLY

11) PRESS HEAD BOLT

Insert Ihe threaded shalt through the appropriate hale in the breaker press head assembly and then tighten the lever nut until both ends of the breaker press head assembly are in f irm contact with the rim.

NOTE

Insert bolts through the holes in Ihe rim hub mounting tabs and the adapter to position the adapter properly.

9 " RIM

7" AIM

Tighten the press head bolt until the reference mark on the press block is aligned With the top edge of the press head, If the rest of the bead cannot be pushed down into the center of the rim by hand, loosen the press head bolt and the lever nut. ROlate the breaker arm assembly and breaker press head assembly 118 to 114 the circumference of the rim. Tighten the lever nut and then tighten the press head bolt as described .

Repeat this procedure as necessary until the remainder of the bead can be pushed dawn into the center of the flm.

(1) REFERENCE

MARK

(2) TOP EOGE OF PRESS HEAD

,/

Assemble the Universal Bead Breaker on the other side of the wheel and break the bead following the same procedures .

Remove the tire form the rim using e tire changer machine or tire irons and rim protectors.

(3) AIM BEAD LOCKS

11-7

FRONT WHEELS/BRAKES/STEERING SYSTEM (11 TIRE BREAKER ATTACHMENT (FRONT TIRE ONLY)

REMOVAL IEXCEPT U.S.A.l

--..; CAUTION

--

路 路 路

{)o

--

nOI apply water. soupy ....ater, oil etc.

(0

the life. rim lind

fool .,.,hen removing Ihe rire. Till' 1001 breaker arm may slip off (he fire and the bead COli nor be broken oJf Ihe fire.

Do flor damage thl' bead sealing area 0/ the rim.

:C

Foltaw the breaker momque/u,"'s instruction.

-

-

Front tire only:

Install the ttre breaker attachment onto the rim with the wheel nuts and tighten the nuts securely .

TOOL: Tire breaker attac hmen t

(2) WHEEL NUT /

07GMF-HB30101 Not Byallable in U.S ,A .

111 BRI'A':ER ARM

Insert the narrow end (A sidel of the breaker arm between the Ilfe and the rim.

TOOL :

Tire breaker let -

Break er 8rm compresso r

- Breaker 8rm

07772 - 0050001 07772 - 0050101 07712 - 0050200 Not available in U.S.A .

121 NAf>ROW":NO IA SIDEI

Position tha braaker arm compressor onto the rim center as shown.

(1) BREAKER ARM Keep the breaker arm horizontal end align the and of the com路 pressor bah with the arm hole .

Screw in the breaker arm compressor bolt to bre ak the bead from the tire.

If th e res t of Ihe bead canno t be pushed down int o the center of the rim . remove and reposition the complessor and arm 1/ 8 to 114 the circumference of Ihe rim. Tighten the compressor bah to break the bead. Repeat this procedure as necessary until the remainder of the bead can be pushed down into the center of the rim.

11-8

FRONT WHEelS/ BRA KES/STEERING SYSTEM If the bead breaking is difficult with the narrow end (A side) of the breaker arm, use the wide end (8 side) of the arm and

(1) WIDE END (B SIDE)

repeat the procedure above .

Atter removing the tire from the rim, cut the valve off at the bottom , being careful not to damage the rim.

NOTE Be sure to replace the valve with a new one whenever the tire is removed form the rim.

TIRE REPA IR NOTE

Use the manufacturer's instructions for the tire repair kit you are using. If your kit does not have instructions, use the procedures provided here.

Check the tire for puncturing objects. Chalk mark the punctured area and remove the puncturing object.

Inspect and measure the injury. Tire repairs for injuries larger than 15 mm (518 in) should be a section repair. Section repairs should be done by a professional tire repa ir shop.

If the injury is smaller than 15 mm (518 in). proceed with the repair as described here.

Install a rubber plug into the injury as follows : Apply cement to a plug inserting needle and work the needle into the injury to clean and lubricate it. Do this three times. Do not let the cement dry.

Insert and center a rubber plug through the eye of the inserting needle.

Apply cement to the rubber plug.

Push the inserting needle with plug into the injury until the plug is slightly above the tire. Twist the needle and remove it form the tire, the plug will stay in the tire.

NOTE Be careful not to push the plug all the way into the tire to prevent it from falling inside.

Trim the plug 6 mm (1/4 in) above the tire surface.

Repeat the above procedure if the puncture is large.

Do not use more than two plugs per injury.

Allow the repair to dry. Drying time wilt vary with air temperature. Refer to the tire repair kit manufacturer's recommenda tions .

11 -9

FRONT WHEELS/BRA KES/STEERING SYSTEM Inflate the tire and test the seal by dabbing a small amount of cement around the plug . Escaping air will cause a bubble in the cement . If there is leakage . remove the tire ~page 11 ~ 6 ) and apply a cold patch 10 the inside of the tire as described.

If a plug has been inserted, trim it even with the inner tire surfa ce.

Temporarily place a rubber patch that is at least twice the size of the puncture over the injury. Make a mark around the patch , slightly larger than the patch itself.

Remove the patch.

Roughen the area marked inside the tire with a tire buffer or a wire brush. Clean the rubber dust from the buffed area.

Apply cement over the area marked and allow it to dry.

Remove the lining from the patch and center it over the injury.

Press the patch against the injury using a special roller.

NOTE

•

Allow cement to dry until tacky before applying patch.

Do not touch the cement with dirty or greasy hands .

ASSEMBLY Clean the rim bead seat and flanges.

USf! onl}, l'I"at~r as a lubricant I'I"h~n mounting tires. Soap or mounting lubricants may I~al·~ a slippery residuf! I'I"hich can cauu th~ lirf! to shifl on Ih~ rim and lose air pressure during riding.

som~

Install the valve core and inflate the tire to seat the bead.

Deflate the tire. Wait 1 hour and inflate the tire to the specified pressure.

Front

Rear

Recommended pressure

2.5 psi (17.5 kPa, 0.175 kg/cm 2 )

2.2 psi (15 kPa, 0.15 kg fcm 2 )

Max. pressure

2.9 psi (20.5 kPa, 0 .205 kg/cm 2)

2.6 psi (18 kPa,

2.1 psi 114.5 kPa,

1.8 psi (12 kPa, 0.12 kg /cm 2)

Min, pressure

0 . 145 kg/cm 2)

0.18 kg /cm 2)

Check for air leaks and install the valve cap.

111

FRONT BRAKES Grf!au on Ih~ brakf! finings reduces stopping po ....er. Keep grNSf! off th~ linings.

FRONT BRAKE INSPECTION Remove the fornt wheel (page 1 1·6).

Remove the cotter pin.

Remove the front axle nut and brake drum.

11-10

13) enTT';.

FRONT WHEELSI BRAKESI STEERING SYSTEM Measure the brake lining thickness.

SERVICE LIMIT : 2 mm (0.1 inl Replace the brake linings if they are thinner than the service limit.

NOTE

-

Always replace the brake linings in pairs and right and left sets to assure even operation.

Measure the brake drum 1.0.

SERVICE LIMIT : 111 mm 14.4 in) Check the rubber seal for damage.

Replace it, if necessary .

NOTE Apply bond for the rubber to the inside of the new rubber seal.

Apply grease to the rubber seal tip.

-<

I 111 HUtiti'H SEAL

Contaminated brake linings reduce slOpping power, Keep grease off the finings of the brake dmm. Wipe excess grease off the brake dmm inside.

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 hub.

Remove and discard the bearings if the races do not turn smoothly. quietly. or if they fit they fit loosely in the hub .

NOTE â&#x20AC;˘

Replace hub bearings in pairs .

BRAKE DRUM BEARING REPLACEMENT

n)

BEARING REMOVER SHAFT

V

Remove the hub collar and dust seal.

Remove the bearings and spacer.

TOOLS : Bearing remover shaft or equivalent commercially available in U.S. A .

07746 - 0050100 Bearing remover head, 17 mm or equivalent commercially 07746 - 0050500 available in U.S.A.

-

- I.

121 BEARI",,]

11-11

FRONT WHEELS/BRAKES/STEERING SYSTEM BRA KE DRUM ASSEMBLY III BRAKE DRUM

/

(2) OI$T ANCE COLLAR

{31 DUST SEAL (8) DUST SEAL

v.(j

{7) 1NSIDE

BEARING

I

(6) RUBBER

(5) OUTSIDE

SEAL

BEARING

(1)

Pack grease with the bearing cavi t ies.

Drive in a new bearing to the inside firSI. Install the distance collar and drive in a new bearing to the outside.

TOOLS : Drive r Attachment, 32 x 35 m m Pilot , 17 mm

(4) COLLAR

DRIVER

-

07749 - 0010000 07746 - 0010100 07746 - 0040400

NOTE

Drive in the bearings squarely with the sealed ends facing

32 x 35 mm

out.

Apply grease to the dust seal lips and install them.

NOTE

â&#x20AC;¢

Aun the dust seals against the bearings.

Install the hub collar .

11-12

FRONT WHEELS/ BRAKES/STEERING SYSTEM REMOVAL E)(pand and remove the brake shoes by hand.

Remove the brake panel.

121 RElrU~IN SPRING

Remove the brake arm .

Remove the indicator plate, return spring, felt seal and brake cam .

/"",

(31 BRAKE CAM

\

(41 FELT SEAL

(5) BRAKE ARM

INSTALLATI ON If you removed the dust seals, install new ones anct apply

grease to their lips.

.G

(1)

SEALS

Apply grease to the brake cam and anchor pin.

Install the brake cam.

(2) BRAKE

11-13

FRONT WHEELS/BRAKES/STEERING SYSTEM Soak the felt seal in clean engine oil and install it.

Install the return spring.

Install the wear indicator plate onto the brake cam by aligning

the indicator tab with the cut-out in the brake cam.

RETURN SPRING

(4) INDICATOR PLATE

(') BRAKE CABLE

Connect the brake secondary cable to the brake arm.

Install the brake arm, aligning the punch mark s.

Torque the brake arm bolt and nut.

TORQUE: 8 - 12 N·m (0.8 - 1.2 kg-m , 6 - 9 ft-Ib)

'\ (4)

AND NUT

Install the brake panel.

Position the brake shoes in their ariginal loc8tions.

Grease on the brake linings reduces stopping power. Keep

gresal' of! the Unings.

(2) BRAKE SHOES

Install the brake drum and tighten the axle nut to the speci f ied

torque.

TORQUE: 70 -90 N·m (7.0 - 9 .0 kg -m , 51 - 65 ft -Ib) Apply NOX-RUST 1028B or equivalent to the thread ends of the knuckle spindle.

Install a new cotter pin.

Install the front wheel (page 11 -6).

Adjust the front brake lever free play and the equalizer arm function (page 3- 10).

11-14

111

(2) BRAKE ARM

FRONT WHEELS/BRAKES/STEERING SYSTEM

STEERING SYSTEM KINGPIN/ KNUCKLE/TIE-ROD REMOVAL Remove the front wheels and brakes.

(1) BOLT

~

Remove the aU cotter pins.

Remove the castle nuts from the tie-rod ball joints and remove the tie-rods.

Remove the kingpin nut and bolt and the knuckle.

141 KNlJOKLt

Remove the dust seals and kingpin.

TIE-ROD INSPECTION

(1) BALL JOINT RUBBERS

Inspect the tie-rod for damage or bending.

Inspect the ball joint rubbers for damage, wear or deteriora-

tion.

Turn the baH joints with your finger. The ball joints should turn smoothly and quietly.

.-

â&#x20AC;¢

r

(2) TIE-ADD

KINGPIN INSPECTI ON Inspect the kingpin for damage or cracks.

Measure the kingpin 0.0.

SERVICE LIMIT : 17.90 m m (0. 70 5 inl

(1) KINGPIN

i

- - 11-15

FRONT WHEELS/BRAKES/STEERING SYSTEM KINGPIN BUSHING INPSECTION Check the kingpin bushings for wear or damage.

Measure the 1.0. of the bushings.

SERVICE LIMIT: 18. 17 mm (0.715 inl Measure the thickness of the bushings.

SERVICE LIMIT: 2.75 mm (0.108 in)

KNUCK LEPIPE REPLACEMENT Remove the four knucklepipe mounting bolts.

Replace the knucldepipe.

Tighten the knucklepipe mounting bolts.

TORQUE: 80- 100 N·m 18.0- 10.0 kg -m, 58 - 72 ft -Ib)

STEERING SHAFT REMOVAL Remove the following parts: - handlebar (page 11 -3) - front fender (page 13- 1) - headlight/choke knob bracket - front brake equalizer

- steering shaft bearing holder bolts and nuts

(2) BUSHING HOLDER

- steering shaft bushing, holder bolts and nuts - steering shah with bushing and holders Remove the bushing from the steering shaft.

TS AND NUTS

11-16

FRONT WHEELS/ BRAKES/STEERING SYSTEM BU SHING INSPECTION (2) T HICKNESS

Inspect the bushing for wear or damage, replace if necessary_ Measure the thickness of t he bushing.

SERVICE LIMIT: 2 .85 mm (0. 112 in!

(1 )

STEERING SHAFT INSPECTION

STE ERING SHAFT

Inspect t he steering shaft fo r damage or cracks, and replace if necessary.

Measure the 0.0 . t he steering sha ft.

SERVICE LIMIT: 28.43 mm (1.119 in)

STEERING SHAFT BEARING INSPECTION/REPLACEMENT Check that the steering shaft nu t is tig htened to its correct t orque value.

TORQUE : 35- 43 N·m (3 .5 - 4.3 kg -m , 25 - 31 ft -Ib) Turn t he bearing holder w ith your f inger. The bea ring holder should turn smoothly and quietly.

Also c heck that the bearing oute r race fits in the holder.

Replace the bearing if necessary .

Unstake the peen and remove the nut, beari ng and holder.

Apply grease to the dust seal lip and install it to the holder from the bearing side as shown. o rille in a new bearing t o the holder.

TOOLS : Driller Attachment, 37 x 40 mm Pilot, 17 mm

---

(1) DUST SEAL

07749 - 0010000 07746 - 0010200 or 07949 - 6110000 07746 - 0040400

(2) BEARING

SIDE

•

Install the bearing holder t o the steering shaft.

Tigh t en the nut to the specified t orque.

TORQUE: 35 - 43 N·m (3.5 - 4 .3 kg-m. 25 - 31 ft-Ib) Peen the nut.

(4)

ATTACHMENT, 37 x

mm

11-17

FRONT WHEELS/BRAKES/STEERING SYSTEM STEERING SHAFT INSTALLATION Apply grease to the bushing.

Install the steering shaft with bushing and bushing holder.

Tighten the bolts and nuts to the specified torque.

TORQUE : 24 - 30 N·m 12.4 - 3.0 kg-m, 17 -22 ft-Ibl

111 HE,'Dl-'GI<TICH!DKE KNOB BRACKET

Install the following parts: - front brake equalizer - headlight/choke knob bracket - front fender (page 1 3· ' ) - handlebar (page' 1-3)

KINGPIN/KNUCKLE/TIE-ROD INSTALLATION

m ATTACHMENT,

If the kingpin bushings were removed, drive in new bushings.

TOOLS; Driver

Attachment, 28

II

30 mm

07749 - 0010000 07946 - 1870100

Apply grease to the dust seal lips and kingpin bushing.

Install the kingpin and dust seals.

","'N

[11 . " ,

(3) BUSHINGS

11-18

-_\_-

(2) DUST SEALS

FRONT WHEELS/BRAKES/STEERING SYSTEM Install the ball joint with the "L" mark on the steering shaft side.

Install the tie·rod with the groove on the wheel side .

12) BALL JOINT 111 } ' MARK

\"

~G ,

... - 0

(4) BALL JOINT

(3) GROOVE

Temporarily. set the temporary distance between the ball joints.

STANDARD SETTING: 310 mm 112.2 in) NOTE

•

Set the same distances in the "R " and " l" threads.

I·

310 mm 112,2 in)

·1

4rr-------l\ =+= (1) THREADS

(1) THREADS

Install the knuckle.

Install the tie -rod and tighten the castle nuts to the specified torque while holding the ball joint.

TORQUE : 35 - 43 N·m (3 .5- 4 .3 kg -m , 25 - 31 ft -Ibl

(2) KNL)CKILE

Tighten the kingpin nut to the specified torque.

TORQUE : 50 -70 N·m 15.0 - 7 .0 kg -m , 36-5 1 ft-Ib)

11-19

FRONT WHEelS/BRAKES/STEERING SYSTEM Install new cotter pins.

Pump grease into the kingpin pivot through the grease fitting (page 3-15), Install the front brake (page 11 - 13).

Install the front wheel (page 1 1¡6) .

Adjust the toe-in (page 3- 14) .

11-20

MEMO

REAR WHEELS/BRAKES/DRIVE MECHANISM

, 40 - 150 N·m (14.0 - 1 5.0 kg-m.

101 - 108 ft-Ibl

40 - 50 N·m (4.0 - 5.0 kg -m, 29 - 36 ft-Ib)

70-80 N·m (7.0 - 8.0 51-58 ft -Ib l

2 N·m (0.8 - 1.2 kg -m,

6-9 ft -Ib)

/~ 50 - 60 N'm (5.0 - 6.0 kg-m,

36 - 43 ft·lbl

12-0

, 50 N·m (11.0- 15.0 kg-m , aO-l08 ft·lbl

12. REAR WHEElS/BRAKES/DRIVE MECHANISM SERVICE INFORMATION

12-1

REAR AXLE/ FINAL DRIVEN SPROCKET 12-9

TROUBLESHOOTING

12-2

REAR AXLE BEARING HOLOER

12- 11

REAR WHEELS

12-3

BRAKE PEDAL

12- 13

REAR BRAKES

12-3

SERVICE INFORMATION GENERAL

I, .., [ Brake dusl may contain asbestos .....hlch cun be harmful to )'o/lr health. DQ nOI use compn-ssed air to dean brake drums or brake panels. Use a I'uell"'" with Q sealed (fllst collector. Wear a protecli l'e Jace mask and thoroughl)1 wash yom hunds when jinlshed.

• This section covers maintenance of the rear wheel and drive mechanism.

• A jack or block is required to support the vehicle.

• Refer to Section 11 for tire servicing.

SPECIFICATION S mm(in)

ITEM

STANDARD

SERVICE LIM IT

--

3.0 (0.12)

Aear allie runout Rear brake drum

to.

140 (5.5) 4 (0.2)

Rear brake lining thickness

---

Axial

Rim (unout

141 (5.6)

Radial

2 (0.1)

4.0 (0.16) 4.0 (0.16)

TORQUE VA LUES Rear wheel hub nut Rear brake 8rm nut Rear brake drum nut

Inner :

Outer: Rear axle nut Rear axle bearing holder bolt Driven sprocket nut

50- 60 N·m (5.0 - 6.0 kg -m , 36 - 43 ft-Ib) 8- 1 2 N·m (0.8 - 1.2 kg -m, 6 - 9 ft -lbJ 40-50 N·m (4.0 - 5.0 kg -m, 29 - 36 ft -Ib) 140 - 150 N·m (14.0-15.0 kg-m, 101 - 108 ft-Ib) 110- 150 N·m 111 .0 - 1 5.0 kg -m, 80 - 108 ft-lbJ 70 - 80 N'm 17.0-8.0 kg -m , 51 - 58 ft-Ib ) 70 - 80 N'm 17 .0 - 8.0 kg -m , 51 - 58 ft-Ib )

TOOLS Special Spanner wrench, 41 mm Wrench attachment , 41 mm

07916-9580200 or 07916 - 958020A (U.S.A. Only) 07916 - 9580400 or 07916 - 958010A (U.S.A.Only)

Common Driver Attachment, 52 )( 55 mm

07749 - 0010000 07746 - 0010400

12-1

REAR WHEELS/BRAKES/DRIVE MECHANISM

TROUBLESHOOTING Wobble or vibration.

Bent rim Loose wheel bearing Faulty reBr axle bearing holder Faulty tire A)(ie not t ightened properly Bent A)(le

Poor brake performance Improper brake adjustment Worn brake shoas Brake linings oily. greasy or dirty Worn brake cam

Worn brake drum Brake arm serrations improperl y engaged Brake shoes worn at cam contact area Brake drag Incorrect brake adjustment Sticking brake cam Sticking brake cable

12-2

REAR WHEELS/BRAKES/DRIVE MECHANISM

REAR WHEELS RIM RUNOUT INSPEC TION Measure the reaf wheel rim (unout.

SERVICE LIMIT : 4 .0 mm 10.16 inl

REMOVAL Raise the rear wheels off the ground with a jack or block under the engine.

Remo ve the fear wheel hub nuts and the rear wheels.

WHEEL DISASSEMBLY/ASSEMBLY For tire disassemblv, assemblv and repair, refer to pages 11 -6

to 11-10.

NOTE Each rear tire has one rim support plate located on the inside rim.

INSTALLATION Install the rear wheel with the tire valve facing out .

Tighten the wheel nuts .

TORQUE : 50 - 60 N·m 15.0 - 6 .0 kg·m, 36 - 43 ft -Ibl

NOTE Install the rear wheels with the directional arrows going counterclockwise as shown.

REAR BRAKES REMOVAL Remove the following: - right rear wheel (page' 2-3)

- cotter pin and axle nut - right rear wheel hub and wheel hub washer

/\

(4) COTTER PIN

(31 AXLE NUT

12-3

REAR WHEELS/BRAKES/DRIVE MECHANISM Remove the rear brake cable and parking brake cable adjusting nuts.

Disconnect the cables from the rear brake arm.

BRIIKE CABLE

l2!A[)JUSTING NUTS

Remove t he brake drum nuts using the special tools .

TOOLS: Spanner wrench, 41 mm

07916-9580200 or 07916 - 958020A (U .S .A. Only)

Wrench attachment, 41 rnm

07918 - 9580400 or 07916 - 958010A IU .S .A. Only)

:j (21 WRENCH ATTACHM ENT, 41 mm

Remove the t apered washer, washer , drum cover mounting

bolts and drum cover.

Remove the D -ring and rear brake drum.

12-4

,

REAR WHEELS/BRAKES/ DRIVE MECHANISM INSPECTION Measure the brake drum I.D. SERVICE LIMIT: 141 mm (5.6 inl

Check the brake drum collar for damage.

•

•

( 1)

•

DRUM COLLAR

Check the cover dust seat for damage and repl ace if necessary.

. ~. ,

•• - ; ~'-

~

"-.

~.

.

---

./ ~

..

Measure the brake lining thickness .

SERVICE LIMIT: 2 mm 10. 1 inl Replace the brake lining if it is thinner than the service limit.

12-5

REAR WHEELS/ BRAKES/DRIVE MECHANISM DISASSEMBLY Expand and remove the brake shoes by hand.

Remove the brake arm nut, bolt and brake arm.

Remove the indicator plate and felt seat.

Remove the brake cam, return spring and dust seals.

BRAKE ASSEMBLY /INSTALLATION Install new dust seals into the brake cam hole.

Apply grease to the lips of the dust seals.

Apply grease 10 the anchor pin and brake cam and insert the brake cam into the hole.

12-6

REAR WHEELS/BRAKES/DRIVE MECHANISM Install the return spring as shown.

Apply oil to the felt seal .

Install the felt seal and align the tab on the indicator plate with the punch mark on the brake cam and install the indicator plate.

Align t he punch marks and install the brake arm over the brake cam.

Install the brak e arm bolt and nut.

T ighten t he bolt securely.

TORQUE: 8 - 12 N¡m (0 .8 - 1.2 kg-m. 6 - 9 ft-Ibl

Position the brake shoes in their original locations.

Install the brake shoes and springs. :

:

Contaminared brake Unings reduce stopping po wer.

Keep grease off the linings. Wipe excess grease off the cam.

12-7

REAR WHEELS/BRAKES/DRIVE MECHANISM Apply oil to the new O"ring.

Install the a·ring and brake drum.

Install t he rubber seal onto the brake drum cover.

Pack the dust seal lip with grease.

II I RUBBER SEAL

Instatl the drum cover and tighten t he six bolts.

Install the washer and tapered washer.

NOTE •

Note the direction of the tapered washer.

Apply lOCKTITE® or equivalent to the shaft threads.

Tighten the inner nut.

TORQUE : 40 - 50 N·m 14.0 - 5.0 kg-m , 29 - 36 ft-Ibl

(1) LOCKTITE® OR eQUIVALENT 0. 1 -0.2 cm 3

Tighten the outer nut.

TORQUE : 140 - 150 N·m 114.0 - 15.0 kg- m . 101 - 108 ft-Ibl

TOOL : Sp anner wren ch , 41 nim

0791 6 - 9580200 or 07916 - 958020A (U.S. A . Only )

W renc h atta chment. 41 mm

07916 - 9580400 or 07916 - 958 010A (U.S.A. Only)

12-8

(21 NUT (OUTER) (3) NUT (INNER)

WflENCH ATTACHMENT, 41mm

REAR WHEELS/BRAKES/DRIVE MECHANISM PAIRKING BRAKE CABLE

Connect the pedal brake cable and parking brake cables.

-

Install the wheel hub washer onto the axle right side.

NOTE

•

Use the wheel hub washer with the fear axle right side only .

Apply grease to the spline of the axle.

Install the wheel hub and axle nut.

Tighten the axle nut and install new cotter pin .

TORQUE : 110 - 150 N·m (11 .0- 15.0 kg-m. 80 - 1 08 ft -Ibl Adjust the rear brake cables (page 3- 1 0).

REAR AXLE/FINAL DRIVEN SPROCKET

--

(4) COTTER PIN

(1 )

(3 ) AXLE NUT

CHAIN CASE

AX LE REMO VA L Remove the rear wheets (page 12-3\.

Remove the right wheel hub, wheel hub washer and left wheel hub by removing the cotter pins and nuts.

Remove the brake drum cover and drum (page' 2-4),

Remove the drive chain cover.

(2 )

CHAIN COVER BOLTS

Loosen the drive chain adjusting nut and bearing holder bolts.

Loosen and remove the drive chain by pushing the axle fo rward .

12-9

REAR WHEELS/BRAKES/DRIVE MECHANISM Drive the rear axle out of the right side using a soft hammer.

~

• AXLE DISASSEMBLY

.

•

111 DRIVE~

Remove the tour driven sprocket nuts, and driven sprocket

from the rear axle.

Check the condition of the final driven sprocket teeth.

Replace the sprocket if it is worn or damaged.

NOTE

If the 'driven sprocket is worn or damaged, the drive chain and the drive sprocket must be inspected.

Never install a new drive chain on a worn sprocket or a worn chain on new sprockets. Both chain and sprocket must be in good condition or the replacement chain or sprockets will wear rapidlV .

(2) DRIVEN SPROCKET NUTS

AXLE INSPECTION Place the resr axle in V-blocks and measure the runout.

The actual f unout is 112 of the Total Indicator Reading.

SERVICE LIMIT; 3.0 mm 10. 12 in)

AX LE ASSEMBLY

111 SPFIOCKET

Install the sprocket and nuts; torque the nuts as specified : and tighten it wit h the driven sprocket nut .

TORQUE: 70-80 N'm 17. 0 - 8 .0 kg -m, 51 - 58 ft -Ib)

{21 SPROCKET NUTS

12-10

REAR WHEELS/BRAKES/DRIVE MECHANISM AX LE INSTALLATI ON Insert the axle into the bearing holder from the leh side.

Install the drive chain over the sprocket.

Install t he following: - drive chain cover - brake drum {page t 2-8) - side washer and right wheel hub (page 12-9) - left wheel hub - feaf wheels (page 12-3) Adjust the drive chain slack (page 3-8).

Tighten the bearing holder bolts.

TORQUE: 70 - 80 N'm 17.0 - 8.0 kg-m. 51 - 58 ft-Ibl Adjust the rear brake (page 3 - 10).

REAR AXLE BEARING HOLDER REM OVAL Remove the following: - rear w heel (page 12·31 - rear axle (page' 2·9)

Remove the rear brake panel breather tube.

Remove two drive chain case bolts .

Remove the four bearing holder mounting bolts and t he bearing holder from t he fra m e.

12-11

REAR WHEELS/BRAKES/DRIVE MECHANISM REAR W HEEL BEARING INSPECTION Turn the inner face of each bearing with your f inger.

The bearings should turn smoothly and quietly. Also check that the bearing outer race fi ts tightly in the hold er.

Replace the bearings if the races do not turn smoot hly, quietly, or if they fit loosely in the holder.

NOTE

•

Replace the bearings in pairs.

0 1 DUST

BEARING REPLA CEMENT Remove t he dust seals and drive out the bearings.

Remove the center collar.

111 Dlffi/Eif-

ASSEMBLY

-U

NOTE

•

Install t he bearings with the sealed ends facing out.

Drive a new left bearing securely into the bearing ho lder until it

seats.

Install t he center collar and drive a new right bearing securely unlil it seat s.

TOOl: Driver

Attachment. 52

;II

5 5 mm

07749 - 00 10000 07746 - 00 10400

Coat the dust seal lips with grease and install t he dust seals.

12-12

(2) ATT

_

~ {1

DUST SEAL

REAR WHEELS/BRAKES/DRIVE MECHANISM INSTALLATION Connect the rear brake panel breather tube .

Install two drive chain case bolts .

Instal! the bearing holder and drive chain adjuster with the four holder bolts .

NOTE â&#x20AC;˘

Do not tighten the bolts until after adjusting the drive chain .

Install the removed parts in the reverse order of removal.

Adjust the drive chain slack {page 3-8 1.

Adjust the fear brake (page 3 - 101Tighten the bearing holder mounting bolts.

TORQUE : 70 - 80 N¡m 17.0 - 8 .0 kg -m. 5 1- 58 ft -Ib)

BRAKE PEDAL REMOVAL Remove the rear brake and parking brake cable adjusting nuts.

:!:Q~JIJSTING NUTS

Remove the brake pedal return spring.

Remove the cotter pin, washer and rear brake pedal and disconnect the brake cable from the pedal linkage .

12-13

REAR WHEELS/BRAKES/DRIVE MECHANISM INSTALLATION Install the brake pedal in the reverse order of removal.

NOTE

Apply grease to the brake pedal pivot shaft, dust seals and cable end.

Adjust the rear brake (page 3- 10).

( 1) WASHER

RETURN SPRING

(2)

12-14

PEDAL

13. FRONT FENDER/REAR FENDER/EXHAUST PIPE FRONT FENDER

13- 1

REAR FENDER

13-2

EX HAUST PIPE

13-3

FRONT FENOER (H FUEL TANK COVEA

(2 ) FRONT FENDER

(3 ) FRONT CARRIER

13-1

FRONT FENDER/REAR FENDER/EXHAUST PIPE

REAR FENDER DISASSEMBLY/ ASSEMBLY

OJ SEAT

Vi~,-..--_ _---~ V

& (2) TOOL BOXES

REAR FENDER

"

\

13-2

'"

)

(4 )

CARRIER

FRONT FENDER/REAR FENDER/EXHAUST PIPE

EXHAUST PIPE Refer to page 3 -' 2 for spa rk arreste r cleaning.

Do not sUl'ice

Ih~ ~xhQust

pipe 01 muf flu ,,'hile the" au hot.

REMOV AL Remove t he rear fender (page 13· 2).

Remove t he exhaust pipe joint nuts.

Remove the two exhaust muffler mounting bolts and the ex·

haust pipe assembly .

INSTALLATION Installation is the reverse order of rem oval.

TORQU E: Exhaust muffler bolts:

70 - 80 N·m (7 .0 - 8 .0 kg-m . 5 1 - 58 ft -Ibl Exhaust muffler protector bolts: 10 - 1 5 N·m (1.0 - 1 .5 kg -m . 7 - "

ft -Ib)

NOTE Alter installation. make sure tha t there are no exhaust leaks .

~----7

70- 80 N·m (7.D - B.O kg-m. 51 - 58 ft-lb J

10- 15 ·m 11.0- 1.5kg-m , 7 - 1' ft-Ib)

13-3

IGNITION SYSTEM (21 REVERSE '"ID";AT"OR LAMP (31 IGNITION SWITCH (1) 'NGIN,' ~;;:;_-., STOP c:.\

(4) IGNITION COil SPARK PLUG

(101

IBI

(91 Al""RNA"rOR

GENERATOR (6)

TORI RECTIFIER

(7)

CH" NOlE SWITCH

(1) ENGINE STOP SWITCH

---'l

r----<Y~ 0-0 (3) IGNITION SWITCH

t----<,...--'o (2 ) REVERSE INDICATOR

LAMP 12 V 3 .4 W

B

~ , G~G'

I

BIIW ,--'------, ('DI CDI UNIT SI/ A

"''''IV''''

l (4) IGNITION COIL

BI/Y---':'7~II~r~'

Bu/Y GIW

-L (7) CHANGE SWITCH

(5 ) SPARK PLUG

"1"61' --'---' IRE~E_R.:.

S'.:.I-, REGULATORI RECTif iER

G

y

(8) PULSE GENERATOR

G

1 14-0

(9) ALTERNATOR

14. IGNITION SYSTEM SERVICE INFORMATION

14-1

PULSE GENERATOR

14-3

TROUBLESHOOTING

14-1

ALTERNATOR EXCITER COIL

14-4

SYSTEM INSPECTION

14-2

IGNITION TIMING

14-4

IGNITION COIL

14-3

SERVICE INFORMATION GENERAL • Ignition t iming does not normallv need to be adjusted since the CDllCapacitive Discharge Ignition) unit is factory preset.

• For spark plug inspection, refer to page 3~6 .

• For pulse generator removal, see page 9-6.

SPECIFICATIONS STANDARD

ITEM Spark plug

NGK ND Initial

Full advance

'0 0

,j:

2 0 BTDClidle

28 °:t: 2 ° 8TDC /5,OOO ± 100 rpm 0.1 - 0 .3 fl I20 o C/68 ° F)

Ignition primary coil resistance Ignition secondary coil resistance

X24ESA-U

0.6 - 0 .7 mm (0.024 - 0 .028 in)

Spark plug gep Ignition timing

DR8ES-L

w ith spark plug cap

7 .4 k - l 1 kO 120 o C/G8 ° F)

without spark plug c ap

3 .7 k - 4 .5 kO (20 G C/ 6B OF)

n (20DC/G8 ° F)

Pulse generator coil resistance

290 - 360

Alternator exciter coil resistance

100 - 300 n (20°C / 68 ° F)

Alternator lamp coil resistance

0. 1- 1.00 (20°C/ 68 ° F)

Regulator/rectifier-regulated voltage

13. 5 - 15.5 Vat 5 ,000 rpm

III

TROUBLESHOOTING Engine starts but stops No spark at plug • Improper ignition timing • Faulty spark plug No spark at plug Engine stop switch " OFF" Poorly connected, broken or shorted wires - Between elternator and COl unit - Between alternator and regulator/rectifier - Between regulator frectifier and change switch - Between change switch and COl unit - Between COl unit and engine stop switch - Between COl unit and ignition switch - Between COl unit and ignition coil - Between ignition coil and spark plug - Between pulse generator and COl unit - Between COl unit and body ground Faulty ignition coil Faulty COl unit Faulty pulse generator Faulty alternator Faulty regulator/ rectifier Faulty change switch Faulty ignition switch Faulty engine stop switch

Engine starts but run s poorly Ignition primary circuit - Faulty ignition coil - loose or bare wire - Faulty alternator - Faulty COl unit - Faulty pulse generator - Faulty ignition switch - Faulty engine stop switch Ignition secondary circuit - Faulty plug - Faulty plug cap - Faulty high tension wire Improper ignition timing - Faulty advance rotor - Faulty pulse generator - Faulty COl unit

14-1

IGNITION SYSTEM

SYSTEM INSPECTION If the problem is weak or no spark, inspect as follows : NOTE

This method does not include an inspection of the ignition timing advance system at the COl unit.

Inspect the spark plug for condition before system inspection (page 3·6).

Oisconnect the COl unit couplers and check them for loose contact or rusting the terminals.

Measure the resistance between coupler terminals of the following below chart.

ITEM

TERMINALS

5T ANDARDS (20°C/68 °C)

Ignition coil (primary coit)

black/ yellow -green/ white

0.1 - 0 .30

Ignition coil (secondary coil)

high tension wire-green/ white

7.4 - 11Kn

Pulse generator

blue /yellow-green /white

290 - 360

Alternator exciter coil

black/red-g reen/w h ite

100 - 300 n

Ignition switch "O N"

with spark plug cap

Engine stop switch "RUN"

NO CONTINUITY black/ white-green/ white

Engine stop switch "OFF"

CONTINUITY

Ignition switch "OFF" Regulated voltage line

CONTINUITY grey 1+) and green/white 1-)

If there is no problem, inspect the following circuits; replace or repair them if necessary.

- alternator charging coil {page 1 5·5!.

- regulator/ rectifier (page 15·5).

- change switch (page 17·21.

If there is no problem about all above checks, replace the COl unit.

Jf there is indication of abnormality. inspect the related circuit as follows; replace or repair them if necessary.

- ignition coil primary coil (page 14·3).

- ignition coil secondary coil (page 14·3).

- pulse generator (page 14-3).

- alternator exciter coil (page 14-4 ).

- ignition switch (page 17-3).

- engine stop switch (page 17-4 1.

If the above circuits are normal, check the wire harnesses for short or open circuits, or the coupler or connectors for loose or poorly contact .

14-2

n

Battery voltage comes with ignition switch "ON".

11)

I UNIT

IGNITION SYSTEM

IGNITION COIL CONTINUITY TEST Remove the spark plug cap from the spark plug.

Disconnect the ignition coil primary wire.

Measure the primary coil resistance.

111 SECONDARY COil (WITH PLUG CAP)

STANDARD: 0.1 - 0 .3 0 (20 o e /68 ° F) Measure the secondary coil resistance with the spark plug cap

in place .

STANDARD : 7.4 k- l 1 kG (20 o C/68 ° F)

(3) GREEN TERMINAL If the secondary coil resistance is out of the specification, remove the spark plug cap from the wire and measure the secondary coil resistance.

(2) PRIMARY

11 1 ~"._" ••• TERMINAL

STANDARD: 3 .7 k - 4.5 kO (20 o C/G8° F)

INSTALLATION Install the ignition coil and connect the black /yellow wire co-nnector to the black terminal of the ignition coil and the green

wire connector to the green terminal.

Install the spark plug cap to the plug .

PULSE GENERATOR

12 ) SECONDARY COil (WITHOUT PLUG CAP)

INSPECTION (1 ) PULSE GENERATOR

Disconnect the pulse generator wire coupler.

Measure the resistance between the green and blue /yellow wires.

COUPLER

STANDARD: 290 -3600 (20°C/68° F) If the reading is not w ithin the specification, remOlle the pulse generator (page 9-6 ) and check the following: - pulse generator connector for loose contact or rusting the terminal.

- wire harness for bare or open circui t in them.

If they are normal, replace the pulse generator.

14-3

IGNITION SYSTEM

ALTERNATOR EXCITER COIL Disconnect the alternator black/red wire connector.

Check the resistance between the black /red wire and ground

with an ohmmeter.

STANDARD : 100-300

n (20 0 C/ 68 ° F)

Replace the alternat or stator if t he reading is not w ithin the specification Ipage 9-6).

IGNITION TIMING NOTE

The Capacitive Discharge Ignition (COli system is factory pre-set and does not reQuire adjustment. To inspect the function of the COl components, ignition timing inspection procedures are given here.

Remove the timing hole cap.

Connect a lachometer and timing light.

Start the engine and allow it to idle.

IDLE SPEED: 1,500

~

100 rpm

Inspect the ignition timing .

Timing is correct if the "F" mark on the alternator rotor is aligned with the index mark on the left crankcase cover at idle.

To check the advance, raise the engine speed to 4 ,000 Âą 1 DO rpm. The index mark should be between the advance marks.

If the ignition timing is incorrect, perform the system inspection (page 14-21.

14-4

IRS

MEMO

BATTERY/CHARGING SYSTEM

t1) IGNITION SWITCH

(2) BATTERY

(5) ALTEI";I TelA CHARGING COIL ) REGULATOR RECTIFIER

(4) FUSE

(5) ALTERNATOR CHARG ING COIL

il

131 .------l REGULATORI

(9) LIGHTING

J

_-1~__SW~~

RECTIFIER

f

(4) FUSE 15 A

(1) IGN~IT~'O~N~-4-----~-P-~c-_~-~ SWITCH

(8) TAILLIGHT 12V 5W LO W

y

9

(6) OIMMER SWITCH

auMI

nmHEADUGHT 12V45/45W

15-0

Ie l2VIAH9

(2) BATTERY

15. BATTERY/CHARGING SYSTEM SERVICE INFORMATION

15-1

CHARGING SYSTEM

15-4

TROUBLESHOOTING

15-2

REGULATOR/RECTIFIER

15-5

BATTERY

15-3

ALTERNATOR CHARGING COIL

15-5

SERVICE INFORMATION GENERAL • Quick charging should be limited to an emergency. Slow charging is preferred.

• Remove the battery from the vehicle for charging. If the battery must be charged on the vehicle, disconnect the battery ca~ bles.

• The battery on this vehicle is a sealed type. Never remove the filling hole caps even when the battery is being charged.

• Be sure to charge the battery with the amount of current and fo r the time indicated on the battery label and as given below .

Charging with excessive current Of too fast charging may cause battery failure .

,I. Do not smoke around a charging battery, and keep sparks away from it. The gas produced by a battery will explode if a flame or spark is brought near.

• •

Use only a sealed· type battery on this vehicle.

All charging system components can be tested on the vehicle.

SPECIFICATIONS Battery

v- a AH

Capacity

12

Charging current

At slow: 0.9 A

Charging time

At slow: 5.0 hours, At quick: 1.0 hour

At quick: 4 A

Alternator capacity

130 W / 5,000 rpm

Voltage regulator

Transistorized non-adjustable regulator

Reg ul ator / rec t ifier-regu lated voltage

13.5 - 15.5 Va t 5 ,000 rpm

Alternator charging coil resistance

0. 1 - 1.0

(1

(20°C/68 0 Ft

TOOLS Digital multitester (KOWA t Circuit tester mANWAf

07411 - 0020000 or KS - AHM - 32 - 003 (U.S.A. only) 07308 - 0020000

m Circuit tester (KOWAl

T H - 5H - l

15-1

BATTERY/CHARGING SYSTEM

TROUBLESHOOTING No power-key turned on Dead battery

Disconnected battery cable Fuse burned out Faulty ignition swit ch Low power - key turned on

Weak battery

• loose battery connection Low power- engine running Battery undercharged • Charging system failure

Intermittent power

Loose battery connection •

Loose charging system connection

Charging system failure Loose, broken, or shorted wire or connec tion

Faulty voltage reg ulator Faulty alternator Faulty ignition switch

15-2

BATTERY I CHARGING SYSTEM

BATTERY INSPECTION NOTE

You can service the battery without removing the rear fend -

".

Measure the battery voltage using a digital vol tmeter.

VOLTAGE: FuliV charged : 13.1 V Undercharged : Below 12.8 V TOOL: Digitsl Multitest er 07411 - 002 0000 or KS - AHM - 32 - 003 (U.S .A. only)

REMOVAL Remove the battery holder bolt.

Disconnect the negative cable and then the positive cable and

remove the battery.

CHA RGING Connect the charger positive (+) cable to the battery positive (+) terminal.

Connect the charger negative I-I cable to the battery negative I-I terminal.

Charging current Charging time

At slow

At quick

0.9 A

4A

5 hours

1 hour

,I Keep flames Qnd sparks Qway from Q battery being charged.

Turn power ON/ OFF or the charger, not at the battery term;nals.

CAUTION

Quick charging should be limited to an emergency; slo", charging is pre/erred.

For battery charging, do not exceed the charging current and time specified on the baltery cover. Using excessive current or extending the charging time may damage the ballery.

INSTALLATI ON Install the battery in the reverse order of removal.

After installing the battery, coat the terminals with clean grease.

15-3

BATTERY/CHARGING SYSTEM

CHARGING SYSTEM LEAK TEST Turn the ignition switch off and disconnect the negative cable

from the battery.

Measure the voltage between the battery negative terminal and negative (ground) cable.

There should be no voltage with the ignition switch off.

REGULATED VOLTAGE INSPECTION NOTE

â&#x20AC;˘

Be sure the battery is in good condition before performing

this test.

Warm up the engine to the normal operating temperature.

Stop the engine, and connect the voltmeter as shown.

(You can service the battery without remov ing the rear fend er.)

Connect a tachometer.

Allow the engine to idle, and increase the engine speed gradually .

The voltage should be controlled to 13.5-15.5 V at 5,000 rpm.

CAUTION â&#x20AC;˘

Be can' jill not to con/ael the balfery positive cable to the/rame while testing.

If the reading does not rise from the battery voltage, check the following items and recheck the regu lated voltage.

- wire harness for short or open circuit, and coupler or fuse for loose or poorly contact, in the charging syst em.

- alternator charging coil (page 15-51.

- regulator/ rectifier {page 15-51.

If the reading is over 1 5.5 V, perform the following items and recheck the regu lated voltage.

- regulator/ rectifier connector (black) for loose or poorly con tact.

- voltage between the black (+) and green (- I terminals of the regulator/ rectifier coupler. (Battery voltage should be indicated with the ignition switch "ON") If the reading is still over 15.5 V after performing the above item , replace the regulator/ rectifier (page 1 5-51.

15-4

BATTERY {CHARGING SYSTEM

REGULATOR/ RECTIFI ER INSPECTION If the regulated voltage reading is out of specification , inspect as follow : Disconnect the 2P coupler and connectors from the regulatorl rectifier.

Check them for loose contact or rusting the terminals.

Check the items between terminals following below chart.

ITEM

Battery charging Regulated vortage

TERMINALS

SPECIFICATIONS

red ( + I and green ( I

Battery voltage comes.

black I + I and green (- I

Battery voltage comes with ignition switch ON.

Alternator charging coil

yellows ..

0 .1- 1.0

n (20 ° C/68°F)

If there IS no problem, replace the regulator/ rectIfier.

If there is indication of abnormality, replace or repai r the related circuit.

REPLACEMENT Open the junction box and disconnect the regulator/ rectifier coupler and connectors.

Remove the two bolts, and remove t he regulator/rectifier.

Install the new regulator/ recti f ier in the reve rse order of the reo movaL

ALTERNATOR CHARGING COIL IN SPE CTI ON Open the junction box and disconnect the alternator charging coil coupler .

Check the resistance between the yellow and the yellow wire terminals.

STANDARD; 0 . ' - 1.0 n (2 0 0 C/68 ° F) Check for continuity bet ween the wire terminals and ground.

Replace the alternator stator if readi ngs are not within the specification , or if any lead has continuity to ground. Refer t o Section 9 fo r stator removal.

15-5

STARTER SYSTEM

IGNITION SWITCH l 11 NEUTRAL - -_ __

INDICATOR

(8) STARTER SWITCH

171 <T.,O;"O MOTOR STARTER RELAY SWITCH

(5) FUSE

161 CHAN(;' SWITCH

m STARTER M

:::~O=R__~~_+~~=j----~R

r-__- ._______ (1 ) NEUTRAL INDICATOR 12V 3.4W

C

(6) CHANGE SWITCH (NEUTRAL)

16-0

(5) FUSE 15A

Y/ R (4) STARTER RELAY SWITCH

'-c_... ~~ ' 0_ _--'

(S) STARTER SWITCH

(2) IGNITION SWITCH

12VSAH (3) BATTERY

16. STARTER SYSTEM SERVICE INFORMATION

16-1

STARTER MOTOR

16-2

TROUBLESHOOTING

16-1

STARTER RELAY SWITCH

16-5

SERVICE INFORMATION GENERAL â&#x20AC;¢ The starter motor can be ramoved with the engine in the frame.

SPECIFICATIONS rnm(in) ITEM

Starter motor brush length

STANDARD

SERVICE LIMIT

12.0 - 12.5 (0.47 - 0.49)

5.5 (0.22)

TROUBLESHOOTING Starter motor will not turn Dead battery Faulty ignition switch Faulty starter switch Faulty neutral switch (change switch) Faulty starter relay switch Loose or disconnected wire or cable Starter motor turns e ngine slowly low battery Excessive resistance in circuit Binding in starter motor Loose or poorly contacted battery or starter motor cable terminals

Starter motor turns. but engine does not turn Faulty starter dutch Faulty starter motor gears

Faulty starter motor or idle gear Starter motor and engine turn. but engine does not start Faulty ignition system Engine problems Faulty engine stop switch

16-1

STARTER SYSTEM

STARTER MOTOR REMO VA L CAUTION

With the ignition s .....itch OFF, remove the negative cable at the oouery before servicing the Starler mOlor.

Disconnect the crankcase breather lube f rom t he crankcase.

Disconnect the starter cable.

Rem ove the starter motor mountin g bolts and p ull the motor to the left side out of the engine case.

BRUSH INSPECTION Remove the starter motor case screws, covers and commutator.

NOTE

â&#x20AC;¢

Record the location and number of thrust washers.

Inspect the brushes and measure the brush length .

SERVICE LIMIT: Brush length: 5 .5 mm (0.22 in l

DU ST SEAl/BUSHING INSPECTION Check the bushing of t he f ront cover fo r wear, damage and el(cassive scratc hes.

Check t he dust seal f or wear or fatigue.

121

COMMUTATOR IN SPECTION Inspect the commutator bars for discoloration. Bars discolored in pairs indicate grounded armature coils, in w hich case the starter motor must be replaced.

16-2

SEAL

111 Cm' MlJTA"TOR

STARTER SYSTEM Check for continuity between pairs 0 1 commutator bars. Also, make a resistance check between individual commutator bars and the armature shaft .

There should be no continuity.

(11 CONTINUITY: NORMAL

(2) NO CONTINUIT Y: NORMAL

CONTINUITY BETWEEN COMMUTATOR BAR PAIRS: NORMAL

NO CONTINUITY BETWeEN COMMUTATOR BAAS AND ARMATURE SHAFT : NORMAL

CASE INSULATION TEST

III CONTINUITY: NORMAL

Check for continuity from the cable terminal to the motor case and from the cable terminal to the brush wire.

Replace the starter motor if the field coil is not continuous or if it is shorted to the motor case.

CABLE TERMINAL-MOTOR CASE NO CONTINUITY : NORMAL CABLE TERMINAL-BRUSH (YELLOW WIRE) CONTINUITY: NORMAL (21 NO CONTINUITY:

ASSEMBLY

(1)

BRUSH

(2) ARMATURE COIL

16-3

STARTER SYSTEM Assemble the brush terminal to the terminal holder as shown and Install them in the motor case .

Install the O-ring and washers as illustrated on the previous page and tighten the nut securely.

Assemble the brush holder. Align the case notch with the brush holder pin.

Set the brushes on the brush holder.

(1)

I ALIGN

a -RING

Install the commutator to the case.

Set the brush springs.

Install the washers in recorded order.

Install the O-ring on the case.

Install the rear cover aligning its sial with the brush holder pin.

\5\ S?'"NC

InSlall the washers as illustrated on the previous page.

111 D-RING

\41 :,,\S~~U..ÂŁj3i<:Or~MUTATI'A (2) WASHERS

Install the O-ring on the case.

Install the front cover.

(3) FRONT COVER L

Tighten the screws aligning the index marks.

16-4

STARTER SYSTEM INSTALLATION

(4) TERMINAL

Apply oil to the O-ring, and install it in the starter motor front cover.

Install the motor to the engine case from the left side, aligning the gear teeth.

Tighten the starter motor mounting bolts securely.

Connect the starter motor cable.

Cover the terminal with the rubber cap.

Connect the crankcase breather tube to the crankcase.

STARTER RELAY SWITCH INSPECTION Open the junction box.

Depress the starter switch button with the ignition ON. The coil is normal if the starter relay switch clicks.

Remove the starter relay switch.

Connect an ohmmeter to the starler relay switch terminals .

Connect a 12 V baltery to the switch wire terminals. The switch is normal if there is continuity,

12Y

16-5

MEMO

17. LIGHTS/SWITCHES SERVICE INFORMATION

17-1

IGNITION SWITCH

17-3

TROUBLESHOOTING

17- 1

HANDLEBAR SWITCHES

17-4

HEADLIGHT

17-2

WIRING DRIAGRAM

17-5

TAILLIGHT

17-2

NEUTRAL AND REVERSE INDICATOR LIGHTS/SWITCH

17-2

SERVICE INFORMATION GENERAL â&#x20AC;¢ A continuity check can usually be made without removing the part from the vehicle by simply disconnecting the connectors and couplers, and connecting a continuity tester or voltmeter to the terminals .

SPECIFICATIONS Headlight (High/Low beam) Taillight Neutral and reverse indicator

12 V-45/45 W

, 2 v-5 W '2 V-3.4 W x 2

TROUBLESHOOTING light does not come on w hen light switch is turned on (Engin e is running) Bulb burned out Faulty switch Wiring to the component has open circuit

Headlight beam does not change w hen hi-Io switch is operated Faulty dimmer switch Bulb burned out Wiring to the component has open circuit

m

17-1

LIGHTS/SWITCHES

HEADLIGHT REMOVAL Remove the headlight case mounting bolts and remove the headlight.

To replace the headlight bulb, disconnect the socket from the headlight .

INSTALLATION Align the locking tabs of the socket with the cutouts of the headlight with the arrow of the socket facing up.

Install the rubber cover over the socket properly.

11 I HEADLIGHT CASE BOLTS Install the headlight with the headlight case mounting bolts.

/

NOTE Align the center line of the headlight with the index marks of the headlight case .

TAILLIGHT REMOVALIINSTALLATION Remove the taillight case.

Rotate the taillight socket and remove the taillight bulb.

Replace the bulb with a new one.

Install the bulb socket, aligning the locking tabs of the socket with the cutouts of the taitlight case.

Install the taillight case .

NOTE

â&#x20AC;¢

Align the arrows of the socket and taillight case.

NEUTRAL AND REVERSE INDICATOR LIGHTS/ SWITCH BULB REPLACEMENT Remove the headlight (page 17-21.

Remove the indicator light lens and pull the bulb socket out of the headlight case.

(2) BULB SO'O""T

17-2

LIGHTS/SWITCHES ~ElASE

Replace the bulb with a new one.

Install the bulb socket in the reverse order of removal.

SWITC:H INDICATOR

CHANGE SWITCH (NEUTRAL AND REVER SEI Remove the junction cover and disconnect the switch coupler.

Check the continuity between the switch terminal and ground.

The neutral switch is functional if continuity exists with the transmission in neutral.

The reverse switch is functional if continuity exists with the transmission in reverse.

IGNITION SWITCH

/11 IGNITION,

Remove the front fender and disconnect the ignition switch

wire connectors.

Check continuity of the ignition switch wires in each switch

position.

Terminal IG

E

BAT

HO

BI/ W

G

A

BI

Position

OFF ON

Color

REMOVAL/I NSTALLATI ON Remove two bolts and screws, and front fender.

Disconnect the ignition switch wire connectors.

~(1 )

17-3

LIGHTS/SWITCHES 111 N01'CHI05

Release the notches on the ignition switch and remove the switch from the handlebar upper holder cover.

Install in the reverse order of removal.

NOTE

â&#x20AC;¢

Align the tab of the switch with the groove of the cOlier.

121

HANDLEBAR SWITCHES

(1) DIMMER SW'ITCH

121 LlGiHTIN G SWITCH

The handlebar switches (tights, engine SlOp and starter) must be replaced as assemblies.

Remove the headlight and front fende r, and disconnect the switch wire connector and couplers.

Perform con t inuity tests for the components of the handlebar

switches.

141 STARTER SWITCH

The switch is normal if there is continuity between the circui t s marked "0--0".

Engine stop switch

~I

IG

E

BI/W

G

Position OFF RUN OFF

Color

lighting switch

Starter switch DIMMER

LIGHTING

...........

C

TL

(HU

...........

HI

(HU

LO

OFF

HI

FREE

ON

INI

PUSH

Color

BI

I

I

17-4

B,

LO

Color

Bu

I

"'W

Color

BAT

ST

BI

VI R

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18. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 18-1 ENGINE LACKS POWER

18-2

POOR PERFORMANCE AT LOW AND IDLE SPEEDS

18-3

POOR PERFORMANCE AT HIGH SPEEDS 18-4 POOR HANDLING

18-4

ENGINE DOES NOT START OR IS HARD TO START Probable Cause: 1. Check if fuel is getting to

carburetor.

••

NOT GETTING TO - - - -- - _ CARBURETOR

Clogged float valve Clogged fuel tank cap breather hole

GETTING TO CARBURETOR

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2 . Try spark test.

No fuel in fuel lank

Clogged fuel tube or fuel filter

WEAK OR NO S P A A K - - - - -_

••

Faulty spark plug Fouled spark plug

Faulty COl unit

GOOD SPARK

Broken or shorted spark plug wire Faulty alternator Broken or shorted ignition coil Faulty pulse generator Poorly connected, broken or shorted wires Faulty ignition switch Faulty regulator/rectifier Faulty change switch FaUlty engine stop switch 3. Test cylinder compression .

LOW COMPRESSION - - - - -_

••

COMPRESSION NORMAL

j 4 . Start by following normal starting procedure.

ENGINE STARTS BUT - - - - -SOON STOPS

••

ENGINE DOES NOT STAAT

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5. Remove spark plug.

DRY

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WETPLUG--------~ •

Low battery charge Valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Incorrect valve seat contact Improper valve timing Choke excessively open Carburetor pilot screw excessively closed Air leaking past carburetor insulator Improper ignition timing (COl unit or pulse generator faulty) Carburetor flooded Carburetor choke excessively closed Throttle valve excessively open Air cleaner dirty

6 . Start with choke applied.

18-1

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TROUBLESHOOTING

ENGINE LACKS POWER Probable Cause:

1. Raise wheels off the ground and spin by hand .

WHEEL DOES NOT SPIN

FREELY

••

Drive chain too tight

WHEELS SPIN FREELY

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2 . Check tire pressure with tire

Brake dragging Worn or damaged wheel bearing Wheel bearing needs lubrication

PRESSURE TOO LOW

gauge .

••

Punctured tire

Faulty tire valve

PRESSURE NORMAL

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3. Check clutch

CLUTCH SLIPS

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NORMAL

j 4 . lightly accelerate engine.

ENGINE SPEED DOES NOT INCREASE SUFFICIENTLY

•

ENGINE SPEED INCREASES

J 5 . Check ignition timing.

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Worn clutch disc/plate Warped clutch disc/ plate Worn clutch lining

Carburetor choke closed Clogged air cleaner Restricted fuel line Clogged fuel tank cap breather hole Clogged muffler

INCORRECT

••

INCORRECT

••

TOO LOW

••

Valve stuck open Worn cylinder and piston rings Leaking head gasket Improper valve timing

CLOGGED

••

Carburetor not serviced frequently enough

FOULED OR DISCOLORED

••

Plug not serviced frequently enough

CORRECT 6 . Check valve clearance.

Weak clutch spring

Faulty COl unit Faulty pulse generator Improper flywheel installation Improper valve adjustment Worn valve seat

CORRECT

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7. Test cylinder compression using a compression gauge.

NORMAL

I 8 . Check carburetor for clogging.

NOT CLOGGED

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9. Remove spark plug .

NOT FOULED OR DISCOLORED

18-2

Use of plug with improper heat range

TROUBLESHOOTING 10. Remove dipstick and check oil level .

Oil LE VEL

INCORRECT-----~.~ ·

Oil teval too high Oil level too low Contaminated oil

CORRECT

, 1. AemtOVe CVlinder head cover and inspect lubrication.

VALVE TRAIN N O T - - - -- -_.

Clogged oil passage

LUBRICATED PROPEAL Y

Clogged oit control orifice

OVERHEATED--------~·~

Excessive carbon build-up In com bustion chamber Use of improper quality of fuel Clutch slipPing Fuel-air mixture too lean

ENGINE KNOCK$-- - - - - - -__ •

Worn piston and cvlinder Fuel-air mixture too lean Use of improper grade of fuel Excessive carbon build-up in combustion chamber Ignition timing too advanced (Faulty COl unit or pulse generator)

VALVE TRAIN LUBRICATED PROPERLY

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12. Check if engine overheats.

NOT) OVERHEATED

13. Accelerate or fun at high speed.

ENGINE DOES NOT KNOCK

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POOR PERFORMANCE AT LOW AND IDLE SPEEDS Probable Cause' 1. Check ignition timing and valve clearance.

INCORRECT - - - - - - - - - -__ °

CORRECT

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2 . Check carburetor pilot screw adjustment.

INCORRECT

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Improper valve clearance Improper ignition timing (Faulty COl unit or pulse generator) Fuel-air mixture too tean Fuel-air mixture too rich

COR1 ECT 3 . Check if air is leaking past carburetor insulator.

LEAKING- - - - - - -- - - - -__ °

Det eriorated insulator O-ring Loose carburetor

NOT LEAKING

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4. Try spark test.

GOOD SPARK

WEAK OR INTERMITTENT SPARK_ o

Faulty, wet or carbon-fouled spark plug Faulty CO l unit Faulty alternator Faulty ignition coil Faulty pulse generator

18-3

TROUBLESHOOTING

POOR PERFORMANCE AT HIGH SPEEDS Probable Cause: 1. Check ignition timing and valve

INCORRECT----------__ •

Improper valve clearance

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clearance.

Faulty

CORRECT

Faulty pulse generator Improper flywheel installation

•

2. Disconnect fuel tube at carburetor.

FUEL FLOW

RESTRICTED-----.~·

FUEL FLOWS FREELY

j 3. Remove carburetor and check for a clogged jet.

unit

Lack of fuel in tank Clogged fuel line Clogged fuel tank cap breather hole Clogged fuel strainer

CLOGGED'- - - - - - - - - _ .. Clean

N°iCLOGGEO INcORRECr"--- - - - - - - - _ .. Cam sprocket not installed

4. Check valve timing .

properly

CORRECT

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5: Check valve spring tension.

. ) t o J E A K ' - - - - - - - - - - - - --- Faulty spring

NORMAL

POOR HANDLlNG----choo. t;" P"'""'" Probable Cause: 1. If steering is heavy. - - - - - - - - - - - - - - - - - - - - - -__ •

Steering shaft bushing holder nut too tight Damaged steering ball bearing

2. If either wheel is wobbling. - - - - - - - - - - - - - - - - - - - - . .

Excessive wheel bearing play Bent rim Improperly installed wheel hub Bent frame Improper drive chain tension or adjustment

3 . If the Fourtrax pulls to one

18-4

side. ------------------.~

Front and rear wheels not aligned Bent tie-rod Front brake cables not adjusted properly.

19. INDEX Air Cleaner Case ............................................. .

Drain Tube ......... ... .......... ... ...... ... .. ... . . .

Air Cleaner Element

Alternator . ....

. .................... ........ . .

4· 3 3· 6 3·5 9·5 15-5

Charging Coil .. ................. .......... .

E:JI:citer Coil ... . ............................... .

Battery/Charging System ................................. .

'4-4

Battery

15·3

.... . ................... ...... .................. .... .

1 6-1

Bearing Replacement .......... ,. ............ ...... ..... ..... 10 ·7 Brake Pedal ....................... .. ..... ................ ... ' " 12· 13 Shoe Wear ........ ... ... . ..... ............. ....... .. ..

3 ·9 System .... .... . .... .... . ....... ..... ... ....

3 - 10 Cable & Harness Routing ... ....... ..... ... ...... .... ......

1-9 Cam Chain Tensioner/C ylinder Head/Vailies ........

6 -1 Camshaft/ Cam Chain Tensioner .....................

6 ·3 Carburetor .. ......... .. .

4· 5 Choke .............. .. . ..... . ...... ...... .... ... .. ...... .

3·4 Idle Speed ................................ .. ...... .... .

3·7 Centrifugal Clutch ................. ... ..................... .. .

8·5 Charging System ...................................... _... .. . 15-4 Clutch/Gearshift linkage . .. ........................ .. .

8 ·' Clutch System .............. ... ........... ....... ... .. ...... . 3 - 12 Crankcase Assemblv ............................ ... .. ...... . 10- 10 Separation ............................................ . , 0-"3 Crankshaft ................... .......... .................... ... . 10· 4 Cylinder/Piston ............. .... .. ..... ............ .. .. ... ... .

7·' Cylinder CompreSSion ..................... _............... .

3·7 Head ........................................ .. .. .. .... .

6·7 Head COlier .................................... ..... .

6· 5 Installation .......... .

7· 6 Removal . ... . .

7·' Drive Chain ....... .. . .

3·8 Engine Removal/Installation ........................... ... .

5· ' Installation ............................................ .

5· 3 Oil & Filter Change ................................ .

Oil level .............................................. .

Removal ............................................. .. .

5·' Exhaust Pipe .... .. ........................................... . . , 3·3 Flywheel/Starter Clutch ........ . ... ... ........ ......... .

9·7 , 3 -1 Front Fender/ Rear Fender/Exhaust Pipe ..

Front Wheels/Brakes /Steering System ... .... ........ . 11 -1 Brakes .................................................. . l ' - 10 Fender ................. .. ... ... ........................ . , 3 - 1 Wheels .............................................. ... . '1 ·6 Fuel System ............ .. . .. .. ... .. .......... .

4· ' line ............. .. ...... ... .................... .... ..... .

3·3 Strainer Screen .................................. .

3·3 fink ........................ .. . .. ................ ....... .

4·3 Gearshift linkage ............ ................................ . 8- 13 General Information ........................................ .

Safety .................................................. . , 1-3 Handlebar Switches .............................................. . 17 -4 17-2 Headlight ...... .... ........... . .... ... .... ............ .... .

Aim ... .. .. ... ...... ... . . ................. .

3- '3 High Altitude Adjustment ... .................. ............ . 4 -11 Ignition System .............................................. . 14· 1 Coil ...................... ... ......................... .. . . 14-3 Switch ......................................... _...... . 17-3 Timing .......... ..... .................................. . '4·4 lights/Switches ... .. . .... .. ... ......... ...... . .... . 17- 1 lubrication .............................................. .... .. .

,.,,.,

,., ,.,

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lubrication Points .. ' ·7 Maintenance ......................... .

3· ' Schedule ............................... .. ............ .

3·' Manual Clutch ................................................ .

8· 9 Model Identification ........................................ .

Neutral And Reverse Indicator lights/Switch ...... . 17-2 Noise Emission Control System ... ......... ...... .. ... . , - 12 Nuts, Bolts. Fasteners .. .. ........... .. .. ....... . ... ...... . 3 -'3 Oil Filter Screen .... ' ·3 Pump ' ·3 Pilot Screw Adjustment .................. .... ............. . 4- 10 Piston Installation . .. ........................................ .

7·5 Removal .................................. .. . ' ·3 Pulse Generator ..... ...... . .................. .. ... .. .. ....... . '4-3 Rear Wheels/ Brakes/ Drive Mech anism .... ........... . , 2- 1 Axle Bearing Holder ...... ... . .......... .. . , 2 - 1 1 Axle/ Final Driven Sprocket ...................... . 1 2-9 Brakes .................................................. . '2· 3 Fender ........... ...... .................. ...... .

13-2 Wheels ....... ... .......................... ....... ...... . 12-3 Recoil Starter/ Alternator ..................... .. ........... .

9· ' Starter ........ ... ...................... ................ .

9·' Regulator/ Rectifier .......................... .. .............. . , 5-5 Reverse lock Syst em .......................... .

3-11 Right Crankcase Cover Installation.. . ... ..... .. 8 - 16 Removal ............................................. ..

8· 3 Service Information Battery/Charging System ........................ . 15- 1 Cam Chain Tensioner/Cylinder Head/ Valves ................................................. .

6· ' Clutch/ Gearshift Linkage ........... ........... ... .

8· 1 Cylinder/Piston ...................................... .

7· ' Engine Removal/Installation .... ........... ...... .

5· ' Front Wheels/ Brakes/ Steering System _..... . 11 - 1 Fuel System ..... ..................................... .

4· ' Ignition System ..................... . ............... . , 4 - 1 lights/ Switches ... .. ................................ . 17- 1 lubrication ........................................... .

Maintenance ......................................... .

3·' Rear Wheels /Brakes/ Drive Mechanism ...... . 12- 1 Recoil Starter/Alternator . .. ... ........ .......... .

9· ' Starter System ...................................... . 16- 1 Transmission/Crankshaft .............. .. ....... .. 10- 1 Service Rules .................................. ......... .... ..

Spark Arrester ....... ......... ... .. .......... .......... ..... .. 3-12 Plug ........................... ..

3·6 Specifications . .................. .............. ......... ..... . ' ·3 Starter System ............................................... . 16-1 16-2 Motor ........ ..... ............................ .

Relay Switch ......................................... . 16-5 Steering System .............................. ....... 3 - 13, 11 - 15 System Inspection .......................................... . 14-2 Taillight .......... .. ..... ........................... .......... .. . 17-2 1 1-5 Throttle lever .................................. .

Operation ........................................... .

3·3 Thronle Valve Assembly .................................. .

4· 9 4·5 Oisassembly .. .. ...................................... .

Tires ..................... .. ...................................... . 11 -6 Tools ............................................... .. ........... . ' ·7 Torque Values ........ ........... .. ... ... ......... .......... . ' ·5 10- 1 Transmission /Crankshaft .................... .

10-5 Transmission assembly ..

,.,

,., ,.,

19-1

ID

INDEX Transmission Disassembly ................................

Troubleshooting BatteryfCharging System .........................

Cam Chain TensionerfCylinder Head/ Valves ..........................................

Clutch/Gearshift linkage ..................

Cylinder/Piston ...............................

Front Wheels/Brakes/Steering System Fuel System ...................... ....................

Ignition System ..... ...... ....... ...... ...... ..... ... lights/Switches .......... ....................

Lubrication .................. .... ..................

Rear Wheels/Brakes/Drive Mechanism .......

Recoil Starter/Alternator ........................ .

Starter System ..................................... .

TransmisSion/Crankshaft ..

Valve Clearance .......................... .

Wheels/Tires .................................... .

Wiring Oriagram ............................................. .

19-2

10-5 15¡2

6-2 8-2 7-1 11 -2 4-2 14-1 17- 1 2-1 12-2

9- 1 16- 1

10-2

3-6 3-13 17-5

(1921